Dehydrogenation catalyst, its use and method of preparation

Patent metadata

Field	Value
Publication number	US-9415378-B2
Application number	US-201314093630-A
Country	US
Kind code	B2
Filing date	Dec 2, 2013
Priority date	Dec 2, 2013
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

Abstract

A dehydrogenation catalyst is formed by forming a mixture comprising a bayerite aluminum hydroxide (Al(OH) 3 ), a lanthanum (La) source, a cerium (Ce) source, a barium (Ba) source, a zirconium (Zr) source, and water into a shaped body. The shaped body is calcined at a temperature of at least 750° C. to form a catalyst support. The catalyst support is treated with a dehydrogenation catalyst component to form a treated catalyst support containing the dehydrogenation catalyst component. The treated catalyst support is then calcined. The resulting catalyst composition may be used by contacting a paraffin hydrocarbon feed with a catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products.

First claim

We claim:

1. A method of forming a dehydrogenating catalyst comprising:
forming a mixture comprising a bayerite aluminum hydroxide (Al(OH) 3 ), a lanthanum (La) source, a cerium (Ce) source, a barium (Ba) source, a zirconium (Zr) source, and water into a shaped body;
calcining the shaped body at a temperature of at least 750° C. to form a catalyst support;
treating the catalyst support with a dehydrogenation catalyst component to form a treated catalyst support containing the dehydrogenation catalyst component; and
calcining the treated catalyst support.

2. The method of claim 1 , wherein;
the dehydrogenation catalyst component is comprised of at least one of platinum (Pt), tin (Sn), nickel (Ni), phosphorus (P), and calcium (Ca).

3. The method of claim 1 , wherein:
the catalyst support contains lanthanum oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the lanthanum source of the mixture.

4. The method of claim 1 , wherein:
the catalyst support contains cerium oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the cerium source of the mixture.

5. The method of claim 1 , wherein:
the catalyst support contains barium oxide in an amount of from 0.5% to 10% by weight of the catalyst support provided by the barium source of the mixture.

6. The method of claim 1 , wherein:
the catalyst support contains zirconium oxide in an amount of from 5% to 20% by weight of the catalyst support provided by the zirconium source of the mixture.

7. The method of claim 1 , wherein:
the catalyst support contains lanthanum oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the lanthanum source of the mixture, cerium oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the cerium source of the mixture, barium oxide in an amount of from 0.5% to 10% by weight of the catalyst support provided by the barium source of the mixture, and zirconium oxide in an amount of from 5% to 20% by weight of the catalyst support provided by the zirconium source of the mixture.

8. The method of claim 1 , wherein:
the catalyst support is in a substantially eta alumina phase.

9. A method of dehydrogenating paraffin hydrocarbons comprising:
contacting a paraffin hydrocarbon feed with a catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products, the catalyst being that formed by a method comprising:
forming a mixture comprising a bayerite aluminum hydroxide (Al(OH) 3 ), a lanthanum (La) source, a cerium (Ce) source, a barium (Ba) source, a zirconium (Zr) source, and water into a shaped body;
calcining the shaped body at a temperature of at least 750° C. to form a catalyst support;
treating the catalyst support with a dehydrogenation catalyst component to form a treated catalyst support containing the dehydrogenation catalyst component; and
calcining the treated catalyst support.

10. The method of claim 9 , wherein;
the dehydrogenation catalyst component is comprised of at least one of platinum (Pt), tin (Sn), nickel (Ni), phosphorus (P), and calcium (Ca).

11. The method of claim 9 , wherein:
the catalyst support contains lanthanum oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the lanthanum source of the mixture.

12. The method of claim 9 , wherein:
the catalyst support contains cerium oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the cerium source of the mixture.

13. The method of claim 9 , wherein:
the catalyst support contains barium oxide in an amount of from 0.5% to 10% by weight of the catalyst support provided by the barium source of the mixture.

14. The method of claim 9 , wherein:
the catalyst support contains zirconium oxide in an amount of from 5% to 20% by weight of the catalyst support provided by the zirconium source of the mixture.

15. The method of claim 9 , wherein:
the catalyst support contains lanthanum oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the lanthanum source of the mixture, cerium oxide in an amount of from 1% to 8% by weight of the catalyst support provided by the cerium source of the mixture, barium oxide in an amount of from 0.5% to 10% by weight of the catalyst support provided by the barium source of the mixture, and zirconium oxide in an amount of from 5% to 20% by weight of the catalyst support provided by the zirconium source of the mixture.

16. The method of claim 9 , wherein:
the catalyst support is in a substantially eta alumina phase.

17. A dehydrogenation catalyst composition useful for the dehydrogenation of hydrocarbons, the catalyst composition comprising:
a catalyst support of bayerite aluminum hydroxide (Al(OH) 3 ) having a substantially eta alumina phase and containing lanthanum (La), cerium (Ce), barium (Ba), and zirconium (Zr) synthesized within the crystal structure of the catalyst support.

Assignees

• Saudi Basic Ind Corp

Inventors

• Kauffman James W
• Hooks Patricia A
• Nair Balamurali Krishna R
• Zhang Xiankuan

Classifications

• B01J27/1856 Primary

  with platinum group metals · CPC title

• C07C5/3337

  of the platinum group · CPC title

• B01J37/04

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

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C07C2523/02

  of the alkali- or alkaline earth metals or beryllium · CPC title