Cluster-supporting catalyst having an improved heat resistivity, and method for producing the same are provided. The cluster-supporting catalyst includes boron-substitute zeolite particles, and catalyst metal clusters supported within the pores of the boron-substitute zeolite particles. The method for producing a cluster-supporting catalyst, includes the following steps: providing a dispersion liquid containing a dispersion medium and boron-substitute zeolite particles dispersed in the dispersion medium; and in the dispersion liquid, forming catalyst metal clusters having a positive charge, and supporting the catalyst metal clusters on the acid sites within the pores of the boron-substitute zeolite particles through an electrostatic interaction.

An alkylation catalyst having a zeolite catalyst component and a binder component providing mechanical support for the zeolite catalyst component is disclosed. The binder component is an ion-modified binder that can include metal ions selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and combinations thereof. The metal ions reduce the number of acid sites on the zeolite catalyst component. The metal ions can range from 0.1 to 50 wt % based on the total weight of the ion-modified binder. Optionally, the ion-modified binder is present in amounts ranging from 1 to 80 wt % based on the total weight of the catalyst.

An alkylation catalyst having a zeolite catalyst component and a binder component providing mechanical support for the zeolite catalyst component is disclosed. The binder component is an ion-modified binder that can include metal ions selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and combinations thereof. The metal ions reduce the number of acid sites on the zeolite catalyst component. The metal ions can range from 0.1 to 50 wt % based on the total weight of the ion-modified binder. Optionally, the ion-modified binder is present in amounts ranging from 1 to 80 wt % based on the total weight of the catalyst.

A method for producing a metal nanoparticle complex according to the present invention is a method for producing a metal nanoparticle complex in which metal nanoparticles are supported in pores of a porous body, said method comprising at least: an adsorption step of allowing an organic metal complex to adsorb in pores of a porous body; and a decomposition/reduction step of heating the porous body, which has had the organic metal complex adsorbed in the pores thereof, under a reductive atmosphere to decompose an organic compound in the organic metal complex adsorbed in the pores of the porous body and also reduce a metal cation in the organic metal complex, thereby causing metal nanoparticles to be supported in the pores of the porous body.

The invention provides methods, catalysts and systems for producing styrene from DME and toluene. Zeolite catalysts comprising potassium, rubidium or cesium and containing at least 0.1 wt % B are described. Methods of making the catalysts are also described.

Methods of simultaneously converting butanes and methanol to olefins over Ti-containing zeolite catalysts are described. The exothermicity of the alcohols to olefins reaction is matched by endothermicity of dehydrogenation reaction of butane(s) to light olefins resulting in a thermo-neutral process. The Ti-containing zeolites provide excellent selectivity to light olefins as well as exceptionally high hydrothermal stability. The coupled reaction may advantageously be conducted in a staged reactor with methanol/DME conversion zones alternating with zones for butane(s) dehydrogenation. The resulting light olefins can then be reacted with iso-butane to produce high-octane alkylate. The net result is a highly efficient and low cost method for converting methanol and butanes to alkylate.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575 C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.