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US20070144942A1 - Catalyst and method for the preparation thereof - Google Patents

Catalyst and method for the preparation thereof Download PDF

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US20070144942A1
US20070144942A1 US10/579,494 US57949404A US2007144942A1 US 20070144942 A1 US20070144942 A1 US 20070144942A1 US 57949404 A US57949404 A US 57949404A US 2007144942 A1 US2007144942 A1 US 2007144942A1
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oxide
noble metal
catalyst
support
aluminum
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Marja Tiitta
Vesa Niemi
Marina Linblad
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Neste Oyj
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Neste Oyj
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/03—Catalysts comprising molecular sieves not having base-exchange properties
    • B01J29/0308—Mesoporous materials not having base exchange properties, e.g. Si-MCM-41
    • B01J29/0316—Mesoporous materials not having base exchange properties, e.g. Si-MCM-41 containing iron group metals, noble metals or copper
    • B01J29/0325—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/041—Mesoporous materials having base exchange properties, e.g. Si/Al-MCM-41
    • B01J29/042—Mesoporous materials having base exchange properties, e.g. Si/Al-MCM-41 containing iron group metals, noble metals or copper
    • B01J29/043—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/064—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof containing iron group metals, noble metals or copper
    • B01J29/068—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
    • B01J29/74—Noble metals
    • B01J29/7415—Zeolite Beta
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0238—Impregnation, coating or precipitation via the gaseous phase-sublimation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/58—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
    • C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
    • C10G45/62—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used containing platinum group metals or compounds thereof
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/58—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
    • C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
    • C10G45/64—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/18—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/18—Carbon
    • B01J21/185—Carbon nanotubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/42—Platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/70—Catalysts, in general, characterised by their form or physical properties characterised by their crystalline properties, e.g. semi-crystalline

Definitions

  • the present invention relates to a noble metal catalyst, to a method for the preparation thereof based on gas phase technique, to the use of the catalyst in reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions, and to a method for the manufacture of middle distillates.
  • noble metal catalysts are active in hydrocarbon reforming, isomerisation, isodewaxing, dehydrogenation and hydrogenation reactions.
  • Commercially available noble metal catalysts typically consist of platinum, palladium, ruthenium, rhodium, iridium or mixtures thereof.
  • noble metal catalysts are traditionally prepared in liquid phase by impregnation or ion-exchange technique. Only a few reports on the deposition of noble metals from gas phase on porous support materials, in the preparation of heterogeneous catalysts, are known from the literature. Vaporised noble metal precursors are most commonly deposited intact, usually by physisorption/condensation, on the support surface and afterwards decomposed to form metallic particles, or they are thermally or chemically decomposed during deposition.
  • a method for producing Pd/Au shell catalysts by a CVD process is disclosed in WO 99/67022.
  • Evaporable Pd/Au precursors form metal particles on the support surface either during the deposition or afterwards by thermal or chemical reduction.
  • the thickness of the shell containing the metal particles is controlled by process parameters.
  • Lashdaf et al. Appl. Catal. A 241 (2003) 51-63 present a different approach, where vaporised Pd and Ru beta-diketonates were deposited on alumina and silica supports in gas-solid reactions.
  • the reaction temperature was kept high enough to ensure chemisorption of the metal precursor, and the reactions were allowed to proceed until saturation of the surface was achieved.
  • This reactive interaction with the support surface generally leads to well-dispersed species.
  • the reactive interaction of a vaporizable noble metal precursor with a support has also been utilized by Mu et al. ( Appl. Catal. A 248 (2003) 85-95).
  • saturating gas-solid reactions in a gas phase process for the manufacture of a heterogeneous catalyst, is disclosed in WO 91/10510.
  • Said process comprises an optional pre-treatment step wherein the support, which may be an inorganic oxide, such as alumina or silica, or a zeolite, is thermally and/or chemically treated in order to provide the desired binding sites for the catalytically active component that is to be bound to the support. Then the surface activated support is contacted and allowed to interact with vapour containing the catalytically active species or its precursor at conditions ensuring that saturating gas-solid reactions take place, i.e.
  • an optional post-treatment follows, which may comprise a heat-treatment step carried out at oxidizing or reducing conditions.
  • Zeolite-supported zinc, alumina-supported rhenium and silica-supported chromium are mentioned as main groups.
