U.S. patent application number 10/406764 was filed with the patent office on 2003-10-30 for process for the dehydrogenation of hydrocarbons.
Invention is credited to Sachtler, J. W. Adriaan, Vora, Bipin V., Voskoboynikov, Timur V., Wei, Daniel H..
Application Number | 20030202934 10/406764 |
Document ID | / |
Family ID | 28674469 |
Filed Date | 2003-10-30 |
United States Patent
Application |
20030202934 |
Kind Code |
A1 |
Voskoboynikov, Timur V. ; et
al. |
October 30, 2003 |
Process for the dehydrogenation of hydrocarbons
Abstract
A hydrocarbon dehydrogenation process utilizing a novel catalyst
composite. The catalyst composite comprises a Group VIII noble
metal component, a Group IA or IIA metal component, and a component
selected from the group consisting of tin, germanium, lead, indium,
gallium, thallium, or mixtures thereof, all on an alumina support
comprising essentially theta-alumina, having a surface area from
about 50 to about 120 m.sup.2/g, an apparent bulk density of at 0.5
g/cm.sup.3 and a mole ratio of the Group VIII noble metal component
to the component selected from the group consisting of tin,
germanium, lead, indium, gallium, thallium or mixtures thereof in
the range from about 1.5 to about 1.7.
Inventors: |
Voskoboynikov, Timur V.;
(Arlington Heights, IL) ; Wei, Daniel H.;
(Naperville, IL) ; Sachtler, J. W. Adriaan; (Des
Plaines, IL) ; Vora, Bipin V.; (Naperville,
IL) |
Correspondence
Address: |
JOHN G TOLOMEI, PATENT DEPARTMENT
UOP LLC
25 EAST ALGONQUIN ROAD
P O BOX 5017
DES PLAINES
IL
60017-5017
US
|
Family ID: |
28674469 |
Appl. No.: |
10/406764 |
Filed: |
April 3, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10406764 |
Apr 3, 2003 |
|
|
|
10118642 |
Apr 8, 2002 |
|
|
|
Current U.S.
Class: |
423/651 |
Current CPC
Class: |
B01J 23/626 20130101;
B01J 37/0207 20130101; B01J 35/1014 20130101; B01J 35/0026
20130101; B01J 23/58 20130101; B01J 21/04 20130101; B01J 35/1019
20130101; C07C 2523/62 20130101; C07C 5/325 20130101; B01J 35/002
20130101; B01J 37/0072 20130101; B01J 23/62 20130101 |
Class at
Publication: |
423/651 |
International
Class: |
C01B 003/26 |
Claims
What is claimed:
1. A hydrocarbon dehydrogenation process comprising the steps of
contacting a hydrocarbon at dehydrogenation conditions with a
catalytic composite comprising a first component selected from
Group VIII noble metal components or mixtures thereof, a second
component in an amount from 0.9 to 1.1 weight percent, based on the
total composite weight selected from the group consisting of alkali
or alkaline earth metal components or mixtures thereof and a third
component selected from the group consisting of tin, germanium,
lead, indium, gallium, thallium and mixtures thereof, all on an
alumina support comprising essentially theta-alumina and having a
surface area from about 50 to about 120 m.sup.2/g and an apparent
bulk density of at least 0.5 g/cm.sup.3 wherein the mole ratio of
the first component to the third component is in the range from
about 1.5 to about 1.7.
2. The process of claim 1 wherein the first component is
platinum.
3. The process of claim 1 wherein the second components is
potassium.
4. The process of claim 1 wherein the third component is tin.
5. The process of claim 1 wherein the catalytic composite comprises
from about 0.01 to about 5 weight percent platinum, from 0.9 to 1.1
weight percent potassium and from about 0.01 to about 5 weight
percent tin.
6. The process of claim 1 wherein the hydrocarbon comprises
dehydrogenatable hydrocarbons having from 2 to 30 carbon atoms.
7. The process of claim 1 wherein the hydrogenation conditions
include a temperature from about 400 to about 900.degree. C., a
pressure from about 0.01 to about 10 atmospheres and a liquid
hourly space velocity (LHSV) from about 0.1 to about 100 hr-1.
8. The process of claim 6 wherein the dehydrogenatable hydrocarbons
having from 2 to 30 carbon atoms are comprised of normal paraffins
and branched paraffins.
9. The process of claim 8 wherein the dehydrogenatable hydrocarbons
are comprised of propane and butanes.
10. A hydrocarbon dehydrogenation process comprising the steps of
contacting a hydrocarbon at dehydrogenation conditions with a
catalytic composite comprising platinum, a potassium component in
an amount from 0.9 to 1.1 weight percent based on the total
composite weight and a tin component, all on an alumina support
comprising essentially theta-alumina and having a surface are from
about 50 to about 120 m.sup.2/g and an apparent bulk density of at
least 0.5 g/cm.sup.3 wherein the mole ratio of the platinum to tin
is in the range from about 1.5 to about 1.7.
11. A hydrocarbon dehydrogenation process comprising the steps of
contacting a hydrocarbon selected from the group consisting
essentially of propane and butane at dehydrogenation conditions
including a temperature from about 400.degree. to about 900.degree.
