CA2432200C - Catalyst with bimodal pore radius distribution - Google Patents

Catalyst with bimodal pore radius distribution Download PDF

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CA2432200C
CA2432200C CA002432200A CA2432200A CA2432200C CA 2432200 C CA2432200 C CA 2432200C CA 002432200 A CA002432200 A CA 002432200A CA 2432200 A CA2432200 A CA 2432200A CA 2432200 C CA2432200 C CA 2432200C
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catalyst
catalysts
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pore radius
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Daniel Heineke
Klaus Harth
Uwe Stabel
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BASF SE
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/066Zirconium or hafnium; Oxides or hydroxides thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61Surface area
    • B01J35/61310-100 m2/g
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61Surface area
    • B01J35/615100-500 m2/g
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/63Pore volume
    • B01J35/633Pore volume less than 0.5 ml/g
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/64Pore diameter
    • B01J35/6472-50 nm
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/66Pore distribution
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/66Pore distribution
    • B01J35/69Pore distribution bimodal
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/32Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
    • C07C5/321Catalytic processes
    • C07C5/324Catalytic processes with metals
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/32Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
    • C07C5/321Catalytic processes
    • C07C5/324Catalytic processes with metals
    • C07C5/325Catalytic processes with metals of the platinum group
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/02Boron or aluminium; Oxides or hydroxides thereof
    • C07C2521/04Alumina
    • CCHEMISTRY; METALLURGY
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    • C07C2521/00Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/06Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
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    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/06Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • C07C2521/08Silica
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    • C07C2523/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/02Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the alkali- or alkaline earth metals or beryllium
    • C07C2523/04Alkali metals
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    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/14Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of germanium, tin or lead
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    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
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    • C07C2523/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals
    • C07C2523/40Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals of the platinum group metals
    • C07C2523/42Platinum
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    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2531/00Catalysts comprising hydrides, coordination complexes or organic compounds
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Abstract

Catalysts with bimodal pore radius distribution, comprising a) 10 to 99.9 wt . % zirconium dioxide, b) 0 to 60 wt. % aluminium oxide, silicon dioxide and/or titanium dioxide and c) 0.1 to 10 wt. % of at least one element of the first or second main group, an element of the third sub-group, an element of the eighth sub-group of the periodic element system, lanthanum and/or zinc, with the proviso that the total of the weight percentages is 100.

Description

~

CATALYST WITH BIMODAL PORE RADIUS DISTRIBUTION

The present invention relates to catalysts having a bimodal pore radius distribution and comprising a) zirconium dioxide and, if desired, b) aluminum oxide, titanium dioxide and/or silicon oxide and c) at least one element of main group I or II, an element of transition group III, an element of transition group VIII, of the Periodic Table of the Elements, lanthanum and/or tin.

US-A-5,220,091 discloses catalysts comprising Pt/Sn as active component on a Zn spinel support for the dehydrogenation of small hydrocarbon molecules such as isobutane using steam as diluent. The performance of these catalysts is in need of improvement since, despite the high dilution of the feed with steam (ratio 4:1), only relatively low yields and selectivities are achieved at high reaction temperatures of 600 C. Likewise deserving of improvement is the operating life of the catalysts, since they have to be regenerated after an operating time of only 7 hours.

US-A-4,788,371 discloses Pt/Sn/Cs/A1203 catalysts for the dehydrogenation of hydrocarbons using steam dilution (e.g.
steam/propane = 10:1). Despite the high degree of dilution, only low conversions of 21% are achieved.

WO-A-94/29021 discloses catalysts based on mixed oxides of magnesium and aluminum and further comprising a noble metal of group VIII, a metal of group IVa and, if desired, an alkali metal of group Ia, of the Periodic Table of the Elements for the dehydrogenation of, for example, a gas mixture of H20/propan/H2/N2 in a ratio of 8:7:1:5. A drawback of these catalysts in industrial applications is their low hardness, which makes industrial use difficult. Furthermore, the performance of these catalysts, in particular at low reaction temperatures, is in need of improvement. A further disadvantage is the complicated operating procedure which, to maintain the performance, requires the addition of hydrogen to the feed and the mixing in of nitrogen for further dilution.

