US20070267324A1 - Process and Catalysts for the Production of Linear Alkanes - Google Patents

Process and Catalysts for the Production of Linear Alkanes Download PDF

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US20070267324A1
US20070267324A1 US10/590,313 US59031305A US2007267324A1 US 20070267324 A1 US20070267324 A1 US 20070267324A1 US 59031305 A US59031305 A US 59031305A US 2007267324 A1 US2007267324 A1 US 2007267324A1
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zeolite
process according
partial
total substitution
catalytic
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Leonardo Dalloro
Alberto Cesana
Roberto Buzzoni
Franco Rivetti
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Versalis SpA
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Polimeri Europa SpA
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    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING 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
    • C10G47/00Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
    • C10G47/02Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
    • C10G47/10Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
    • C10G47/12Inorganic carriers
    • C10G47/16Crystalline alumino-silicate carriers
    • C10G47/20Crystalline alumino-silicate carriers the catalyst containing other metals or compounds thereof
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    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/085Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead
    • B01J29/088Y-type faujasite
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    • B01J29/00Catalysts comprising molecular sieves
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    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/10Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • B01J29/12Noble metals
    • B01J29/126Y-type faujasite
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    • B01J29/00Catalysts comprising molecular sieves
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    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/10Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • B01J29/14Iron group metals or copper
    • B01J29/146Y-type faujasite
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/16Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J29/166Y-type faujasite
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C4/00Preparation of hydrocarbons from hydrocarbons containing a larger number of carbon atoms
    • C07C4/02Preparation of hydrocarbons from hydrocarbons containing a larger number of carbon atoms by cracking a single hydrocarbon or a mixture of individually defined hydrocarbons or a normally gaseous hydrocarbon fraction
    • C07C4/06Catalytic processes
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING 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
    • C10G47/00Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
    • C10G47/02Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
    • C10G47/10Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
    • C10G47/12Inorganic carriers
    • C10G47/16Crystalline alumino-silicate carriers
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING 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
    • C10G47/00Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
    • C10G47/02Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
    • C10G47/10Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
    • C10G47/12Inorganic carriers
    • C10G47/16Crystalline alumino-silicate carriers
    • C10G47/18Crystalline alumino-silicate carriers the catalyst containing platinum group metals or compounds 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
    • B01J2229/00Aspects of molecular sieve catalysts not covered by B01J29/00
    • B01J2229/10After treatment, characterised by the effect to be obtained
    • B01J2229/18After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself
    • B01J2229/183After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself in framework positions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2229/00Aspects of molecular sieve catalysts not covered by B01J29/00
    • B01J2229/10After treatment, characterised by the effect to be obtained
    • B01J2229/20After treatment, characterised by the effect to be obtained to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2229/00Aspects of molecular sieve catalysts not covered by B01J29/00
    • B01J2229/30After treatment, characterised by the means used
    • B01J2229/42Addition of matrix or binder particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/86Borosilicates; Aluminoborosilicates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/87Gallosilicates; Aluminogallosilicates; Galloborosilicates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/88Ferrosilicates; Ferroaluminosilicates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/89Silicates, aluminosilicates or borosilicates of titanium, zirconium or hafnium
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00Catalysts comprising molecular sieves
    • C07C2529/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • C07C2529/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • C07C2529/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • C07C2529/10Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00Catalysts comprising molecular sieves
    • C07C2529/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • C07C2529/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • C07C2529/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • C07C2529/10Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • C07C2529/12Noble metals
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00Catalysts comprising molecular sieves
    • C07C2529/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • C07C2529/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • C07C2529/08Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • C07C2529/10Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • C07C2529/14Iron group metals or copper

Definitions

  • the present invention relates to a process for the production of linear alkanes containing less than 6 carbon atoms, which comprises putting a mix including one or more hydrocarbons containing at least 6 carbon atoms, in contact with a suitable catalytic composition containing one or more metals and a Y-type zeolite.
  • mixtures which can be used for the process of the present invention are, for example, mixtures comprising one or more C6+ hydrocarbons selected from alkanes, alkenes with one or more unsaturations, aromatic compounds.
  • these mixtures can be fractions from mineral oil, fractions from catalytic or thermo conversion plants, and fractions deriving therefrom by hydrogenation.
  • Low molecular weight aromatic compounds ( ⁇ 9 carbon atoms) which can be obtained from these mixtures, are widely used as chemical intermediates and as components of motor-vehicle fuels.
  • the use of medium molecular weight (up to 12 carbon atoms) components of these mixtures as chemical intermediates and in fuels is more restrained, but still economically important.
  • the use of higher molecular weight components is less advantageous and their main destination is as a low-price fuel.
  • mixtures containing hydrocarbons with a different chemical structure for which the necessity is presently felt for finding alternative means of exploitation are those deriving from so-called cracking gasolines and reforming residues.
