Catalyst with improved activity/selectivity for light naphtha aromatization

Patent metadata

Field	Value
Publication number	US-2016288108-A1
Application number	US-201415035505-A
Country	US
Kind code	A1
Filing date	Nov 6, 2014
Priority date	Nov 22, 2013
Publication date	Oct 6, 2016
Grant date	—

Abstract

In an embodiment, a method for making a catalyst, comprises: forming a mixture comprising a germanium source, an alkali metal source, an aluminum source, and a silica source, wherein the mixture has a pH; adjusting the pH of the mixture to a value of greater than or equal to 9.5; crystallizing and calcining the mixture to form a zeolite; depositing platinum on the zeolite; and calcining the zeolite to form the final catalyst. The final catalyst is non-acidic and has an aluminum content of less than or equal to 0.75 wt % based on the total weight of the final catalyst excluding any binder and extrusion aide and a Si:Al2 mole ratio of greater than or equal to 125.

First claim

I/We claim:

1 . A method for making a catalyst, comprising:
forming a mixture comprising a germanium source, an alkali metal source, an aluminum source, and a silica source, wherein the mixture has a pH; adjusting the pH of the mixture to a value of greater than or equal to 9.5; crystallizing and calcining the mixture to form a zeolite; depositing platinum on the zeolite; and calcining the zeolite to form the final catalyst; wherein the final catalyst is non-acidic and has an aluminum content of less than or equal to 0.75 wt % based on the total weight of the final catalyst excluding any binder or extrusion aide, and a final Si:Al 2 mole ratio of greater than or equal to 125.

2 . The method of claim 1 , wherein the forming of the mixture comprises:
forming a first aqueous solution, wherein the first solution comprises the germanium source and the alkali metal source; forming a second aqueous solution, wherein the second solution comprises the aluminum source; combining the first and second aqueous solutions to form a combined solution; and adding the silica source to the combined solution to form the mixture.

3 . The method of claim 1 , wherein the mixture has a mixture Si:Al 2 mole ratio of 175 to 290, a mixture Si:Ge mole ratio of 5 to 100, and a mixture Na:Al mole ratio of 10 to 60.

4 . The method of claim 1 , wherein the zeolite is a ZSM-5 zeolite.

5 . The method of claim 1 , wherein the final catalyst has one or both of a final Si:Ge mole ratio of 40 to 400 and a final Na:Al mole ratio of 0.9 to 2.5.

6 . The method of claim 1 , wherein the final catalyst comprises one or more of a Ge content of 0.1 to 3 wt %, an Na content of 0.5 to 2 wt %, and a Pt content of 0.05 to 3 wt %, wherein the wt % values are based on the total weight of the final catalyst excluding any binder and extrusion aide.

7 . The method of claim 1 , wherein the method does not include an ion-exchange step with an alkali metal.

8 . The method of claim 1 , wherein the final catalyst is free of cesium.

9 . The method of claim 1 , wherein the alkali metal source comprises at least one of a sodium source and a potassium source.

10 . The method of claim 1 , wherein the alkali metal source comprises at least one of NaOH and NaCl.

11 . The method of claim 1 , wherein the pH is 9.5 to 12.5.

12 . A catalyst comprising:
a zeolite comprising Si, Al, and Ge in the framework with Pt deposited thereon; wherein the catalyst has an Si:Al 2 mole ratio of greater than or equal to 125, an Si:Ge mole ratio of 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5, wherein the catalyst has an aluminum content of less than or equal to 0.75 wt %, wherein the catalyst is non-acidic.

13 . The catalyst of claim 12 , wherein the Ge is present in an amount of 0.3 to 3 wt %, and/or the Na is present in an amount of 0.5 to 2 wt % and/or the Pt is present in an amount of 0.05 to 3 wt %, wherein the wt % values are based on the total weight of the final catalyst excluding any binder and extrusion aide.

14 . A method for the aromatization of hydrocarbons comprising:
contacting an alkane containing 6 to 12 carbon atoms per molecule with a catalyst comprising: a zeolite comprising Si, Al, and Ge in the framework with Pt deposited thereon; wherein the catalyst has an Si:Al 2 mole ratio of greater than or equal to 125, an Si:Ge mole ratio of 40 to 400, and an Na:Al mole ratio of 0.9 to 2.5, wherein the catalyst has an aluminum content of less than or equal to 0.75 wt % excluding any binder and extrusion aide.

15 . The method of claim 14 , wherein the Ge is present in an amount of 0.3 to 3 wt %, and/or the Na is present in an amount of 0.5 to 2 wt % and/or the Pt is present in an amount of 0.05 to 3 wt %, wherein the wt % values are based on the total weight of the final catalyst excluding any binder and extrusion aide.

16 . The method of claim 1 , wherein the final catalyst has a Ge content of 0.1 to 3 wt % based on the total weight of the final catalyst excluding any binder and extrusion aide.

17 . The method of claim 1 , wherein the final catalyst has a Ge content of 0.4 to 1.5 wt % based on the total weight of the final catalyst excluding any binder and extrusion aide.

18 . The method of claim 1 , wherein the final catalyst comprises Al in an amount of 0.45 to 0.7 wt % based on the total weight of the final catalyst excluding any binder and extrusion aide.

19 . The method of claim 1 , wherein the final catalyst has a Ge content of 0.1 to 3 wt %, an Na content of 0.5 to 2 wt %, and a Pt content of 0.05 to 3 wt %, wherein the wt % values are based on the total weight of the final catalyst excluding any binder and extrusion aide.

20 . The method of claim 1 , wherein the final catalyst has a final Si:Ge mole ratio of 40 to 400 and a final Na:Al mole ratio of 0.9 to 2.5.

Assignees

• Saudi Basic Ind Corp

Inventors

• Khanmamedova Alla
• Stevenson Scott

Classifications

• C07C2/76

  by condensation of hydrocarbons with partial elimination of hydrogen · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• C07C2529/62

  Noble metals · CPC title

• C07C2529/44

  Noble metals · CPC title

• C10G45/10

  containing platinum group metals or compounds thereof · CPC title