C., a pressure from about 200 kPa to about 20 MPa (0.01 to 10
atmospheres) and a liquid hourly space velocity (LHSV) from about
0.1 to about 100 hr.sup.-1 with a catalytic composite comprising
platinum, a potassium component in an amount from 0.9 to 1.1 weight
percent based on the total composite weight and a tin component,
all on an alumina support comprising essentially theta-alumina and
having a surface area from about 50 to about 120 m.sup.2/g and an
apparent bulk density of at least 0.5 g/cm.sup.3 wherein the mole
ratio of the platinum to tin is in the range from about 1.5 to
about 1.7.
Description
RELATED APPLICATIONS
[0001] The present application is a division of application Ser.
No. 10/118,642 filed on Apr. 8, 2002, all the teachings of which
are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the conversion of hydrocarbons,
especially the dehydrogenation of dehydrogenatable hydrocarbons, in
the presence of a catalyst composite. This invention also pertains
to a new catalyst composite.
[0003] The dehydrogenation of hydrocarbons is an important
commercial process because of the great demand for dehydrogenated
hydrocarbons for the manufacture of various chemical products such
as detergents, high octane gasolines, pharmaceutical products,
plastics, synthetic rubbers, and other products well known to those
skilled in the art. One example of this process is dehydrogenating
isobutane to produce isobutylene which can be polymerized to
provide tackifying agents for adhesives, viscosity-index additives
for motor oils, impact-resistant and anti-oxidant additives for
plastics and a component for oligomerized gasoline.
INFORMATION DISCLOSURE
[0004] The prior art is cognizant of various catalytic composites
which contain a Group VIII noble metal component, an alkali or
alkaline earth metal component, and a component selected from the
group consisting of tin, germanium, lead, indium, gallium,
thallium, or mixtures thereof. However, the prior art has not yet
known of a catalyst composite having a surface area of 120
m.sup.2/g or less, having an ABD of 0.5 g/cm.sup.3 or greater and a
mole ratio of the Group VIII noble metal component to the component
selected from the group consisting of tin, germanium, lead, indium,
gallium, thallium or mixtures thereof in the range from about 1.5
to about 1.7.
[0005] U.S. Pat. No. 4,070,413 describes a dehydrogenation process
utilizing a catalyst comprising a Group VIII metal and lithium,
both impregnated on an alumina support. The alumina support is
further characterized in that it has been hydrothermally treated in
steam at a temperature from about 800.degree. to 1200.degree. C.
The catalyst of this invention is distinguished from that of the
'413 patent in that the instant catalyst comprises, in addition to
a Group VIII metal component and an alkali or alkaline earth metal
component, a component selected from the group consisting of tin,
germanium, lead, indium, gallium, thallium, or mixtures thereof.
Additionally, the catalyst support of this invention has a higher
ABD than that disclosed in the '413 patent. The '413 patent
discloses a catalyst having a pre-hydrothermally treated ABD of
from about 0.25 to about 0.45 g/cm.sup.3. From Example III, it is
seen that the final catalyst composites of the catalyst of the U.S.
Pat. No. '413 have an ABD of about 0.3. The catalyst of this
invention must have a final ABD of at least 0.5 g/cm.sup.3.
[0006] U.S. Pat. No. 4,608,360 describes a catalytic composite
comprising a Group VIII noble metal component, a co-formed IVA
metal component, and an alkali or alkaline earth metal on an
alumina support having a surface area of from 5 to 150 m.sup.2/g.
Additionally, the alumina support of the '360 patent is
characterized in that the mean pore diameter is about 300 angstroms
or less and more than about 55% of the total pore volume of the
support is associated with pores having a mean diameter of 600
angstroms or more. In distinction, the catalyst of this invention
is characterized in that it has a surface area of 120 m.sup.2/g or
less and an ABD of 0.5 g/Cm.sup.3 or more. The catalyst of the '360
patent from Example II has an ABD of about 0.3. Additionally, the
catalyst of the present invention contains very little of its total
pore volume in pores having a diameter of 600 angstroms or more
while the '360 catalyst has over 50% of its total pore volume
associated with pores having mean diameters of about 600 angstroms
or more.
[0007] U.S. Pat. No. 4,717,779 discloses a process for
dehydrogenating dehydrogenatable hydrocarbons using a selective
oxidation catalyst comprising a Group VIII noble metal component, a
Group IVA component, and if desired a Group IA or IIA component.
The components are composited on an alumina support wherein an
alumina precursor possesses an ABD less than about 0.6 g/cm.sup.3
which, after calcination at a temperature of from about 9000 to
1500.degree. C., will result in an alumina possessing an ABD of
from 0.3 to 1.1 g/cm.sup.3 and where more than 40% of the pore
volume is present in pores greater than 1500 angstroms. In
contrast, the catalyst of the present invention comprises an ABD of
0.5 g/cm.sup.3 or greater and preferably from 0.6 g/cm.sup.3 or
greater and a mole ratio of the Group VIII noble metal component to
the Group IVA, Group IA or IIA component is in the range from about
1.5 to about 1.7. Additionally, very little of the total catalyst
pore volume, that is, much less than 40% of the total catalyst pore
volume, is comprised of pores of 1500 angstroms or greater.