  • These hydrocarbon fractions derive from cracking gasolines (also called pyrolysis asoline or pygas) or from reforming gasoline after the ore valuable components, such as benzene, toluene and ylenes, have been at least partially separated from hem.
  • Cracking/reforming gasolina residue does not have a fixed composition, also because mixtures of a different origin can be joined in varying proportions.
  • benzene, toluene and xylenes are still present in these mixtures, as the previous separation process is never total, the main components present are aliphatic hydrocarbons with varying structures having 7-9 carbon atoms, ethyl benzene and other alkyl benzenes with 9-12 carbon atoms, styrene and methyl styrenes, methyl cyclopentadiene, dicyclopentadiene and various co-dimers of cyclopentadiene and methyl cyclopentadiene starting from 9 carbon atoms (for example in the case of the codimer between cyclopentadiene and butadiene) up to 15 carbon atoms (for example in the case of co-dimers between methyl styrene and methyl cyclopentadiene), indene and methyl indenes, naphthalene and methyl naphthalenes
  • Fractions containing alkanes and/or alkenes with one or more unsaturations for which the necessity is felt for finding alternative means of exploitation, can directly derive from the fractionation of crude mineral oil, but for the purposes of the present invention, mixtures deriving from other processings and which, being by-products, have a low commercial value, are considered as being preferential.
  • Mixtures of hydrocarbons of particular interest are those which do not require any further preliminary intervention of a chemical or physico-chemical nature, for example residual paraffinic waxes from the dewaxing treatment of lubricants, mixtures, however, obtained with known treatments, which are relatively simple and with a wide application, can also be well used, such as for example naphthene fractions deriving from the hydrogenation of aromatic hydrocarbon mixtures.
  • U.S. Pat. No. 5,831,139 describes a process for the production of aliphatic fuels from naphtha with a high boiling point.
  • the naphtha is subjected to hydrogenation, in a first step, to transform the aromatic compounds into cyclic alkanes.
  • the synthesis of isoparaffins is effected in a second phase.
  • liphatic gasoline components are produced with this process by the opening of the ring and the synthesis of isoparaffins, with as many branchings as possible, without a decrease in the number of carbon atoms with respect to the hydrocarbons charged.
  • the octane number of the product must in fact be high.
  • the processes of the known art therefore aim at transforming aromatic or cyclo-aliphatic compounds into iso-alkanes or alkanes with a high number of carbon atoms, suitable for diesel fuels, i.e. the transformations take place without a substantial variation in the number of carbon atoms.
  • An object of the present invention relates to a process which allows hydrocarbons mixtures deriving from mineral oil, to be transformed by means of a catalyzed hydrocracking reaction, into linear alkanes with a lower molecular weight, in particular linear alkanes containing less than 6 carbon atoms, which are an excellent charge for steam-cracking plants.
  • WO 01/27223 claims, for this purpose, the use of zeolites with a Spaciousness Index (S.I.) lower than 20, exchanged with hydrogenating metals.
  • the preferred zeolite is ZSM-5 exchanged with palladium.
  • Italian patent application MI2003A000347 describes a process for the conversion of mixtures containing aromatic compounds in linear alkanes which uses a catalytic composition containing at least one lanthanide, at least one metal of group VIII and a Y-type zeolite.
  • An object of the present invention therefore relates to a process for the production of linear alkanes containing less than 6 carbon atoms which comprises putting a mixture comprising one or more hydrocarbons containing at least 6 carbon atoms, in contact with a catalytic composition comprising:
  • the process of the present invention allows n-alkanes to be obtained, with a lower number of carbon atoms than that of the hydrocarbon fed.
  • n-alkanes to be obtained, with a lower number of carbon atoms than that of the hydrocarbon fed.
  • prevalently linear alkanes containing from 2 to 5 carbon atoms are obtained.
  • the mixtures which can be subjected to the process of the present invention are mixtures comprising one or more hydrocarbons, whose structure contains at least 6 carbon atoms, selected from aromatic compounds, alkanes or alkenes with one or more unsaturations.
  • the aromatic compounds can contain several condensed benzene rings.
  • Mixtures containing aromatic compounds or mixtures containing one or more alkanes with open chains or cyclic structures and/or alkenes having one or more unsaturations with open-chains or cyclic structures, optionally mixed with aromatic compounds, are preferably used.
  • catalytic compositions comprising:
  • Modified Y-zeolite always refers in this description to a Y-zeolite modified by partial or total substitution of the Si with Ti or Ge and/or partial or total substitution of the aluminum with Fe, Ga or B.
  • mixtures containing aromatic compounds can be treated with catalytic compositions which essentially consist of:
  • catalytic compositions additionally containing one or more lanthanides, can be used.