  • a similar, improved gas phase method for the manufacture of a heterogeneous catalyst, based on saturating gas-solid reactions, is presented in FI 913438. It discloses control methods that can be employed in saturating reactions to attain a desired content of the active metal species.
  • Said process comprises an optional pre-treatment step wherein the support is thermally and/or chemically treated.
  • the chemical treatment may comprise treating the support with an inhibiting reagent, such as hexamethyl disilazane, which deactivates a portion of the available surface bonding sites, or a reagent, such as water, which increases the number of available surface bonding sites.
  • Noble metal catalysts are chemically stable, easy to store and handle. Mechanical stability and formability lie mainly on the support used in the catalyst. Noble metal catalysts are widely used in oil refining and in chemical and pharmaceutical industry in several reactions like hydrocarbon reforming, isomerisation, isodewaxing, dehydrogenation, hydrogenation and dry reforming processes.
  • Hydrocarbon reforming reactions typically comprise aromatics and hydrogen formation as well as isomerisation.
  • olefin isomerisation processes double bond isomerisation and skeletal isomerisation take place, in addition to side reactions such as cracking and dimerisation.
  • the desired reaction in n-paraffin isomerisation processes is isomerisation of n-paraffins to isoparaffins.
  • Isodewaxing processes comprise isomerising of wax molecules, and in dehydrogenation reactions olefins are produced from paraffins.
  • Hydrogenation processes comprise addition of hydrogen into a molecule, and thus olefins and diolefins are hydrogenated to paraffins and olefins, respectively, and aromatics to naphthenes.
  • olefins and diolefins are hydrogenated to paraffins and olefins, respectively, and aromatics to naphthenes.
  • methane and carbon dioxide react to produce hydrogen and carbon monoxide.
  • Carbon monoxide is an important reactant in many processes, such as the Fischer-Tropsch synthesis and the process for the manufacture of methanol.
  • the required carbon monoxide and hydrogen may be prepared by dry reforming technique utilizing carbon dioxide and paraffins as reactants and by steam reforming technique using water and paraffins as reactants and a catalyst for said carbon monoxide activating reactions comprises nickel, rhodium, ruthenium, palladium, platinum or mixtures thereof on a support.
  • a catalyst for ring-opening reactions of cyclic organic compounds is presented in U.S. Pat. No. 6,235,962.
  • the catalyst comprises a catalytically active metal selected from platinum, palladium, rhodium, rhenium, iridium, ruthenium, nickel, cobalt and mixtures or combinations thereof, a metal modifier selected from tungsten, molybdenum, lanthanum and rare earth metals and mixtures and combinations thereof, on a carrier selected from alumina, silica, zirconia and mixtures thereof.
  • Said catalysts are efficient heterogeneous catalysts for ring-opening reactions of cyclic compounds in the presence of hydrogen.
  • Cyclic compounds include derivatives of cyclopentane, cyclohexane, decalin, indane, indene, benzene and naphthalene present in diesel fuel.
  • a naphthalene ring-opening catalyst for forming high cetane number distillates having high degree of linear paraffins is disclosed in WO 00/08156.
  • the catalyst comprises iridium and an effective amount of metals of group VIII, such as platinum, rhodium and/or ruthenium.
  • the catalyst composition is especially effective in opening compounds containing C 6 naphthene rings to C 5 naphthene rings bearing at least one tertiary carbon.
  • WO 00/08157 discloses a catalyst system comprising naphthene ring-isomerising catalyst (50-90%) and naphthene ring-opening catalyst (50-10%).
  • the isomerising catalyst contains a specific metal supported on a first catalyst support for isomerising compounds containing C 6 naphthene rings to C 5 naphthene rings, preferably platinum or palladium on alumina
  • the naphthene ring-opening catalyst contains another specific metal on a second catalyst support, for ring-opening compound containing naphthene rings, preferably iridium on alumina.
  • WO 00/08158 teaches the use of a catalyst for naphthenic ring-opening of distillates, comprising group VIII metal e.g. iridium, platinum, palladium, rhodium and/or ruthenium, supported on a substrate (e.g. alumina modified with magnesium) having at least one group IB, IIB and IVA metal in an amount effective to moderate cracking of naphthene ring containing feed to form methane.
  • the catalyst also suppresses dealkylation of any pendant substituents optionally present in the ring structure.
  • the catalyst exhibits desirable tertiary bond cleavage activity.