[0008] U.S. Pat. No. 4,786,625, discloses a catalyst for the
dehydrogenation of dehydrogenatable hydrocarbons comprising a
platinum group metal component, a modifier metal component selected
from the group consisting of tin, germanium, rhenium, and mixtures
thereof, and optionally an alkali or alkaline earth metal
component, all on a refractory oxide support, preferably alumina.
The catalyst is characterized in that the platinum group metal
component is surface impregnated. The catalyst of the present
invention does not comprise any surface-impregnated components and,
in addition, the alumina catalyst support of the '625 patent is not
characterized as requiring a limited ABD or surface area.
[0009] U.S. Pat. No. 4,788,371, discloses a catalytic oxidative
steam dehydrogenation process utilizing a single catalyst
comprising a Group VIII noble metal component; one or more
components selected from the group consisting of lithium, sodium,
potassium, rubidium, cesium, and francium; and one or more
components selected from the group consisting of boron, gallium,
indium, thallium, germanium, tin, and lead, all on an inorganic
oxide support, preferably alumina having a surface area of from 1
to 500 m.sup.2/g, but preferably from 5 to 120 m.sup.2/g. The
catalyst does not disclose a specific range for the alumina
support.
[0010] U.S. Pat. No. 4,914,075 discloses a catalytic composite
comprising a Group VIII noble metal component, a Group IA or IIA
metal component and a component selected from the group consisting
of tin, germanium lead, indium, gallium, thallium or mixtures
thereof, all on an alumina support having a low surface area of 120
m.sup.2/g or less and an ABD of 0.5 g/cm.sup.3 or more. This
reference discloses a catalyst which has a platinum to tin mole
ratio of 0.914.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention is a catalytic composite and process
for its use with the catalyst having a support with a surface area
of 120 m.sup.2/g or less in conjunction with an apparent bulk
density (ABD) of at least 0.5 g/cm.sup.3. The support is utilized
in conjunction with a platinum group metal component, an alkali or
alkaline metal component and a third component selected from the
group consisting of tin, germanium, lead, indium, gallium, thallium
and mixtures thereof. It has surprisingly been discovered that a
superior catalyst, which possesses an alkali or alkaline metal
component in an amount from 0.9 to 1.1 weight percent based on the
total composite weight and a mole ratio of the platinum group metal
component to the third component from about 1.5 to about 1.7,
demonstrates a higher initial maximum hydrocarbon dehydrogenation
activity and a higher conversion from 5 to 20 hours on stream.
[0012] It is an object of the present invention to provide an
improved catalytic composite and a process for the conversion of
hydrocarbons and especially for the dehydrogenation of
dehydrogenatable hydrocarbons utilizing the improved catalytic
composite. Accordingly in a broad embodiment, the invention is a
hydrocarbon dehydrogenation process comprising the steps of
contacting a hydrocarbon at dehydrogenation conditions with a
catalytic composite comprising a first component selected from
Group VIII noble metal components or mixtures thereof, a second
component in an amount from 0.9 to 1.1 weight percent, based on the
total composite weight selected from the group consisting of alkali
or alkaline earth metal components or mixtures thereof and a third
component selected from the group consisting of tin, germanium,
lead, indium, gallium, thallium and mixtures thereof, all on an
alumina support comprising essentially theta-alumina and having a
surface area from about 50 to about 120 m.sup.2/g and an apparent
bulk density of at least 0.5 g/cm.sup.3 wherein the mole ratio of
the first component to the third component is in the range from
about 1.5 to about 1.7.
DESCRIPTION OF THE FIGURE
[0013] The FIGURE is a graph plotting propane conversion versus
total hours on stream comparing two prior art catalysts with the
catalyst of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] To summarize, the present invention is an improved catalytic
composite as well as a process for the use of the catalytic
composite.
[0015] One essential feature of the present invention lies in the
characteristics of the support for the instant catalyst.
Specifically, it is important that the alumina catalyst support
have a surface area of 120 m.sup.2/g or less and a corresponding
Apparent Bulk Density (ABD) of 0.5 g/cm.sup.3 or greater. The
support comprises a number of catalytic components including a
Group VIII noble metal component, an alkali or alkaline earth
component, and a component selected from the group consisting of
tin, germanium, lead, indium, gallium, thallium, or mixtures
thereof. Another essential feature of the present invention is that
the mole ratio of the Group VIII noble metal to the component
selected from the group consisting of tin, germanium, lead, indium,
gallium, thallium, or mixtures thereof is in the range from about
1.5 to about 1.7. Such a catalyst exhibits improved catalyst
conversion in a hydrocarbon dehydrogenation process in comparison
to similar dehydrogenation catalysts of the prior art. In addition,
it has been discovered that when the preferred mole ratio is used,
the catalyst demonstrates a higher initial maximum hydrocarbon
dehydrogenation activity.