it is an object of the present invention to remedy the abovementioned disadvantages.
We have found that this object is achieved by new and improved catalysts having a bimodal pore radius distribution and comprising:
a) from 30 to 99.9% by weight of zirconium dioxide and b) from 0 to 60% by weight of aluminum oxide, silicon dioxide and/or titanium dioxide; and c) from 0.1 to 10% by weight of at least one element of main group I and II, an element of transition group III, an element of transition group VIII, of the Periodic Table of the Elements, lanthanum and/or tin, with the proviso that the sum of the percentages by weight is 100, a process for the dehydrogenation of C2-C16-hydrocarbons and the use of these catalysts for this purpose and also a process for producing these catalysts.

The catalysts of the present invention as claimed, more specifically consist of a catalyst having a bimodal pore radius distribution and consisting essentially of:
a) from 30 to 99.9% by weight of zirconium dioxide of which from 50 to 100% by weight is in the monoclinic modification and;
b) from 0 to 60% by weight of aluminum oxide, silicon dioxide and/or titanium dioxide; and c) from 0.1 to 10% by weight of at least one element selected from among main groups one and two and transition groups three and eight of the Periodic Table of the Elements and tin, with the proviso that the sum of the percentages by weight is 100.
The catalysts of the present invention, preferably consist of, a) from 30 to 99.9% by weight, preferably from 20 to 98% by weight, particularly preferably from 30 to 95% by weight and even more preferably from 64 to 95% by weight, of zirconium dioxide of which from 50 to 100% by weight, preferably from 60 to 99% by weight, particularly preferably from 70 to 98% by weight, is in the monoclinic and/or tetragonal modification and b) from 0.1 to 30% by weight, preferably from 0.5 to 25% by weight, particularly preferably from 30 to 20% by weight, of silicon dioxide and c) from 0 to 60% by weight, preferably from 0.1 to 50% by weight, particularly preferably from 1 to 40% by weight, in particular from 5 to 30% by weight, of aluminum oxide, silicon dioxide and/or titanium dioxide in the form of rutile or anatase and d) from 0.1 to 10% by weight, preferably from 0.2 to 8% by weight, particularly preferably from 0.5 to 5% by weight, of at least one element of main group I or II, an element of transition group III, an element of transition group VIII, of the Periodic Table of the Elements, lanthanum and/or tin, where the sum of the percentages by weight is 100.
Preferably, the catalysts of the present invention comprise potassium or cesium as an element of main group I of the Periodic Table.

The amount of a noble metal present in the catalysts of the present invention is generally from 0.01 to 5% by weight, preferably from 0.1 to 1% by weight, particularly preferably from 0.2 to 0.5% by weight.

According to another preferred embodiment, the catalysts preferably contain from 0.1 to 5% by weight of potassium and/or cesium.

Moreover the catalysts advantageously contain from 0.05 to 1% by weight of platinum and from 0.05 to 2% by weight of tin.

In the catalysts of the present invention, from 70 to 100%, preferably from 75 to 98%, particularly preferably from 80 to 95%, of the pores are smaller than 20 nm or in the range from 40 to 5000 nm.

To produce the catalysts of the present invention, use can be made of precursors of the oxides of zirconium, titanium, silicon and aluminum (forming the support) which can be converted by calcination into the oxides. These can be prepared by known methods, for example by the sol-gel process, precipitation of the salts, dehydration of the corresponding acids, dry mixing, slurrying or spray drying. For example, a Zr02 = xA1203 = xSiOz mixed oxide can be prepared by first preparing a water-rich zirconium oxide of the formula Zr02 = xH2O by precipitation of a suitable zirconium-containing precursor. Suitable zirconium precursors are, for example, Zr(N03)4, ZrOC12 or ZrC14. The precipitation itself is carried out by addition of a base such as NaOH, KOH, Na2CO3 and NH3 and is described, for example, in EP-A-849 224.