  • a further aspect of the present invention therefore relates to a process for the production of linear alkanes containing less than 6 carbon atoms which comprises putting a mixture comprising one or more hydrocarbons containing at least 6 carbon atoms, in contact with a catalytic composition comprising:
  • compositions can be well used, containing:
  • mixtures containing aromatic compounds can be converted using catalytic compositions essentially consisting of:
  • Y-zeolite is described for the first time in U.S. Pat. No. 3,130,007 and has the following formula expressed in terms of moles of oxides 0.9 ⁇ 0.2 Na 2 O.Al 2 O 3 .wSiO 2 .xH 2 O wherein w has a value greater than 3 up to about 6 and x can be a value up to about 9.
  • Its preparation is described for example in “Verified Synthesis of Zeolitic materials” H. Robson Editor, Elsevier, second revised edition 2001, whereas the post-synthesis treatment to which the Y-zeolite can be subjected, including dealumination, is described in “Introduction to Zeolite Science and Practice” chapter 5, H. van Bekkum et al.
  • Y-zeolites can be used with a molar ratio SiO 2 /Al 2 O 3 ranging from 3 to 400.
  • Modifications of the Y-zeolite obtained by partial or total isomorphous substitution of the aluminum of the zeolite with Fe, Ga or B, and/or partial or total substitution of the Si with Ti or Ge, can also be used in the process of the present invention.
  • These modifications of the Y-zeolite can be prepared, for example, by substituting, in the synthesis process of the Y-zeolite described in U.S. Pat. No. 3,130,007, part of the silicon and/or aluminum sources with sources of Fe, Ga, B, Ti and/or Ge.
  • the Y-zeolite in which Ge has totally substituted the Si is described in R. M. Barrer et al. J. Chem. Soc., 195-208 (1959) and in G. M.
  • the catalytic composition of the present invention preferably contains the zeolite in partially acidic form, that is part of the cationic sites present in the zeolite is occupied by hydrogen ions.
  • a particularly preferred aspect is to use Y-zeolite.
  • the molar ratio between silicon oxide and aluminum oxide preferably ranges from 5 to 50.
  • compositions containing Pt, Pd, Ti, Mo, Zn, Cu or Ni are preferably used.
  • Pd is preferably adopted.
  • the mixtures of elements preferably used are selected from Pd/Ti, Zn/Mo, Cu/Zn and Ni/Mo.
  • the element Me can be present in the catalytic composition in the form of an oxide, ion, metal, sulfide or a mixture of these forms can be present.
  • the elements Zn, Mo, Cu, Ga, In, W, Ta, Zr, Ti are prevalently present in the form of oxides
  • the elements of group VIII are prevalently present in the metal form.
  • Me is an element selected from Zn, Mo, Cu, Ga, In, W, Ta, Zr, Ti
  • the quantity of Me, expressed as an element can vary from 0.1 to 50% by weight, preferably from 0.5 to 30% by weight, with respect to the total weight of the catalytic composition.
  • Me is an element selected from metals of group VIII
  • the quantity of Me, expressed as an element can vary from 0.001 to 10% by weight, preferably from 0.1 to 5% by weight with respect to the total weight of the catalytic composition.
  • the element belonging to the group of lanthanides which is preferably used is lanthanum.
  • the lanthanide, or lanthanides, present in the catalytic composition can be in the form of an oxide or ion or a mixture of these forms can be present.
  • the quantity of lanthanide, or lanthanides, expressed as an elements can vary from 0.5 to 20% by weight, preferably from 1 to 15% by weight, with respect to the total weight of the catalytic composition.
  • the catalytic compositions of the present invention are prepared by introducing the element Me by means of the ionic exchange or impregnation techniques.
  • the zeolite preferably in acidic form, is treated with an aqueous solution of a salt of the element Me.
  • an aqueous solution can be used with a concentration of 0.01-0.5 M, preferably 0.01-0.1 M, of a corresponding complex.
  • Pd(NH 3 ) 4 (NO 3 ) 2 can be used, for example.
  • the sample deriving from the ion exchange is dried, after suitable washings, and then calcined at a temperature ranging from 400 to 600° C. for 1-10 hours.
  • the known incipient wetness inbibition technique (wet imbibition) is adopted, wherein the volume of solution containing a salt of the element Me corresponds to the pore volume of the zeolite, it is then dried and calcined as in the case of the ion exchange.
  • an aqueous solution of a salt of the element Me is used, preferably with an anion which does not leave residues in the end-product, for example a nitrate or an acetate decomposable by calcination.
  • the salt to be added is divided and various impregnations are effected, with drying phases in between. The drying is carried out by heating the sample and, in order to facilitate the evaporation of the solvent, vacuum or a stream of gas can be optionally used.
  • Impregnation is the preferred technique for introducing the element Me.
  • the elements can be introduced separately or contemporaneously.
  • the calcination between the introduction step of a first element and the introduction step of a second element is optional; if this calcination is not effected, the partial transformation of the ions into the corresponding oxides, takes place contemporaneously during the calcination effected at the end of the second step.