[0016] As indicated above, one essential feature of the catalytic
composite of the invention is a first component selected from Group
VIII noble metals or mixtures thereof. The Group VIII noble metal
may be selected from the group consisting of platinum, palladium,
iridium, rhodium, osmium, ruthenium, or mixtures thereof. Platinum,
however, is the preferred Group VIII noble metal component.
[0017] Preferably the Group VIII noble metal component is well
dispersed throughout the catalyst. It generally will comprise about
0.01 to 5 wt. %, calculated on an elemental basis, of the final
catalytic composite. Preferably, the catalyst comprises about 0.1
to 2.0 wt. % Group VIII noble metal component, especially about 0.1
to about 2.0 wt. % platinum.
[0018] The Group VIII noble metal component may be incorporated in
the catalytic composite in any suitable manner such as, for
example, by coprecipitation or cogelation, ion exchange or
impregnation, or deposition from a vapor phase or from an atomic
source or by like procedures either before, while, or after other
catalytic components are incorporated. The preferred method of
incorporating the Group VIII noble metal component is to impregnate
the alumina support with a solution or suspension of a decomposable
compound of a Group VIII noble metal. For example, platinum may be
added to the support by commingling the latter with an aqueous
solution of chloroplatinic acid. Another acid, for example, nitric
acid or other optional components, may be added to the impregnating
solution to further assist in evenly dispersing or fixing the Group
VIII noble metal component in the final catalyst composite.
[0019] Another essential feature of the catalyst of this invention
is a second catalytic component comprised of an alkali or alkaline
earth component. The alkali or alkaline earth component of the
present invention may be selected from the group consisting of
cesium, rubidium, potassium, sodium, and lithium or from the group
consisting of barium, strontium, calcium, and magnesium or mixtures
of metals from either or both of these groups. Potassium, however,
is the preferred second catalytic component. It is believed that
the alkali and alkaline earth component exists in the final
catalytic composite in an oxidation state above that of the
elemental metal. The alkali and alkaline earth component may be
present as a compound such as the oxide, for example, or combined
with the carrier materiel or with the other catalytic
components.
[0020] Preferably the alkali and alkaline earth component is well
dispersed throughout the catalytic composite. The alkali or
alkaline earth component will preferably comprise 0.9 to 1.1 wt. %,
calculated on an elemental basis of the final catalytic
composite.
[0021] The alkali or alkaline earth component may be incorporated
in the catalytic composite in any suitable manner such as, for
example, by coprecipitation or cogelation, by ion exchange or
impregnation, or by like procedures either before, while, or after
other catalytic components are incorporated. A preferred method of
incorporating the alkali component is to impregnate the carrier
material with a solution of potassium hydroxide.
[0022] A third essential component of the catalyst of the present
invention is a modifier metal component selected from the group
consisting of tin, germanium, lead, indium, gallium, thallium, and
mixtures thereof. The effective amount of the third modifier metal
component is preferably uniformly impregnated. Generally, the
catalyst will comprise from about 0.01 to about 10 wt. % of the
third modifier metal component calculated on an elemental basis on
the weight of the final composite. Preferably, the catalyst will
comprise from about 0.1 to about 5 wt. % of the third modifier
metal component.
[0023] The third modifier metal component of the present invention
preferably is tin. Some or all of the tin component may be present
in the catalyst in an oxidation state above that of the elemental
metal. This component may exist within the composite as a compound
such as the oxide, sulfide, halide, oxychloride, aluminate, etc.,
or in combination with the carrier material or other ingredients of
the composite. Preferably, the tin component is used in an amount
sufficient to result in the final catalytic composite containing,
on an elemental basis, about 0.01 to about 10 wt. % tin, with best
results typically obtained with about 0.1 to about 5 wt. % tin.
[0024] Suitable tin salts or water-soluble compounds of tin which
may be used include stannous bromide, stannous chloride, stannic
chloride, stannic chloride pentahydrate, stannic chloride
tetrahydrate, stannic chloride trihydrate, stannic chloride
diamine, stannic trichloride bromide, stannic chromate, stannous
fluoride, stannic fluoride, stannic iodide, stannic sulfate,
stannic tartrate, and the like compounds. The utilization of a tin
chloride compound, such as stannous or stannic chloride is
particularly preferred.
[0025] The third component of the catalyst may be composited with
the support in any sequence. Thus, the first or second component
may be impregnated on the support followed by sequential surface or
uniform impregnation of the third component. Alternatively, the
third component may be surface or uniformly impregnated on the
support followed by impregnation of the other catalytic
component.
[0026] The catalytic composite of this invention may also contain a
halogen component. The halogen component may be fluorine, chlorine,
bromine, or iodine, or mixtures thereof. Chlorine is the preferred
halogen components. The halogen component is generally present in a
combined state with the porous carrier material and alkali
component. Preferably, the halogen component is well dispersed
throughout the catalytic composite. The halogen component may
comprise from more than 0.01 wt. % to about 15 wt. %, calculated on
an elemental basis, of the final catalytic composite.