To prepare a Zr02 = xSiOz mixed oxide, the Zr precursor obtained as above can be mixed with an Si-containing precursor. Well suited Si02 precursors are, for example, water-containing sols of Si02 such as LudoxTM. The two components can be mixed, for example, by simple mechanical mixing or by spray drying in a spray dryer.
when using mixed oxides, it is possible to influence the pore structure in a targeted way. The particle sizes of the various precursors influence the pore structure. Thus, for example, macropores can be generated in the microstructure by use of A1203 having a low loss on ignition and a defined particle size distribution. An aluminum oxide which has been found to be useful for this purpose is Puralox (A1203 having a loss on ignition of about 3%).

To prepare a Zr02 = xSi02 = xA1203 mixed oxide, the Si02 = xZr02 powder mixture obtained as described above can be admixed with an Al-containing precursor. This can be carried out, for example, by simple mechanical mixing in a kneader. However, a Zr02 = xSi02 = xA1203 mixed oxide can also be prepared in a single step by dry mixing of the individual precursors.
Compared to pure Zr02, the mixed oxides have the advantage, inter alia, that they can be shaped easily. For this purpose, the powder mixture obtained is admixed in a kneader with a concentrated acid and can then be converted into a shaped body, e.g. by means of a ram extruder or a screw extruder.

A further possible way of producing the support having a specific pore radius distribution for the catalysts of the present invention is to add, during the preparation, various polymers which can be partly or completely removed by calcination so as to form pores in defined pore radius ranges.
The mixing of the polymers and the oxide precursors can, for example, be carried out by simple mechanical mixing or by spray drying in a spray dryer.

4a More preferably, the polymers are selected from the group consisting of polyamines, polyacrylates, polyalcohols, polysiloxanes, carbohydrates, polyvinylpyrrolidone or mixtures thereof.

The use of PVP (polyvinylpyrrolidone) has been found to be particularly advantageous for producing the supports having a bimodal pore radius distribution. If PVP is added during a production step to one or more oxide precursors of the elements Zr, Ti, Al or Si, macropores in the range from 200 to 5000 nm are formed after calcination. A further advantage of the use of PVP is that the support can be shaped more readily. Thus, extrudates having good mechanical properties can be produced easily from freshly precipitated water-containing Zr02 = xHZO
which has previously been dried at 120 C when PVP and formic acid are added, even without further oxide precursors.

The mixed oxide supports of the catalysts of the present invention generally have higher BET surface areas after calcination than do pure Zr02 supports. The BET surface areas of the mixed oxide supports are generally from 40 to 300 m2/g, preferably from 50 to 200 m2/g, particularly preferably from 60 to 150 m2/g. The pore volume of the catalysts of the present invention is usually from 0.1 to 0.8 ml/g, preferably from 0.2 to 0.6 ml/g, and even more preferably from 0.25 to 0.5 mi/g. The mean pore diameter of the catalysts of the present invention, which can be detertmined by Hg porosimetry, is from 5 to 20 nm, preferably from 8 to 18 nm. Furthermore, it is advantageous for from 10 to 80% of the pore volume to be made up by pores > 40 nm.

The calcination of the mixed oxide supports is advantageously carried out after the application of the active components and is carried out at from 400 to 700 C, preferably from 500 to 650 C, particularly preferably from 560 to 620 C. The = 0050/50549 CA 02432200 2003-06-18 calcination temperature should usually be at least as high as the reaction temperature of the dehydrogenation for which the catalysts of the present invention are used.
5 The catalysts of the present invention have a bimodal pore radius distribution. The pores are mostly in the range up to 20 nm and in the range from 40 to 5000 nm. Based on the pore volume, these pores make up at least 70% of the pores. The proportion of pores less than 20 nm is generally from 20 to 60%, while the proportion of pores in the range from 40 to 5000 nm is generally likewise from 20 to 60%.