  • the introduction of several elements is effected contemporaneously and for this purpose, aqueous solutions containing said elements in the desired atomic ratio, are used.
  • any of the known techniques can be used, such as exchange in the solid state with a lanthanide salt, ion exchange in aqueous solution or impregnation.
  • Ion exchange or impregnation is preferably used.
  • the zeolite preferably in acidic or ammonium form, is treated with an aqueous solution of a lanthanum salt having a concentration varying from 0.01 to 1.0 M, preferably from 0.01 to 0.5 M.
  • an aqueous solution can be used, within the concentration limits indicated above of lanthanum nitrate, citrate, acetate, chloride or sulfate, at reflux temperature for 1-24 hours.
  • the sample deriving from the ion exchange is dried and then calcined at a temperature ranging from 400 to 600° C for 1-10 hours.
  • the incipient wetness imbibition technique is used and it is then dried and calcined as in the case of ion exchange.
  • Ion exchange is the preferred technique for introducing the lanthanide.
  • the catalytic compositions of the present invention containing one or more lanthanides and one or more elements Me can be prepared using a mixture of compounds of these elements and any of the techniques described above.
  • These catalytic compositions are preferably prepared by introducing first the lanthanide and then the element Me onto the zeolite.
  • the zeolite used in the preparation is preferably in acidic form.
  • these catalytic compositions contain one or more lanthanide or more than one element Me, a mixture of compounds of these elements is used in their preparation.
  • the catalytic compositions of the present invention containing lanthanum are prepared by inserting the lanthanide in the zeolite in acidic form by means of ion exchange, optionally calcining the product thus obtained, and then depositing the element Me by ion exchange and calcining the product obtained.
  • the calcination between the introduction of the lanthanide and the introduction of the element Me is generally optional and if it is not effected, the partial transformation of the ions into the corresponding oxides takes place contemporaneously during the calcination effected at the end of the second step.
  • Catalytic compositions containing or consisting of Y-zeolite and Pd, Y-zeolite and Pt, Y-zeolite and Zn, Y-zeolite and Mo, Y-zeolite and Ni; Y-zeolite and Pd together with Ti, Y-zeolite and Zn together with Mo, Y-zeolite and Zn together with Cu, Y-zeolite and Mo together with Ni, Y-zeolite and La together with Zn and Mo, Y-zeolite and La together with Zn and Cu, are particularly preferred.
  • the catalytic composition contains elements of group VIII
  • Reduction to the element can be obtained by means of treatment of the catalytic composition with hydrogen or with a reducing agent, and it can be effected on the catalytic composition before its use or in the reactor itself in which the catalytic composition is used.
  • the catalytic composition of the present invention can be used in a mixture with suitable binders such as silica, alumina, clay.
  • suitable binders such as silica, alumina, clay.
  • the catalytic composition and the binder are mixed in a proportion ranging from 5:95 to 95:5, preferably from 30:70 to 95:5, even more preferably from 50:50 to 90:10.
  • the mixture of the two components is processed, according to the known techniques, into the desired end-form, for example cylindrical extruded products or other known forms.
  • the mixtures containing aromatic compounds which are suitable for being treated according to the process of the present invention are for example fractions coming from thermal or catalytic conversion plants, and mineral oil fractions rich in aromatic compounds, such as for example pyrolysis gasolines or pygas, fractions coming from pyrolysis gasolines, in particular those from which the light aromatic compounds (from 6 to 8 carbon atoms) have been separated and residual fractions with a low commercial value coming from production plants of aromatic compounds and reforming.
  • pyrolysis gasolines are a by-product of steam cracking processes in which ethylene and propylene are obtained from light hydrocarbon cuts such as straight-run naphtha (oil fraction substantially containing C 5 and C 6 hydrocarbons), LPG (Liquefied Petroleum Gas, an oil fraction containing C 3 and C 4 hydrocarbons), propane or ethane.
  • light hydrocarbon cuts such as straight-run naphtha (oil fraction substantially containing C 5 and C 6 hydrocarbons), LPG (Liquefied Petroleum Gas, an oil fraction containing C 3 and C 4 hydrocarbons), propane or ethane.
  • Mixtures containing one or more alkanes with open chains or with cyclic structures and/or alkenes having one or more unsaturations with open chains or cyclic structures are those deriving from the fractionation of crude mineral oil or from the hydrogenation of mineral oil fractions or the hydrogenation of cracking plant fractions.
  • the hydrogenation of these fractions can be carried out with any of the known methods and catalysts, such as, for example, those based on Ni carried on alumina.
  • the fractions deriving from this treatment prevalently or completely contain alkane compounds with a cyclic structure.
  • the charges suitable for being treated with the process of the present invention can be optionally mixed with heavier fractions, coming for example from fuel oil from steam cracking (FOK) or Light Cycle Oil (LCO) from fluid bed catalytic cracking.