[0027] The halogen component may be incorporated in the catalytic
composite in any suitable manner, either during the preparation of
the carrier material or before, while, or after other catalytic
components are incorporated. For example, the alumina sol utilized
to form the preferred aluminum carrier material may contain halogen
and thus contribute at least some portion of the halogen content in
the final catalyst composite. Also, the halogen component or a
portion thereof may be added to the catalyst composite during the
incorporation of the carrier material with other catalyst
components, for example, by using chloroplatinic acid to impregnate
the platinum component. Also, the halogen component or a portion
thereof may be added to the catalyst composite by contacting the
catalyst with the halogen or a compound or solution containing the
halogen before or after other catalyst components are incorporated
with the carrier material. Suitable compounds containing the
halogen include acids containing the halogen, for example,
hydrochloric acid. Or, the halogen component or a portion thereof
may be incorporated by contacting the catalyst with a compound or
solution containing the halogen in a subsequent catalyst
regeneration step. In the regeneration step, carbon deposited on
the catalyst as coke during use of the catalyst in a hydrocarbon
conversion process is burned off and the catalyst and the platinum
group component on the catalyst is redistributed to provide a
regenerated catalyst with performance characteristics much like the
fresh catalyst. The halogen component may be added during the
carbon burn step or during the platinum group component
redistribution step, for example, by contacting the catalyst with a
hydrogen chloride gas. Also, the halogen component may be added to
the catalyst composite by adding the halogen or a compound or
solution containing the halogen, such as propylene dichloride, for
example, to the hydrocarbon feed stream or to the recycle gas
during operation of the hydrocarbon conversion process. The halogen
may also be added as chlorine gas (Cl.sub.2).
[0028] The carrier material of the present invention is alumina
having a surface area less than 120 m.sup.2/g. In addition, the
catalyst carrier alumina should have an ABD of 0.5 g/cm.sup.3 or
more. The alumina carrier material may be prepared in any suitable
manner from synthetic or naturally occurring raw materials. The
carrier may be formed in any desired shape such as spheres, pills,
cakes, extrudates, powders, granules, etc., and it may be utilized
in any particle size. A preferred shape of alumina is the sphere. A
preferred particle size is about {fraction (1/16)}-inch in
diameter, though particles as small as about {fraction (1/32)}-inch
and smaller may also be utilized.
[0029] To make alumina spheres, aluminum metal is converted into an
alumina sol by reacting it with a suitable peptizing agent and
water, and then dropping a mixture of the sol into an oil bath to
form spherical particles of the alumina gel. It is also an aspect
of this invention that the third modifier metal component may be
added to the alumina sol before it is reacted with a peptizing
agent and dropped into the hot oil bath. Other shapes of the
alumina carrier material may also be prepared by conventional
methods. After the alumina particles optionally containing the
co-formed third component are shaped, they are dried and
calcined.
[0030] It is the drying and calcination of the alumina base
component that is most important in imparting the catalyst base
with the desired characteristics of this invention. It is important
that the catalyst alumina base of this invention have a surface
area of 120 m.sup.2/g or less and a corresponding ABD of 0.50
g/cm.sup.3 or more. These characteristics are imparted in the
alumina by a final calcination of the alumina at a temperature
ranging from 950.degree. to 1200.degree. C. It is preferable that
the final calcination step be at conditions sufficient to convert
the alumina into theta-alumina which conforms to the desired
characteristics of the alumina base of the instant catalyst. Such
conditions would include a calcination temperature closely
controlled between 950.degree. and 1100.degree. C. and preferably
from 975.degree. to 1050.degree. C.
[0031] It is to be understood that the surface area of the catalyst
as set forth in the description of the invention and the appended
claims are derived by the well-known mercury intrusion technique.
This method may be used for determining the pore size distribution
and pore surface area of porous substances by mercury intrusion
using a Micromeritics Auto Pore 9200 Analyzer. In this method, high
pressure mercury is forced into the pores of the catalyst particles
at incrementally increasing pressures to a maximum of 413,700 kPa
(60,000 psia). Pore volume readings are taken at predetermined
pressures. A maximum of 85 pressure points can be chosen.
Accordingly by this method, a thorough distribution of pore volumes
may be determined.
[0032] The effect of calcination of an alumina base especially at
the elevated temperatures disclosed in this invention is to densify
the alumina base. The densification, i.e. increase in ABD, is
caused by a decrease in the overall catalyst pore volume. In
addition, the high calcination temperatures cause the existing
pores to expand. To accomplish this apparently contradictory
mechanism, the catalyst necessarily contracts in size while the
existing pores expand. By expanding, the mouths of the existing
pores increase so that they become less likely to be plugged or
restricted by coke build-up.
[0033] It is preferred that the alumina component is essentially
theta-alumina. By "essentially theta-alumina", it is meant that at
least 75% of the alumina crystallites are theta-alumina
crystallites. The remaining crystallites of alumina will likely be
in the form of alpha-alumina or gamma-alumina. However, other forms
of alumina crystallites known in the art may also be present. It is
most preferred if the essentially theta-alumina component comprises
at least 90% crystallites of theta-alumina.