The doping of the mixed oxides with a basic compound can be carried out either during their preparation, for example by coprecipitation, or subsequently, for example by impregnation of the mixed oxide with an alkali metal compound or alkaline earth metal compound or a compound of transition group III or a rare earth metal compound. Particularly suitable dopants are K, Cs and lanthanum.
The application of the dehydrogenation-active component, which is usually a metal of transition group VIII, is generally carried out by impregnation with a suitable metal salt precursor which can be converted into the corresponding metal oxide by calcination. As an alternative to impregnation, the dehydrogenation-active component can also be applied by other methods, for example spraying the metal salt precursor onto the support. Suitable metal salt precursors are, for example, the nitrates, acetates and chlorides of the appropriate metals, or complex anions of the metals used. Preference is given to using platinum as H2PtCl6 or Pt(N03)2. Solvents which can be used for the metal salt precursors are water and organic solvents.
Particularly suitable solvents are lower alcohols such as methanol and ethanol.
Further suitable precursors when using noble metals as dehydrogenation-active component are the corresponding noble metal sols which can be prepared by one of the known methods, for example by reduction of a metal salt with a reducing agent in the presence of a stabilizer such as PVP. The preparation technique is dealt with comprehensively in the German Patent Application DE-A-195 00 366.

The catalyst can be used as a fixed bed in the reactor or, for example, in the form of a fluidized bed and may have an appropriate shape. Suitable shapes are, for example, granules (crushed material), pellets, monoliths, spheres or extrudates (rods, wagon wheels, stars, rings).

As alkali metal and alkaline earth metal precursors, use is generally made of compounds which can be converted into the corresponding oxides by calcination. Examples of suitable precursors are hydroxides, carbonates, oxalates, acetates or mixed hydroxycarbonates of the alkali metals and alkaline earth metals.
if the mixed oxide support is additionally or exclusively doped with a metal of main group III or transition group III, the starting materials in this case should be compounds which can be converted into the corresponding oxides by calcination. If lanthanum is used, suitable starting compounds are, for example, lanthanum oxide carbonate, La(OH)3, La3(C03)2, La(N03)3 or lanthanum compounds containing organic anions, e.g. lanthanum acetate, lanthanum formate or lanthanum oxalate.

The dehydrogenation of propane is generally carried out at reaction temperatures of from 300 to 8000C, preferably from 450 to 7000C, and a pressure of from 0.1 to 100 bar, preferably from 0.1 to 40 bar, and at a WI3SV (weight hourly space velocity) of from 0.01 to 100 h-1, preferably from 0.1 to 20 h-1. Apart from the hydrocarbon to be dehydrogenated, the feed may further comprise diluents such as C02, N2, noble gases and/or steam, preferably N2 and/or steam, particularly preferably steam.

A specific feature of the catalysts of the present invention is that they are active in the dehydrogenation of hydrocarbons in the presence of steam and it is therefore possible to utilize the advantages associated therewith, for example removal of the equilibrium limitation, reduction in carbon deposits and lengthening of the operating life.
If desired, hydrogen can be added to the hydrocarbon feed, in which case the ratio of hydrogen to hydrocarbon is generally from 0.1:1 to 100:1, preferably from 1:1 to 20:1. The dehydrogenation of hydrocarbons using the catalysts of the present invention is preferably carried out without use of hydrogen.

Apart from the continuous addition of a gas, in particular of steam, it is possible to regenerate the catalyst by passing hydrogen or air over it from time to time. The regeneration itself takes place at from 300 to 9000C, preferably from 400 to 8000C, using a free oxidizing agent, preferably air, or in a reducing atmosphere, preferably hydrogen. Regeneration can be carried out at subatmospheric pressure, atmospheric pressure or superatmospheric pressure. Preference is given to pressures in the range from 0.5 to 100 bar.
Hydrocarbons which can be hydrogenated by means of the catalysts of the present invention are, for example, C2-C16-hydrocarbons such as ethane, n-propane, n-butane, iso-butane, n-pentane, iso-pentane, n-hexane, n-heptane, n-octane, n-nonane, n-decane, n-undecane, n-dodecane, n-tridecane, n-tetradecane, n-pentadecane, n-hexadecane, preferably C2-C8-hydrocarbons such as ethane, n-propane, n-butane, iso-butane, n-pentane, iso-pentane, n-hexane, n-heptane, n-octane, particularly preferably C2-C4-hydrocarbons such as ethane, n-propane, n-butane and iso-butane, in particular propane and iso-butane.
Propylene is a sought-after product, particularly for the synthesis of polypropylene or for the synthesis of functionalized monomers and their polymerization products. An alternative to the preparation of propylene by steam cracking of light naptha is the dehydrogenation of propane.

isobutene is an important product, particularly for the preparation of MTBE (Methyl tert-butyl ether). It is used, particularly in the USA, as a fuel additive for increasing the octane number. isobutene can be prepared by dehydrogenation of isobutane in a process analogous to that for producing propylene.