  • These heavy fractions contain polycyclic aromatic compounds having up to 20-21 carbon atoms.
  • these heavy fractions also contain sulfur, which is known to be poisonous for hydrogenation catalysts, an unexpected and extremely advantageous aspect is that the catalytic compositions of the present invention do not, on the contrary, undergo any deactivation due to the sulfur and are therefore capable of processing mixtures of aromatic hydrocarbons also containing heavier fractions, such as, for example, FOK and LCO.
  • the dilution of very heavy mixtures (FOK, LCO) with lighter fractions is not indispensable.
  • Another unexpected aspect of the present invention relates to the processing of heavier fractions, coming, for example, from fuel oil from steam cracking (FOK) or Light Cycle Oil (LCO) from fluid bed catalytic cracking, also without dilution with fractions coming from gasolines, provided a process is effected which avoids feeding heavier polycyclic components such as asphaltenes, to the conversion reactor to light paraffins.
  • the fuel oil fraction can be subjected to treatment such as extraction with a solvent, distillation or, even better, evaporation with suitable equipment (Luwa thin film evaporator or similar equipment).
  • U.S. Pat. No. 5,932,090 describes, for example, a process for the conversion of heavy crude oils or distillation residues which, after a hydrocracking phase in the presence of hydrogen and a suitable catalyst, comprises distillation of the product to recover the most volatile hydrocarbons.
  • a mixture of hydrocarbons is obtained (called DAO, deasphalted oil), from which a feed can be obtained, which is suitable for the process of the present invention.
  • the catalytic compositions of the present invention unexpectedly do not undergo any deactivation due to the sulfur which can be contained in these mixtures and there can be an at least partial transformation of the elements Me contained in the cataytic composition used into the corresponding sulfides without a loss in the catalytic activity.
  • the mixtures containing aromatic compounds which can be subjected to the process of the present invention generally prevalently contain toluene, ethyl benzene, xylenes, benzene and C 9 aromatic compounds, but also naphthalene and alkyl derivatives of naphthalene, for example mono and polysubstituted methyl and ethyl derivatives.
  • the intermediate fractions and fuel oils such as FOK and LCO can contain aromatic compounds with >20 carbon atoms, such as, for example, aromatic compounds with 2-4 condensed benzene rings, naphthalene, phenanthrene, anthracene, benzanthracene, with the relative alkyl derivatives (in particular methyl and/or ethyl derivatives) and phenyl derivatives, indene, biphenyl, fluorene, binaphthyl.
  • aromatic compounds with >20 carbon atoms such as, for example, aromatic compounds with 2-4 condensed benzene rings, naphthalene, phenanthrene, anthracene, benzanthracene, with the relative alkyl derivatives (in particular methyl and/or ethyl derivatives) and phenyl derivatives, indene, biphenyl, fluorene, binaphthyl.
  • the resulting fraction of n-alkanes is prevalently made up of ethane, propane, n-butane and n-pentane.
  • the fraction of linear alkanes containing from 2 to 5 carbon atoms ranges from 50 to 90% by weight of the resulting product.
  • the process of the present invention is carried out in the presence of hydrogen or a mixture of hydrogen and H 2 S at a pressure ranging from 5 to 200 bar, preferably from 25 to 100 bar, at a temperature ranging from 200° C. to 700° C., preferably from 3000 to 600° C.
  • a paraffin for example methane or ethane
  • a particular advantageous aspect of the present invention relates to the possibility of using hydrogen or a diluent containing H 2 S impurities.
  • the catalysts used in the present invention are not generally sensitive to the presence of sulfur.
  • the process is preferably carried out in continuous, in a fixed bed or fluid bed reactor, in gaseous or partially liquid phase, at a WHSV (Weight Hourly Space Velocity, expressed in kg of charge/hour/kg of catalyst) ranging from 0.1 to 20 hours ⁇ 1 , preferably from 0.2 to 5 hours ⁇ 1 , even more preferably from 0.5 to 3 hours ⁇ 1 .
  • WHSV Weight Hourly Space Velocity, expressed in kg of charge/hour/kg of catalyst
  • the alkenes with one or more unsaturations present in the feed are converted according to the process described in the present invention analogously to the other hydrocarbons, both alkanes and aromatic compounds. It has been verified however that the presence of compounds of this type can, in some cases, facilitate the formation of oligomers/polymers under the conditions in which the process, object of the invention, is carried out, and it may therefore be preferable to previously subject the mixtures containing them to hydrogenation in order to prolong the duration of the industrial run, without frequent stoppages and intermediate regenerations of the catalytic bed.
  • the preliminary hydrogenating treatment can be carried out at a low temperature, in liquid phase, according to technologies already known, for example applied to the fractions of hydrocarbons destined for use as fuel for motor vehicles; this is generally light hydrogenating treatment normally but not exclusively effected with Pd-based catalysts on alumina.