[0034] As explained, the theta-alumina form of crystalline alumina
is produced from the amorphous alumina precursor by closely
controlling the maximum calcination temperature experienced by the
catalyst support. Calcination temperatures ranging from 800.degree.
to 950.degree. C. are known to produce alumina comprising
essentially crystallites of gamma-alumina. Calcination temperatures
of 1100.degree. C. and above are known to promote the formation of
alpha-alumina crystallites while temperatures of from 950.degree.
to 1100.degree. C. and especially from 975.degree. to 1050.degree.
C. promote the formation of theta-alumina crystallites.
[0035] After the catalyst components have been combined with the
desired alumina support, the resulting catalyst composite will
generally be dried at a temperature of from about 100.degree. to
about 320.degree. C. for a period of typically about 1 to 24 hours
or more and thereafter calcined at a temperature of about
320.degree. to about 600.degree. C. for a period of about 0.5 to
about 10 or more hours. Typically, chlorine-containing compounds
are added to air to prevent sintering of catalyst metal components.
This final calcination typically does not affect the alumina
crystallites or ABD. However, the high temperature calcination of
the support may be accomplished at this point if desired. Finally,
the calcined catalyst composite is typically subjected to a
reduction step before use in the hydrocarbon conversion process.
This reduction step is effected at a temperature of about
230.degree. to about 650.degree. C. for a period of about 0.5 to
about 10 or more hours in a reducing environment, preferably dry
hydrogen, the temperature and time being selected to be sufficient
to reduce substantially all of the platinum group component to the
elemental metallic state.
[0036] As indicated above, the catalyst of the present invention
has particular utility as a hydrocarbon conversion catalyst. The
hydrocarbon which is to be converted is contacted with the catalyst
at hydrocarbon conversion conditions. These conditions include a
temperature of from about 200.degree. to 1000.degree. C., a
pressure of from 0.25 atmospheres absolute (ATMA) to about 25
atmospheres gauge, and liquid hourly space velocities of from about
0.1 to about 200 hr.sup.-1.
[0037] According to one embodiment, the hydrocarbon conversion
process of the invention is dehydrogenation. In the preferred
process, dehydrogenatable hydrocarbons are contacted with the
catalytic composite of the instant invention in a dehydrogenation
zone maintained at dehydrogenation conditions. This contacting may
be accomplished in a fixed catalyst bed system, a moving catalyst
bed system, a fluidized bed system, etc., or in a batch-type
operation. A fixed bed system is preferred in one preferred
embodiment. In this fixed bed system, the hydrocarbon feed stream
is preheated to the desired reaction temperature and then passed
into the dehydrogenation zone containing a fixed bed of the
catalyst. The dehydrogenation zone may itself comprise one or more
separate reaction zones with heating means therebetween to ensure
that the desired reaction temperature can be maintained at the
entrance to each reaction zone. The hydrocarbon may be contacted
with the catalyst bed in either upward, downward, or radial flow
fashion. Radial flow of the hydrocarbon through the catalyst bed is
preferred for commercial scale reactors. The hydrocarbon may be in
the liquid phase, a mixed vapor-liquid phase, or the vapor phase
when it contacts the catalyst. Preferably, it is in the vapor
phase.
[0038] Hydrocarbons which may be dehydrogenated include
dehydrogenatable hydrocarbons having from 2 to 30 or more carbon
atoms including paraffins, alkylaromatics, naphthenes, and olefins.
One group of hydrocarbons which can be dehydrogenated with the
catalyst is the group of normal paraffins having from 2 to 30 or
more carbon atoms. The catalyst is particularly useful for
dehydrogenating paraffins having from 2 to 15 or more carbon atoms
to the corresponding monoolefins or for dehydrogenating monoolefins
having from 3 to 15 or more carbon atoms to the corresponding
diolefins. The catalyst is especially useful in the dehydrogenation
of C.sub.2-C.sub.6 paraffins, primarily propane and butanes, to
monoolefins.
[0039] Dehydrogenation conditions include a temperature of from
about 400.degree. to about 900.degree. C., a pressure of from about
0.01 to 10 atmospheres absolute, and a liquid hourly space velocity
(LHSV) of from about 0.1 to 100 hr.sup.-1. Generally for normal
paraffins, the lower the molecular weight, the higher the
temperature required for comparable conversion. The pressure in the
dehydrogenation zone is maintained as low as practicable,
consistent with equipment limitations, to maximize the chemical
equilibrium advantages.
[0040] The effluent stream from the dehydrogenation zone generally
will contain unconverted dehydrogenatable hydrocarbons, hydrogen,
and the products of dehydrogenation reactions. This effluent stream
is typically cooled and passed to a hydrogen separation zone to
separate a hydrogen-rich vapor phase from a hydrocarbon-rich liquid
phase. Generally, the hydrocarbon-rich liquid phase is further
separated by means of either a suitable selective adsorbent, a
selective solvent, a selective reaction or reactions, or by means
of a suitable fractionation scheme. Unconverted dehydrogenatable
hydrocarbons are recovered and may be recycled to the
dehydrogenation zone. Products of the dehydrogenation reactions are
recovered as final products or as intermediate products in the
preparation of other compounds.
[0041] The dehydrogenatable hydrocarbons may be admixed with a
diluent material before, while, or after being passed to the
dehydrogenation zone. The diluent material may be hydrogen, steam,
methane, ethane, carbon dioxide, nitrogen, argon, and the like or a
mixture thereof. Hydrogen and steam are the preferred diluents.