Examples Catalyst production Example 1 A solution of 0.7793 g of SnC12 = 2H20 and 0.5124 g of H2PtC16 =
6H20 in 400 ml of ethanol was poured over 67.03 g of Zr02 = xSiOZ
= xA1203 (MEL, product designation XZO 747/03, 1.6-2 mm granules). The excess solution was removed under a reduced pressure of 28 mbar on a rotary evaporator over a period of 30 minutes. The composition was dried at 100OC for 15 hours and calcined at 5600C for 3 hours. A solution of 0.5027g of CsN03 and 1.7668g of KN03 in 166 ml of water was then poured over the catalyst. The supernatant solution was removed under a reduced pressure of 30 mbar over a period of 30 minutes. The catalyst , was dried at 100 C for 15 hours and calcined at 560 C for 3 hours.

The catalyst had a BET surface area of 92 m2/g. Mercury porosimetry measurements gave a pore volume of 0.29 ml/g, a pore area of 67 m2/g and a mean pore radius of 4.9 nm. Based on the pore volume, about 31% of the pores had a diameter of less than nm and about 57% had a diameter in the range from 200 and 4000 nm.
The composition of the catalyst is shown in Table 1.
Example 2 186.73 g of ZrOC12 = 8H20 were dissolved in 800 ml of water. At room temperature, 347 ml of 5 M NaOH were added dropwise to this solution at a rate of 1 ml/min. After a time of about 6 hours, the precipitation was complete and the pH was 14. The precipitated material was aged for 15 hours at 100 C. The suspension was subsequently filtered, the solid was washed with 3000 ml of a 5% strength NH4NO3 solution and subsequently with pure water until free chloride could no longer be detected. The solid was dried at 100 C for 16 hours and was then heated at a heating rate of 1 C/min to 600 C and calcined at this temperature for 12 hours.

110 g of a Zr02 powder prepared in this way were pretreated with 3.3 g of walocel in 40 ml of water and the mixture was kneaded for 2 hours, then extruded under a pressure of 30 bar to form 3 mm extrudates and subsequently crushed.

A solution of 0.465 g of SnC12 = 2H20 and 0.306 g of H2PtC16 =
6H20 in 245 ml of ethanol was poured over 40 g of the crushed material produced as described above (sieve fraction: 1.6-2 mm).
The excess solution was removed under a reduced pressure of 28 mbar on a rotary evaporator over a period of 30 minutes. The composition was dried at 100 C for 15 hours and calcined at 560 C for 3 hours. A solution of 0.299 g of CsN03 and 0.663 g of KN03 in 105 ml of water was then poured over the catalyst. The supernatant solution was removed under a reduced pressure of 30 mbar over a period of 30 minutes. The catalyst was dried at 100 C for 15 hours and calcined at 560 C for 3 hours.

The catalyst had a BET surface area of 107 mz/g. Mercury porosimetry measurements gave a pore volume of 0.46 ml/g, a pore area of 102 m2/g and a mean pore radius of 7.7 nm. Based on the ti pore volume, about 37% of the pores had a diameter of not more than 10 nm and about 40% had a diameter in the range from 200 and 5000 nm.

The composition of the catalyst is shown in Table 1..
Example 3 373.46 g of ZrOCl2 = 8H20 were dissolved in 3200 ml of water. At room temperature, 694 ml of 5 M NaOH were added dropwise to this solution at a rate of 1 ml/min. After a time of about 6 hours, the precipitation was complete and the pH was 14. The precipitated material was aged for 15 hours at 100 C. The suspension was subsequently filtered, the solid was washed with 6000 ml of a 5% strength NH4NO3 solution and subsequently with pure water until free C1- could no longer be detected. The solid was dried at 100 C for 16 hours. 6 g of PVP
(polyvinylpyrrolidone) and 6 g of concentrated formic acid in 70 ml of water were added to 200 g of the precipitated material prepared in this way. The mixture was kneaded for 2 hours and extruded under a pressure of 20 bar to form 3 mm extrudates which were subsequently crushed.