  • Said method provides relatively high contents of linear and less branched paraffins and the preferred ring-opening catalyst compositions are Ir—Cu, Ir—Sn, Pt—Ir—Sn, Pt—Cu and Pt—Sn.
  • a catalyst composition comprising iridium is disclosed in WO 02/07881.
  • Said catalyst composition is useful for altering the range of tertiary carbon sites in naphthene or naphthenic ring containing distillates, in order to form products with a higher degree of linear paraffin functionality.
  • the composition is effective in ring-opening compounds containing C 5 and C 6 naphthene rings bearing at least one tertiary carbon.
  • the catalyst composition comprises iridium, which is supported on a composite support of an alumina component and acidic silica alumina molecular sieve component.
  • at least one other or second group VIII metal selected from platinum, ruthenium and rhodium can be added to the iridium containing catalyst.
  • a two-stage process for producing diesel fuel with increased cetane number and particularly for selective naphthenic ring-opening reactions is disclosed in US 2002 / 0121457 .
  • the first stage comprises a hydro-treating stage for removing sulphur from the feed and the second stage is the selective ring-opening stage.
  • the ring-opening catalyst is an extremely low acidic catalyst having a high selectivity to middle distillate, containing highly dispersed platinum.
  • the catalyst contains a crystalline molecular sieve material component and a group VIII noble metal component.
  • the crystalline molecular sieve component is a large pore zeolite having an alpha-acidity of less than 1, and zeolite USY is mentioned as the preferred crystalline molecular sieve material.
  • the group VIII noble metal component can be platinum, palladium, iridium, rhodium or a combination thereof.
  • the ultra low acidity of the catalysts permits the cracking of only carbon-carbon bonds without secondary cracking and hydroisomerisation of desired paraffins for diesel fuel.
  • Middle distillate is a mixture of different hydrocarbons comprising typically molecules with carbon numbers C9-C21 and the typical boiling range of middle distillate is between 432-623 K. Middle distillate contains usually aromatics, paraffins and naphtenes.
  • the reaction from naphthenes to paraffins can also be applied in the production of base oils and in the improvement of the quality of solvents.
  • the quality of crude oils used in oil refineries in the production of base oils effects on the viscosity index and on the viscosity of the obtained products.
  • By opening of naphthenic rings the viscosity index of lube oils can also be increased.
  • naphthenic components may cause undesired odours in solvents
  • by opening naphthenic rings it is possible to decrease the odour and improve the quality of solvents.
  • WO 00/40676 teaches a process for producing of diesel fuel with increased cetane number from hydrocarbon feedstock.
  • the process includes contacting the feedstock with a catalyst, which has large pore crystalline molecular sieve material component having faujasite structure and alpha acidity of less than 1.
  • the catalyst contains a dispersed Group VIII noble metal component which catalyses the hydrogenation/hydrocracking of the aromatic and naphthenic species in the feedstock and the preferred catalyst combination is platinum/USY.
  • the cetane number of the fraction boiling above 477 K was improved from 63 to 65-69.
  • WO 02/07877 discloses a process for opening naphthenic rings of naphthenic ring containing compounds with catalysts comprising at least one group VIII metal selected from iridium, platinum, rhodium and ruthenium wherein these metals are supported on an alkali metal or alkaline earth metal modified support.
  • Said catalysts can be used to provide a reduced number of ring structures in the product stream, to minimize dealkylation of any pendant substituents optionally present in the ring structure and to increase the volume of the product.
  • the catalyst is particularly beneficial in converting naphthene feed containing C 6 naphthene ring containing composition, wherein the C 6 ring contains at least one tertiary carbon site, to a product containing a substantial quantity of linear and less branched paraffin compounds.
  • the group VIII metal is supported on a substrate containing an effective amount of an alkali metal or alkaline-earth metal and the substrate is desirably a refractory inorganic oxide, preferably with lower acidity, such as alumina.
  • the distribution and dispersion of metal particles on a support material are important properties, which affect the behaviour of noble metal catalysts in hydrocarbon reactions.
  • highly dispersed metal particles on suitable support materials are a prerequisite for highly active noble metal catalysts.
  • well-dispersed metal particles may show different behaviour due to variations in their electronic and/or geometric properties. Since noble metals are commonly present in very low concentrations in heterogeneous catalysts, said properties are difficult to measure directly.