Ordinarily, when hydrogen or steam is utilized as the diluent, it
is utilized in amounts sufficient to ensure a
diluent-to-hydrocarbon mole ratio of about 0.1:1 to about 40:1,
with best results being obtained when the mole ratio range is about
0.4:1 to about 10:1. The diluent stream passed to the
dehydrogenation zone will typically be recycled diluent separated
from the effluent from the dehydrogenation zone in a separation
zone.
[0042] A combination of diluents, such as steam with hydrogen, may
be employed. When hydrogen is the primary diluent water or a
material which decomposes at dehydrogenation conditions to form
water such as an alcohol, aldehyde, ether, or ketone, for example,
may be added to the dehydrogenation zone, either continuously or
intermittently, in an amount to provide, calculated on the basis of
equivalent water, about 1 to about 20,000 weight ppm of the
hydrocarbon feed stream. About 1 to about 10,000 weight ppm of
water addition gives best results when dehydrogenating paraffins
have from 6 to 30 or more carbon atoms.
[0043] To be commercially successful, a dehydrogenation catalyst
should exhibit three characteristics, namely, high activity, high
selectivity, and good stability. Activity is a measure of the
catalyst's ability to convert reactants into products at a specific
set of reaction conditions, that is, at a specified temperature,
pressure, contact time, and concentration of diluent such as
hydrogen, if any. For dehydrogenation catalyst activity, the
conversion or disappearance of paraffins in percent relative to the
amount of paraffins in the feedstock is measured. Selectivity is a
measure of the catalyst's ability to convert reactants into the
desired product or products relative to the amount of reactants
converted. For catalyst selectivity, the amount of olefins in the
product, in mole percent, relative to the total moles of the
paraffins converted is measured. Stability is a measure of the rate
of change with time on stream of the activity and selectivity
parameters--the smaller rates implying the more stable
catalysts.
[0044] The dehydrogenation of hydrocarbons is an endothermic
process. In a system employing a dehydrogenation catalyst only, it
is typically necessary to add superheated steam at various points
in the process or to intermittently remove and reheat the reaction
stream between catalyst beds. In an improvement, processes have
been developed which utilize a two-catalyst system with distinct
beds or reactors of dehydrogenation or selective oxidation
catalysts. The purpose of the selective oxidation catalysts is to
selectively oxidize the hydrogen produced as a result of the
dehydrogenation reaction with oxygen that had been added to the
oxidation zone to generate heat internally in the process. The heat
generated typically is sufficient to cause the reaction mixture to
reach desired dehydrogenation temperatures for the next
dehydrogenation step. The instant process may be accomplished in
this previously mentioned system. If such a process is employed,
the instant catalyst would comprise at least the dehydrogenation
catalyst with another specific catalyst being used to accomplish
the oxidation reaction. Before explaining the preferred reactor
configurations, more details of the oxidation aspect of the
invention are disclosed.
[0045] The selective oxidation step, if utilized, uses the hydrogen
which has been produced in the dehydrogenation step of the process
to supply heat to the next dehydrogenation reaction section. To
accomplish this, an oxygen-containing gas is first introduced into
the reactor, preferably at a point adjacent to the selective
oxidative catalyst section. The oxygen in the oxygen-containing gas
is necessary to oxidize the hydrogen contained in the reaction
stream. Examples of oxygen-containing gases which may be utilized
to effect the selective oxidation of the hydrogen which is present
will include air, oxygen, or air or oxygen diluted with other gases
such as steam, carbon dioxide and inert gases such as nitrogen,
argon, helium, etc. The amount of oxygen which is introduced to
contact the process stream may range from about 0.01:1 to about 2:1
moles of oxygen per mole of hydrogen contained in the process
stream at the point where oxygen is added to the process stream. In
the selective oxidation reaction, the process stream which
comprises unreacted dehydrogenatable hydrocarbon, dehydrogenated
hydrocarbon, and hydrogen is reacted with oxygen in the presence of
the selective steam oxidation/dehydrogenation catalyst whereby
hydrogen is selectively oxidized to produce water and heat energy
with very little of the oxygen reacting with the hydrocarbons.
[0046] The selective steam oxidation/dehydrogenation catalyst may
be one that is useful for the selective oxidation of hydrogen in
the presence of hydrocarbons. An example of such a catalyst is
disclosed in U.S. Pat. No. 4,418,237. Alternatively, the catalyst
used for the selective oxidation step may be identical to the
catalyst utilized for the dehydrogenation step. Such catalysts or
processes for their use are disclosed in U.S. Pat. Nos. 4,613,715
and 3,670,044. The instant catalyst exhibits both dehydrogenation
and selective oxidation functions. Therefore, it is possible that
the catalyst of this invention could be used in a single catalyst
containing a process for the dehydrogenation and selective
oxidation of hydrocarbons.