A solution of 0.639 g of SnC12 = xH2O and 0.421 g of H2PtC16 =
6H20 in 337 ml of ethanol was poured over 40 g of the crushed material produced as described above (sieve fraction: 1.6-2 mm).
The excess solution was removed under a reduced pressure of 28 mbar on a rotary evaporator over a period of 30 minutes. The composition was dried at 100 C for 15 hours and calcined at 560 C for 3 hours. A solution of 0.411 g of CsN03 and 0.725 g of KN03 in 144 ml of water was then poured over the catalyst. The supernatant solution was removed under a reduced pressure of 30 mbar over a period of 30 minutes. The catalyst was dried at 100 C for 15 hours and calcined at 560 C for 3 hours.
The catalyst had a BET surface area of 102 m2/g. Mercury porosimetry measurements gave a pore volume of 0.32 ml/g, a pore area of 101 m2/g and a mean pore radius of 7.8 nm. Based on the pore volume, about 50% of the pores had a diameter of not more than 10 nm and about 25% had a diameter in the range from 200 and 2000 nm.

The composition and the performance of the catalyst are shown in Table 1.

Example 4 A solution of 0.384 g of SnC12 = 2H2O and 0.252 g of H2PtCl6 =
6H20 in 196 ml ethanol was poured over 32 g of a crushed Zr02 =
5 xSiOZ mixed oxide from Norton (# 9816590; sieve fraction 1.6-2 mm).

The excess solution was removed under a reduced pressure of 28 mbar on a rotary evaporator over a period of 30 minutes. The 10 composition was dried at 1000C for 15 hours and calcined at 5600C for 3 hours. A solution of 0.247 g of CsN03i 0.435 g of KN03 and 3.147 g of La(N03)3 = 6H2O in 120 ml of H20 was then poured over the catalyst. The supernatant solution was removed under a reduced pressure of 30 mbar over a period of 30 minutes.
The catalyst was dried at 1000C for 15 hours and calcined at 5600C for 3 hours.

The catalyst had a BET surface area of 82 m2/g. Mercury porosimetry measurements gave a pore volume of 0.27 ml/g, a pore area of 65 m2/g and a mean pore radius of 11.7 nm. Based on the pore volume, about 58% of the pores had a diameter of not more than 20 nm, about 18% of the pores had a diameter of from 40 to 100 nm and about 30% had a diameter of more than 40 and less than 5000 nm.
The composition of the catalyst is shown in Table 1.
Comparative Example 1 (Comp. 1) A catalyst was prepared for comparison using the method in WO-A-94/29021, Example l (Pt/Sn/Cs/Mg(Al)O).

The composition of the catalyst is shown in Table 1.
Comparative Example 2(Comp. 2) The catalyst was produced using a method analogous to Comparative Example 1.

The composition of the catalyst is shown in Table 1.
Catalyst test 20 ml of a catalyst produced as described above were installed in a tube reactor having an internal diameter of 22 mm. The catalyst was treated with hydrogen at 5800C for 30 minutes. The catalyst was then exposed to a mixture of 80% of nitrogen and = 0050/50549 CA 02432200 2003-06-18 20% of air (lean air) at the same temperature. After a flushing phase of 15 minutes using pure nitrogen, the catalyst was reduced with hydrogen for 30 minutes. 20 standard 1/h of propane (99.5% pure) and H20 in a molar ratio of propane/steam of 1:1 were then passed over the catalyst at a reaction temperature of 580 C or 610 C. The pressure was 1.5 bar and the GHSV was 1000 h-1. The reaction products were determined by gas chromatography.

The results using the catalysts of Examples 1 to 4 and the Comparative Examples are shown in Table 1.