  • the catalytic composition of the present invention is preferably activated in nitrogen at a temperature ranging from 300 to 700° C., for a time ranging from 1 to 24 hours and at a pressure varying from 0 to 10 barg.
  • an activation with hydrogen can be effected at a temperature of 300-700° C., a pressure of 0-10 barg, for a time ranging from 1 to 24 hours.
  • the catalyst allows long operating periods before showing signs of deactivation; the catalyst however can be subjected to regeneration treatment, re-establishing its original performances.
  • the regeneration it is not necessary for the regeneration to be effected in the same reactor in which the catalyst is introduced for the reaction; the catalyst can be discharged during the periodic plant maintenance phases and regenerated elsewhere, in this way the reactor can be constructed without control devices necessary for carrying out the regeneration.
  • catalytic compositions used in the present invention are new and a further object of the present invention therefore relates to a catalytic composition comprising:
  • compositions can additionally contain one or more lanthanides.
  • An object of the present invention also relates to a process for the production of linear alkanes containing less than 6 carbon atoms from mixtures containing aromatic compounds having a structure with at least 6 carbon atoms using a catalytic composition essentially consisting of:
  • the catalytic compositions used in said process are also new and object of the present invention.
  • Y-zeolite in commercial extruded acidic form (Zeolyst CBV500 CY (1.6)) with a molar ratio SiO 2 /Al 2 O 3 equal to 5.2, and a solution consisting of 160 ml of water and 11.2 g of an aqueous solution of tetra-amine palladium nitrate (Pd 5% max., Alfa Aesar), are charged into a glass flask. The solution is stirred for 4 hours at room temperature; at the end of this period, it is filtered on a Buckner funnel, washed and dried in an oven at 120° C. for 16 hours. Calcination is effected at a temperature of 400° C. in air, for 12 hours. A Y-zeolite is obtained, containing 2.1% by weight of Pd.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 30 g of the same Y-zeolite used in Example 1 are charged into a glass flask.
  • a solution is prepared, using 4.6 g of ammonium heptamolybdate, 5.2 g of hexahydrated zinc nitrate and 62.4 g of demineralized water.
  • the extruded zeolite is impregnated using the incipient wetness imbibition technique, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 7.0% by weight of Mo and 3.2% by weight of Zn.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 30 g of the same Y-zeolite used in Example 1 are charged into a glass flask.
  • a solution is prepared, using 6.08 g of tri-hydrated copper nitrate, 4.76 g of hexahydrated zinc nitrate and 62.4 g of demineralized water.
  • the extruded zeolite is impregnated using the incipient wetness imbibition technique, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 4.8% by weight of Cu and 3.1% by weight of Zn.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 30 g of the same Y-zeolite used in Example 1 are charged into a glass flask.
  • a solution is prepared using 2.316 g of ammonium heptamolybdate and 62.4 g of demineralized water.
  • the extruded zeolite is impregnated using the incipient wetness imbibition technique, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 4.0% by weight of Mo.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 30 g of the same Y-zeolite used in Example 1 are charged into a glass flask.
  • a solution is prepared, using 2.72 g of hexa-hydrated zinc nitrate and 30 g of demineralized water.
  • the extruded zeolite is impregnated using the incipient wetness imbibition technique, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 1.9% by weight of Zn.
  • the material is crushed to granules within the 20-40 mesh range.
  • the suspension is maintained under reflux conditions for 3 hours, under stirring; after this period, it is filtered on a Buckner vacuum funnel, is dried in an oven and calcined at a temperature of 550° C. in air, for 5 hours, obtaining a Y-zeolite in acidic form.
  • a Y-zeolite is obtained, containing 1.5% by weight of Pd, bound with alumina, wherein the amount of binder corresponds to about 30% of the total weight of the catalytic composition.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 25 g of the same Y-zeolite used in Example 1 are treated with a solution containing 43.3 g of hexahydrated lanthanum nitrate in 500 g of demineralized water. The solution is maintained under reflux conditions for 3 hours under stirring. At the end of this period, the solution is filtered, the filtrate is washed with distilled water and is dried in an oven. The above operation is repeated three more times, with a total of four exchanges with the lanthanum nitrate solution.
  • the material obtained, after the last exchange, is dried in an oven and then calcined in a muffle at 550° C.
  • a solution is prepared, using 1.38 g of ammonium heptamolybdate, 1.56 g of hexahydrated zinc nitrate and 38 g of demineralized water. 18 g of the previously prepared zeolite containing lanthanum, are impregnated by means of the incipient wetness imbibition technique, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 4.4% by weight of La, 4.2% by weight of Mo and 1.6% by weight of Zn.
  • the material is crushed to granules within the 20-40 mesh range.
  • the material obtained after the last exchange is dried in an oven and then calcined in a muffle at 550° C.