  • An object of the invention is to provide a selective noble metal catalyst for hydrocarbon conversion reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions, and particularly for ring-opening of naphthenic molecules.
  • a further object of the invention is a method for the manufacture of a selective noble metal catalyst for hydrocarbon conversion reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions, and particularly for ring-opening of naphthenic molecules.
  • a further object of the invention is the use of a selective noble metal catalyst in hydrocarbon conversion reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions, and particularly in ring-opening of naphthenic molecules.
  • a still further object of the invention is a process for the manufacture of middle distillate diesel fuel using a selective noble metal catalyst for ring-opening of naphthenes with two and multiple rings in middle distillate, particularly to manufacture corresponding isoparaffins, n-paraffins and mononaphthenes in the middle distillate region.
  • the present invention relates to a selective noble metal catalyst comprising a noble metal catalyst on a support, wherein the noble metal and the support are active, or the noble metal is active.
  • the method for the manufacture of said selective noble metal catalyst comprises use of gas phase technique.
  • the selective noble metal catalyst according to the invention can be used as a catalyst in hydrocarbon conversion reactions, such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions.
  • the method for the manufacture of middle distillate diesel fuels comprises the use of the selective noble metal catalyst in the process.
  • a selective noble metal catalyst comprising a noble metal catalyst on a support, wherein the noble metal and the support are active, or the noble metal is active, using gas phase technique.
  • the selective noble metal catalyst comprises a group VIII metal selected from platinum, palladium, ruthenium, rhodium, iridium or mixtures or combinations thereof, preferably platinum, on a support and the catalyst activates carbon monoxide at temperature below 323 K.
  • the support is selected from zeolites, inorganic oxides, carbon related materials and mixtures and combinations thereof. Acidic support materials are also catalytically active.
  • the zeolite is selected from medium or large pore zeolites having acid sites, preferably large pore zeolites having weak or medium strength of acid sites.
  • Particularly suitable zeolite materials are mesoporous aluminosilicates, such as MCM-41, crystalline aluminosilicates, such as Y- and beta-zeolites, and mordenites, crystalline aluminophosphates, such as AlPO-5 and AlPO-11, as well as crystalline aluminosilicophosphates, such as SAPO-5 and SAPO-11.
  • the inorganic oxide is selected from silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, tungsten oxide, magnesium oxide and any mixtures thereof and preferably from silicon oxide and aluminum oxide.
  • the carbon related material is selected from activated carbon, graphite and carbon nanotubes.
  • the method for the manufacture of the noble metal catalyst comprises the following steps:
  • the noble metal is deposited on the support by gas phase deposition technique.
  • the gas phase technique is based on gas-solid reactions.
  • the selection of the noble metal precursor is an important feature, as the noble metal precursor should not decompose thermally during the vaporisation and it should also be stable enough to withstand heating to the reaction temperature.
  • the volatile metal compounds used as precursors in the gas phase preparation are selected from a wide range of compounds including metal chlorides, oxychlorides, beta-diketonates, metallocenes, such as (CH 3 ) 3 (CH 3 C 5 H 4 )Pt, and oxides.
  • the precursor may be a liquid, solid, or gas at room temperature.
  • the metal is deposited on the support by gas phase deposition using a corresponding metal precursor.
  • the processing is carried out at ambient or reduced pressure depending on the precursor, in the presence of an inert carrier gas, such as nitrogen, helium, argon, methane or the like.
  • the support is pre-treated at a temperature of 423-1173 K.
  • a pressure in the range of ambient to reduced pressure may be used.
  • the amount of the metal deposited can be minimised in the optional modification step by blocking part of the available surface sites on the support.
  • the optional modification to modify the support surface can be carried out by depositing a blocking agent on the support using gas phase or liquid phase technique, such as impregnation from an organic solution, preferably gas phase technique.
  • a blocking agent known in the art may be used and the suitable ones are selected from compounds, which during final handling can be completely removed from the support surface, preferably such as alcohols, acetylacetone (acacH) or 2,2,6,6-tetramethyl-3,5-heptanedione (thdH), or the blocking agents may leave elements on the surface of the support, common with the support material itself, preferably such as precursors of silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, tungsten oxide and magnesium oxide.
  • the preferable silicon oxide, aluminum oxide, titanium oxide, zirconium oxide, tungsten oxide and magnesium oxide precursors are presented in the following.