Table 1: Performance of the catalysts of Examples 1 to 4 and Comparative Examples 1 and 2 in the dehydrogenation of propane*

Conversion Selecti-[~] after vity [%]
after Example Pt Sn K Cs Zr02 Si02 A1203 1 h 17 h 1 h 17 h No./[ C] [%] [%] [%] [%] [%] [%l [%]
1 /580 0.3 0.6 1.0 0.5 85.6 2.1 12.0 38 36 85 91 2 /580 0.3 0.6 0.5 0.5 98.1 --- --- 41 34 89 85 3 /580 0.3 0.6 1.0 0.5 97.6 --- --- 38 32 92 86 4 /610 0.3 0.6 0.5 0.5 90.8 4.5 --- 49 45 93 95 Comp. 1 0.3 0.3 --- 0.5 --- --- --- 33 29 92 95 Comp. 2 0.3 0.6 --- 0.5 -47 38 93 93 *) Test conditions: 20 ml of catalyst, granule size = 1.6 -2 mm; 580 C or 610 C; propane/H20 = 1:1 (mol/mol); 20 standard 1/h of propane; GHSV = 1000 h-i; 1.5 bar.

**) Comparative catalyst: Pt/Sn/Cs/Mg(Al)O from WO-A-94/29021 Example 1.

Claims (9)

WHAT IS CLAIMED IS:
1. A catalyst having a bimodal pore radius distribution and consisting essentially of:
a) from 30 to 99.9% by weight of zirconium dioxide of which from 50 to 100% by weight is in the monoclinic modification;
b) from 0 to 60% by weight of aluminum oxide, silicon dioxide and/or titanium dioxide; and c) from 0.1 to 10% by weight of at least one element selected from among main groups one and two and transition groups three and eight of the Periodic Table of the Elements and tin, with the proviso that the sum of the percentages by weight is 100.
2. The catalyst as claimed in claim 1 which consists essentially of:
a) from 64 to 95% by weight of zirconium dioxide;
b) from 0.5 to 25% by weight of silicon dioxide;
c) from 0.1 to 1% by weight of platinum;and d) from 0.1 to 10% by weight of at least one element selected from among potassium, cesium, lanthanum and tin, with the proviso that the sum of the constituents present is 100% by weight.
3. The catalyst as claimed in claim 1 or 2, which has a BET surface area in the range from 40 to 300 m2/g.
4. The catalyst as claimed in any one of claims 1 to 3, which has a pore volume of from 0.25 to 0.5 ml/g.
5. The catalyst as claimed in any one of claims 1 to 4, which contains from 0.1 to 5% by weight of potassium and/or cesium.
6. The catalyst as claimed in any one of claims 1 to 5, which contains from 0.05 to 1% by weight of platinum and from 0.05 to 2% by weight of tin.
7. A process for preparing a catalyst as defined in any one of claims 1 to 6, wherein from 2 to 30% by weight of polyamines, polyacrylates, polyalcohols, polysiloxanes, carbohydrates, polyvinylpyrrolidone, or mixtures thereof are added to the catalyst components of the raw catalyst composition, and the mixture is calcined at above 550°C.
8. Use of a catalyst as defined in any one of claims 1 to 6, for the dehydrogenation of C2-C16-hydrocarbons.
9. A process for dehydrogenating C2-C16-hydrocarbons in the presence of a catalyst as defined in any one of claims 1 to 6.
CA002432200A 2000-12-22 2000-12-22 Catalyst with bimodal pore radius distribution Expired - Fee Related CA2432200C (en)

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KR101218453B1 (en) * 2008-12-30 2013-01-04 주식회사 효성 dehydrogenation catalyst
KR101440694B1 (en) * 2012-12-27 2014-09-25 삼성토탈 주식회사 A catalyst for dehydrogenation and dehydroisomerization of n-butane and a method for producing a mixture of n-butane, 1,3-butadiene and iso-butene in high yield using the same
CN109384639B (en) * 2017-08-07 2021-05-11 中国石油化工股份有限公司 Propane dehydrogenation catalyst, preparation method thereof and method for preparing propylene by propane dehydrogenation
CN113839047B (en) * 2020-06-24 2023-01-24 中国石油化工股份有限公司 Organic liquid fuel cell electrode material, preparation method and application thereof, organic liquid fuel cell electrode and fuel cell
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