  • 16 g of the catalyst thus obtained are mixed with 10.81 g of pseudoboehmite VERSAL 250 (UOP) and 64 g of an aqueous solution of acetic acid at 1.5%. The whole mixture is stirred for 30 minutes at room temperature, and is then dried on an heated plate. It is subsequently dried at 120° C. for 16 hours and is calcined at 500° C. for 4 hours.
  • UOP pseudoboehmite VERSAL 250
  • a Y-zeolite is obtained, containing 2.1% by weight of La and 1.0% by weight of Pd, bound with alumina, wherein the amount of binder corresponds to about 30% of the total weight of the catalytic composition.
  • the material is crushed to granules within the 20-40 mesh range.
  • Example 2 30 g of the same Y-zeolite used in Example 1 are charged into a glass flask.
  • a solution is prepared using 2.3 g of ammonium heptamolybdate, 2.6 g of hexahydrated zinc nitrate and 62.4 g of demineralized water.
  • the extruded zeolite is impregnated using the incipient wetness inbibition procedure, with a third of the previous solution, dried at 120° C., impregnated again with a third of the solution, dried again, further impregnated with the remaining volume of the solution, dried and then calcined at 500° C. for 4 hours.
  • a catalyst is obtained with 3.8% by weight of Mo and 1.7% by weight of Zn.
  • the material is crushed to granules within the 20-40 mesh range.
  • the reactor is placed in an oven having differential-zone heating, which allows the selected reaction temperature to be reached.
  • the catalyst used for the test has a particle size of >10 mesh.
  • the catalyst charge is of 2 ⁇ 8 g and is placed in the reactor between two layers of granular corundum.
  • the flow rate of the hydrocarbon mix is regulated by means of an HPLC pump.
  • the hydrogen flow rate is controlled by means of a thermal mass flow meter.
  • the reactor is of the down-flow type. The two feedings are injected and mixed at the inlet of the reactor, in the zone filled with inert material (granular corundum) where the reaction temperature is reached before coming in contact with the catalyst.
  • the plant pressure is controlled through a setting valve at the outlet of the reactor (back pressure valve control). After the pressure setting valve, the stream is sent to a volume flow meter. An aliquot of the gaseous stream is periodically deviated (about every two hours) to an on-line gas chromatograph, for analysis of the products.
  • the catalyst is heated to the reaction temperature, under a nitrogen stream or, alternatively, a hydrogen stream, at low pressure and for one hour, in order to dry the catalyst and remove air from the reactor. Hydrogen is subsequently fed, if nitrogen was used before, and the pressure is increased to the value established for the reaction. The feeding of the hydrocarbon mixture is then started, at the flow rate established for the reaction. The mix of hydrocarbons at the outlet of the reactor is partially cooled before reaching the pressure setting valve, it is then cooled to about 50° C., said temperature being maintained in the whole line to the gas chromatograph. Before reaching the flow volume meter, the gas is cooled to room temperature.
  • composition of the hydrocarbon mix in the feeding is established through an out-of-line gas chromatographic analysis, with sample injection in liquid phase.
  • the catalytic performances are evaluated by calculating the conversion of the reagents and the yield of the products on the basis of the gas chromatographic analysis integrated with the process data, such as the inlet and outlet flow rates.
  • the regeneration of the catalyst is effected, when required, after the activity test. Regeneration is carried out in the same reactor used for the reaction.
  • the treatment starts with a nitrogen flow, to which an equal air flow is progressively added (in about 1 hour), the nitrogen flow is then progressively reduced to zero (in about 1 hour) and the treatment is prolonged from 5 to 24 hours, in relation to the duration of the previous activity test.
  • the reactor is purged with a nitrogen flow and the catalytic activity test can be re-started.
  • WHSV weight space velocity (Weight Hourly Space Velocity) expressed as kg of hydrocarbons fed/hour/kg of catalyst
  • TOS means the working time of the catalyst (Time On Stream), calculated starting from the beginning of the test with fresh catalyst or, in the case of an operating period following a regeneration, from the re-starting of the test with the regenerated catalyst.
  • the performances are expressed in terms of total conversions of the hydrocarbon (or mix of hydrocarbons) fed and composition of the mix of hydrocarbons at the outlet of the reactor.
  • concentration of the following products are specified: methane (CH 4 ), ethane (C 2 H 6 ), propane (C 3 H 8 ), n-butane (n-C 4 H 10 ), isobutane (i-C 4 H 10 ), summation of paraffins with more than 4 carbon atoms ( ⁇ Par. >C 4 ) and summation of all linear paraffins with the exclusion of methane ( ⁇ n-Par.>C 1 ).