  • Preferable silicon compounds are, for example, silicon tetrachloride SiCl 4 , silicon alkoxides, such as tetramethoxysilane Si(OMe) 4 and tetraethoxysilane Si(OEt) 4 , and compounds formed by silicon and organic compounds, such as hexamethyldisilazane (HMDS) (CH 3 ) 3 Si—NH—Si(CH 3 ) 3 or hexamethyldisiloxane (HMDSO) (CH 3 ) 3 Si—O—Si(CH 3 ) 3 .
  • HMDS hexamethyldisilazane
  • HMDSO hexamethyldisiloxane
  • Preferable aluminum compounds are, for example, aluminum chloride AlCl 3 or metalorganic compounds, such as aluminum ethoxide Al(OEt) 3 , aluminum (III) acetyl-acetonate AM(C 5 H 7 O 2 ) 3 , tris(2,2,6,6,-tetramethyl-3,5-heptanedionato)aluminum Al(C 11 H 19 O 2 ) 3 , or organometallic compounds, such as trimethylaluminum (TMA) Al(CH 3 ) 3 and triethylaluminum Al(C 2 H 5 ) 3 .
  • metalorganic compounds such as aluminum ethoxide Al(OEt) 3 , aluminum (III) acetyl-acetonate AM(C 5 H 7 O 2 ) 3 , tris(2,2,6,6,-tetramethyl-3,5-heptanedionato)aluminum Al(C 11 H 19 O 2 ) 3 , or organometallic compounds, such as trimethyl
  • titanium compounds are titanium tetrachloride TiCl 4 and titanium isopropoxide Ti(OCH(CH 3 ) 2 ) 4 .
  • a preferable zirconium compound is zirconium tetrachloride ZrCl 4 .
  • Preferable tungsten compounds are tungsten oxychloride WOCl 4 and tungsten hexachloride WCl 6 .
  • a preferable magnesium compound is tris(2,2,6,6-tetramethyl-3,5-heptanedionato)-magnesium Mg(C 11 H 19 O 2 ) 2 .
  • the precursor selected from volatile metal compounds preferably (trimethyl)methyl cyclopentadienyl platinum (CH 3 ) 3 (CH 3 C 5 H 4 )Pt
  • CH 3 ) 3 CH 3 C 5 H 4
  • the precursor is vaporised in amounts sufficiently high to ensure the desired noble metal content on the support.
  • the amount of the noble metal deposited on the support varies between 0.01-20 wt %, preferably 0.01-5 wt %.
  • final handling is carried out by a heat-treatment performed at oxidising or reducing conditions.
  • the formulation of the catalyst material with a carrier and/or binder can be performed using methods known in the state of the art, such as grinding, tabletting, granulating or extruding.
  • the gas phase processing of the catalyst material can be carried out in a conventional fixed bed reactor, in a fluidised bed reactor or in any other reactors known in the state of the art.
  • the gas phase reaction can be performed in closed reactor systems or in open reactor systems.
  • the obtained noble metal catalyst exhibits the following characteristic features: the catalyst activates carbon monoxide at temperatures below 323 K and it is highly dispersed which is illustrated in example 19. The noble metal content in the catalyst according to the invention is low.
  • the catalyst according to the invention performs well in hydrocarbon conversion reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry-reforming and dehydrogenation reactions, and particularly it is suitable for ring-opening of naphthenic molecules.
  • the noble metal catalyst according to the invention has several further advantages. It is stable, more effective and selective in reactions such as ring-opening, isomerisation, alkylation, hydrocarbon reforming, dry reforming, hydrogenation and dehydrogenation reactions, and it can be used in smaller amounts to achieve high conversions. Additionally it causes less cracking than catalysts according to the state of the art and it can be easily regenerated.
  • the method according to the present invention for the manufacture of the noble metal catalyst, is simpler, it requires less process steps than conventional liquid phase methods, it can be performed in a single apparatus and the manufacture is less expensive as less noble metal is needed. Further, this is a novel method for the manufacture of ring-opening catalysts, as earlier catalysts have not been prepared by gas phase technique.
  • the noble metal catalyst is particularly suitable for the process for the manufacture of middle distillates.
  • a middle distillate feedstock is transferred to a reactor wherein it is allowed to react at a temperature of 283-673 K and under a pressure of 10-200 bar with hydrogen in the presence of the noble metal catalyst according to the invention to accomplish opening of naphthenes with two and multiple rings to produce isoparaffins, n-paraffins and mononaphthenes in the middle distillate region.