[0047] The oxygen-containing reactant may be added to the instant
process in various ways such as by admixing oxygen with a
relatively cool hydrocarbon feed stream or with the steam diluent,
or it may be added directly to the reactor independently of the
feed hydrocarbons or the steam diluent. In addition, the
oxygen-containing reactant can be added at one or more points in
the reactor in such a fashion as to minimize local concentrations
of oxygen relative to hydrogen in order to distribute the
beneficial temperature rise produced by the selective hydrogen
oxidation over the entire length of the reaction zone. In fact,
using a plurality of injection points for introducing the
oxygen-containing gas into the steam oxidation/dehydrogenation
reaction zone is a preferred mode of operation. This procedure
minimizes the opportunity for local build-up of the concentration
of oxygen relative to the amount of hydrogen, thereby minimizing
the opportunity for undesired reaction of the oxygen-containing gas
with either feed or product hydrocarbons.
[0048] The following example is introduced to further describe the
catalyst and process of the invention. This example is intended as
an illustrative embodiment and should not be considered to restrict
the otherwise broad interpretation of the invention as set forth in
the claims appended hereto.
EXAMPLE
[0049] In accordance with the present invention, the
dehydrogenation of a hydrocarbon deactivates the dehydrogenation
catalyst in about 100 hours of operation before it is necessary to
regenerate the catalyst. Therefore, the activity of a
dehydrogenation catalyst is graded by its initial maximum activity
and its performance over a period of time from 5 to about 20 hours
on stream.
[0050] In order to demonstrate the advantages to be achieved by the
present invention, a catalyst of this invention and two state of
the art prior art catalysts were prepared.
[0051] The first prior art catalyst contained 0.2 weight percent
tin and 0.7 weight percent potassium and the second prior catalyst
contained 0.2 weight percent tin and 1 weight percent potassium.
The catalyst of the present invention contained 0.17 weight percent
tin and 1 weight percent potassium. These catalysts are identified
as Catalyst A, Catalyst B and Catalyst C, respectively. First for
all three catalysts, a spherical alumina support was prepared by
the well-known oil-drop method. A tin component was incorporated in
the support by commingling a tin component precursor with the
alumina hydrosol and thereafter gelling the hydrosol. The tin
component in this case was uniformly distributed throughout the
catalyst particles. The catalyst particles were then dried at
600.degree. C. for about 2 hours and calcined at about 1050.degree.
C. The calcined tin-containing particles were then contacted with a
chloroplatinic acid solution and a potassium hydroxide solution to
uniformly impregnate the alumina base with platinum and potassium.
After impregnation, the catalyst was oven-treated in air at about
500.degree. C. for 4 hours in the presence of 3% steam and
chlorine-containing gases, followed by reduction in hydrogen at
about 550.degree. C. for about 2 hours. Catalyst A (prior art
catalyst) was prepared in accordance with the above-described
method to produce a finished catalyst containing 0.45 weight
percent platinum, 0.7 weight percent potassium and 0.2 weight
percent tin and having a platinum to tin mole ratio of 1.37.
Catalyst B (prior art catalyst) was also prepared in accordance
with the above-described method to produce a finished catalyst
containing 0.45 weight percent platinum, 1.0 weight percent
potassium and 0.2 weight percent tin and having a platinum to tin
mole ratio of 1.37. Catalyst C (invention) was similarly prepared
to produce a finished catalyst containing 0.45 weight percent
platinum, 1.0 weight percent potassium and 0.17 weight percent tin
and having a platinum to tin mole ratio of 1.6. The properties of
the catalysts are presented in Table 1 for comparison.
[0052] Each catalyst in turn was tested in a pilot plant to
dehydrogenate propane to produce propylene. The operating
conditions of each pilot plant test included a hydrogen to propane
mole ratio of 0.4, a liquid hourly space velocity (LHSV) of 30
hr.sup.-1, a pressure of 135 kPa (5 psig) and a feed temperature of
655.degree. C. (1210.degree. F.). The results of the tests are
presented in the FIGURE demonstrating the propane conversion
plotted against the total hours on stream.
[0053] From the FIGURE, it can be seen that the catalyst of the
present invention (Catalyst C) demonstrates a higher initial
maximum activity and achieves a higher propane conversion from 5 to
20 hours on stream than the prior art catalysts at the same
operating conditions. The lowering of the tin content from 0.20 to
0.17 weight percent with a potassium content of 1 weight percent
while maintaining the same platinum level of 0.45 weight percent
increases the platinum to tin mole ratio from 1.37 to 1.6 and
thereby surprisingly achieves a catalyst having increased activity
for the dehydrogenation of propane.
1 TABLE 1 Catalyst A Catalyst B Catalyst C Prior Art Prior Art
Invention Calcination Temp., .degree. C. 1050 1050 1050 Surface
area m.sup.2/g 80 80 80 ABD, g/cm3 0.60 0.60 0.60 Platinum, weight
percent 0.45 0.45 0.45 Tin, weight percent 0.20 0.20 0.17
Potassium, weight percent 0.7 1.0 1.0 Platinum/Tin, mole ratio 1.37
1.37 1.6
[0054] The foregoing description, FIGURE and example clearly
illustrate the advantages encompassed by the process of the present
invention and the benefits to be afforded with the use thereof.
* * * * *