  • Tables 2-5 (12 examples, from Ex. 11/A to Ex. 14/C) specify the results obtained with catalysts having a composition different from that of Example 10. They are based on Zn/Mo, Zn/Cu, Mo and Zn, all on USY-zeolites; their preparation is described in examples 2-5. Also in this case, the results were obtained under different operative conditions, with reaction temperatures of 400 ⁇ 450° C. and molar ratio H 2 /Hydrocarbons of 9.8 ⁇ 35.4. The results show that the purposes of the present invention can be achieved with all these catalysts, in a wide composition range. TABLE 1 EXAMPLES 10/A-10/C *Catalyst Type and Preparation Reference Pd/USY Zeolyst CBV 500; See Ex.
  • Example 10/A Operative conditions Hydrocarbons fed 100% 1,2,4-trimethyl benzene Reaction temperature (° C.) 400 WHSV (hours ⁇ 1 ) 0.8 Pressure (bar) 60 H 2 /Hydrocarbons molar ratio 10.3 *Catalytic performances TOS Conv. Mix composition at the reactor outlet (weight %) (hr) (%) CH 4 C 2 H 6 C 3 H 8 n-C 4 H 10 l-C 4 H 10 ⁇ Par.
  • Table 6 (3 examples, from Ex. 15/A to Ex. 15/C) shows the operative conditions and the catalytic performances obtained using a catalyst based on Pd on USY-zeolite, prepared as described in example 6.
  • Table 6 shows the operative conditions and the catalytic performances obtained using a catalyst based on Pd on USY-zeolite, prepared as described in example 6.
  • EXAMPLES 15/A-15/C *Catalyst Type and Preparation Reference Pd/USY Tosoh HSZ 320 HOA; See Ex. 6
  • Table 8 (2 examples, from Ex. 17/A to Ex. 17/B) shows the results relating to the same catalyst used in Examples 16/A-16/C of Table 7, adopted in a test of a longer duration.
  • the results of Example 17/A were obtained after 260 hours of operation after the last regeneration and it was demonstrated that an excellent catalytic performance is maintained.
  • the results of Example 17/B (270 hours after the last regeneration), were obtained after increasing the reaction temperature to 500° C.; the yield to light paraffins, particularly ethane and propane, is extremely good and the methane production is reasonably contained.
  • Example 18 shows the results obtained with a Pd on an La-USY based catalyst, prepared according to the description in Example 8. The test was carried out with a feed consisting of dicyclopentadiene. The catalyst effectively converted the feed into low molecular weight paraffins.
  • TABLE 9 EXAMPLE 18 Catalyst Type and Preparation Reference Pd/La-USY Tosoh HSZ 320 HOA; See Ex. 8 *Operative conditions Hydrocarbons fed 100% di-cyclo pentadiene Reaction temperature (° C.) 450 WHSV (hours ⁇ 1 ) 0.7 Pressure (bar) 60 H 2 /Hydrocarbons molar ratio 34.8 *Catalytic performances TOS Conv.
  • Table 10 (8 examples, from Ex. 19/A to Ex. 19/H) indicates the results obtained with a Pd on USY based catalyst, prepared according to the description in Example 6. The test was carried out by repeatedly changing the feed, as shown in Table 10. 40 ⁇ 50 working hours were effected with each different feed, and the catalyst was always regenerated before passing to the subsequent feed. The test clearly shows that the catalyst is capable of effectively converting all the hydrocarbons tested and, at the same time, that the catalyst can be repeatedly regenerated. TABLE 10 Examples 19/A-19/H Catalyst Type and Preparation Reference Pd/USY Tosoh HSZ 320 HOA; See Ex.
  • Table 12 (2 examples, from Ex. 21/A to Ex. 21/B) indicates the results obtained with the feed, consisting of two different high molecular weight hydrocarbon mixtures (the composition of the mixtures is specified in the same Table 12).
  • a catalyst based on Zn and Mo on La-USY-zeolite was used in this case (prepared according to the description in Example 9). The results show the conversion obtained with aromatic compounds having more than one benzene ring.
  • the feed composition was changed several times during the test, but the catalyst was never regenerated.
  • the test was interrupted after 1,200 working hours.
  • the feed contained; sulfurated compounds with concentrations of 5,000 ⁇ 6,500 ppm, for long running periods, and the catalytic performance was always excellent for the purposes of the present invention.
  • Table 14 indicates the results obtained with a catalyst based on Zn and Mo on USY-zeolite, prepared according to the description in Example 7.
  • the test was carried out with a mix of hydrocarbons containing ethyl benzene, xylenes, styrene, methyl styrenes, cumene, trimethyl benzene, methyl ethyl benzenes, indane, dicyclo pentadiene, naphthalenes and methyl naphthalenes, according to the composition shown in the same Table 14.
  • the test clearly demonstrates that the catalyst is capable of effectively converting the entire hydrocarbon mix fed to low molecular weight paraffins.

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US10494581B2 (en) 2015-09-30 2019-12-03 Sabic Global Technologies B.V. Process for producing LPG from a heavy hydrocarbon feed
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