  • the volume of middle distillate diesel fuels can be increased and higher cetane numbers can be achieved when the catalyst according to the invention is used in a reaction where multi-ring naphthenes are converted into mono-ring naphthenes and paraffins.
  • the supports for the manufacture of noble metal catalysts by impregnation (comparative examples) and by gas phase technique (examples according to the invention) the supports, commercial beta-zeolite and MCM-41, which was supplied by ⁇ bo Akademie University, Finland, were sieved to a particle size of 75-150 ⁇ m and dried overnight at 423 K.
  • the platinum contents of the catalysts were determined by ICP (Inductively coupled plasma emission).
  • the prepared catalysts were characterised by dispersion measured by CO-adsorption analysis. In the analysis the sample (100-200 mg) was inserted in a quartz U-tube and reduced in H 2 stream (20 ml/min).
  • Platinum loaded beta-zeolite catalyst (Pt-beta-1) was prepared by conventional incipient wetness impregnation of standardized metal solutions.
  • the platinum precursor was tetraammineplatinum(II) nitrate [Pt(NH 3 ) 4 ](NO 3 ) 2 ].
  • the catalyst was calcined at 623 K in air and reduced under hydrogen at 573 K.
  • the platinum content was 0.5 wt %.
  • the dispersion measured by CO adsorption was 45%.
  • Platinum loaded beta-zeolite catalyst (Pt-beta-2) was prepared by conventional incipient wetness impregnation of standardised metal solutions.
  • the platinum precursor was tetraammineplatinum(II) nitrate [Pt(NH 3 ) 4 ](NO 3 ) 2 ].
  • the catalyst was calcined at 623 K in air and reduced under hydrogen at 573 K.
  • the platinum content was 4.7 wt %.
  • the dispersion measured by CO adsorption was 24%.
  • Platinum loaded beta-zeolite catalyst (Pt-beta-3) was prepared by conventional incipient wetness impregnation of standardised metal solutions.
  • the platinum precursor was tetraammineplatinum(II) chloride [Pt(NH 3 ) 4 Cl 2 ].
  • the catalyst was calcined at 623 K in air and reduced under hydrogen at 573 K The platinum content was 0.5 wt %.
  • Platinum loaded beta-zeolite was prepared by an ion-exchange procedure as follows. 10 g of H-beta-zeolite was weighed to a 2 l flask and 1 l of ion-exchanged water was added. 52 ml of 0.01 M Pt-solution was measured to a drop funnel and the Pt-solution was dropped slowly (about 15 drops/min) to the flask at a temperature of 343 K and with shaking. The mixture was filtered. The impregnated zeolite was washed with ion-exchanged water, refiltered and placed into an oven at a temperature of 353 K for 16 hours. The obtained catalyst was calcined in an oven at 573 K. The platinum content of the catalyst was 0.11 wt %.
  • Platinum catalysts were prepared on beta-zeolite and mesoporous MCM-41 by gas phase deposition using (trimethyl)methyl cyclopentadienyl platinum (IV) as the precursor (purity 99%).
  • the processing was carried out in a flow-type reactor at reduced pressure of about 5-10 kPa with nitrogen as carrier gas. Before the deposition the supports were preheated at 673 K in a muffle furnace under atmospheric pressure for 16 hours. Additionally, they were heated in situ in the reactor at 473-673 K for 3 hours to remove water adsorbed during their transfer to the reactor.
  • the precursor (CH 3 ) 3 (CH 3 C 5 H 4 )Pt was vaporised at 343 K and allowed to react at 373 K with a fixed bed of the support that had been stabilised to the same temperature.
  • the reaction was completed with a nitrogen purge at the reaction temperature.
  • the catalysts were calcined in air at 623 K.
  • the amount of the required metal could be reduced by blocking part of the available surface sites.
  • the nature of the blocking agent influenced the extent of blocking. This can be seen from following table 2, wherein the blocking reaction conditions and Pt content of the obtained Pt catalysts are presented (examples 8-11).
  • the catalysts were prepared by saturating gas-solid reactions using Pt(acac) 2 TABLE 2 Pt/Al 2 O 3 catalysts prepared by saturating gas-solid reactions using Pt(acac) 2 .
  • HMDS Blocking reaction Vaporization Reaction tem- Reagent temperature, K perature, K Pt, wt %
  • Example 8 no — — 9.0
  • ThdH 323-333 473 4.2
  • Example 10 HMDS 353 453 2.7
  • HMDS hexamethyldisilazane, (CH 3 ) 3 Si-NH-Si(CH 3 ) 3 (CAS-nro 999-97-3)
  • Al(acac) 3 aluminum acetylacetonate, Al(C 5 H 7 O 2 ) 3 (CAS-nro 13963-57-0)
  • Pt(acac) 2 platinum acetylaacetonate, Pt(C 5 H 7 O 2 ) 2 (CAS-nro
  • the processing was carried out in a flow-type reactor at reduced pressure of about 5-10 kPa with nitrogen as carrier gas.
  • the supports zeolites
  • the reaction of the blocking reagent and the reaction of Pt(acac) 2 were carried out as successive reactions, each reaction step being completed with a nitrogen purge at the reaction temperature concerned.
  • the vaporisation and reaction temperatures of the blocking reagents are given in Table 2.
  • the platinum precursor, Pt(acac) 2 was vaporised and allowed to react with the modified support at 453 K.
  • the amount of vaporised blocking/platinum reagent was kept sufficiently high to ensure saturation of the surface.
  • the ligands were removed by a post-treatment in synthetic air at 623 or 723 K.
  • the blocking reagents were totally removed (thdH) or formed silicon oxide (from HMDS) or aluminum oxide (from AM(acac) 3 ) were left on the support surface.
  • Carbon dioxide was formed on the catalyst prepared according to example 6 during CO adsorption at 300 K.
  • FIG. 1 the mass spectrum of exhaust gas in CO adsorption is shown.
  • the x-axis is the mass number and y-axis the abundance of the component.
  • FIG. 2 presents the IR spectrum of the exhaust gas in CO adsorption.
  • the x-axis is the wave number and the y-axis the signal intensity.

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US8067062B2 (en) * 2007-02-15 2011-11-29 Korea Institute Of Energy Research Carbon nano tube electrode formed by directly growing carbon nano tube on surface of carbon paper and supporting platinum-based nano catalyst on carbon nano tube using CVD method and manufacturing method thereof
US20080199696A1 (en) * 2007-02-15 2008-08-21 Hee-Yeon Kim Carbon nano tube electrode formed by directly growing carbon nano tube on surface of carbon paper and supporting platinum-based nano catalyst on carbon nano tube using cvd method and manufacturing method thereof
US20090257796A1 (en) * 2008-04-09 2009-10-15 Houston Advanced Research Center Nanotechnology based image reproduction device
US20100050619A1 (en) * 2008-09-03 2010-03-04 Houston Advanced Research Center Nanotechnology Based Heat Generation and Usage
US9492818B2 (en) 2009-06-12 2016-11-15 Albemarle Europe Sprl SAPO molecular sieve catalysts and their preparation and uses
US10087376B2 (en) 2010-01-20 2018-10-02 Jx Nippon Oil & Energy Corporation Method for producing monocyclic aromatic hydrocarbons
US20120289397A1 (en) * 2011-05-11 2012-11-15 Korea Institute Of Science And Technology Method of fabrication of nano particle complex catalyst by plasma ion implantation and device for the same
US9200217B2 (en) 2011-05-26 2015-12-01 Jx Nippon Oil & Energy Corporation Gas oil composition and method for producing same
US8480964B2 (en) 2011-07-05 2013-07-09 King Fahd University Of Petroleum And Minerals Plate reactor
US9862897B2 (en) 2013-02-21 2018-01-09 Jx Nippon Oil & Energy Corporation Method for producing monocyclic aromatic hydrocarbon
US20180371335A1 (en) * 2017-06-22 2018-12-27 Uop Llc Composition for opening polycyclic rings in hydrocracking
US10472577B2 (en) * 2017-06-22 2019-11-12 Uop Llc Composition for opening polycyclic rings in hydrocracking
CN110773176A (zh) * 2019-11-08 2020-02-11 中国石油化工股份有限公司 用于降低石油焦硫含量的催化剂、其制备方法和应用
CN113620784A (zh) * 2021-07-26 2021-11-09 武汉工程大学 一种耦合烷烃脱氢和木质素基醚类加氢反应工艺
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