US20170072389A1

US20170072389A1 - Catalyst For A Naphtha Reforming Process

Info

Publication number: US20170072389A1
Application number: US15/121,903
Authority: US
Inventors: Nagesh Sharma; Ajay Kumar; Anilkumar Mettu; Veera Venkata satya Bhaskara sita Rama Murthy Katravulapalli; Kalpana Gopalakrishna; Raksh Vir Jasra
Original assignee: Reliance Industries Ltd
Current assignee: Reliance Industries Ltd
Priority date: 2014-02-28
Filing date: 2015-02-26
Publication date: 2017-03-16
Also published as: WO2015128824A1; US9827557B2; EP3110910A1; CA2940799A1; EP3110545A2; EP3110911A4; US20170051212A1; EP3110545A4; EP3110910A4; CA2940800A1; WO2015128823A3; WO2015128823A2; US10343149B2; CA2940798A1; SA516371751B1; EP3110911A1; US20170072387A1; WO2015128822A1; SA516371749B1

Abstract

The present disclosure relates to a catalyst for a naphtha reforming process. The catalyst comprises a chloride free zeolite coated alumina support impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal, characterized in that the thickness of the zeolite coating on the alumina support ranges from 100 μm to 200 μm.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to a catalyst for a naphtha reforming process.

DEFINITIONS

An active metal is a Group VIII metal of the modern periodic table. The Group VIII metals are platinum (Pt), palladium (Pd) and nickel (Ni).
A promoter metal is a Group IV metal of the modern periodic table. The Group IV metals are tin (Sn), rhenium (Re) and iridium (Ir).
ZSM-5 is an aluminosilicate zeolite belonging to the pentasil family of zeolites and its chemical formula is Na_nAl_nSi_96-nO₁₉₂.16H₂O (0<n<27).
Mordenite is a zeolite mineral with the chemical formula Al₂Si₁₀O₂₄.7H₂O.
Ultra-stable Y (USY) zeolite is a form of type Y zeolite with the majority of sodium ions removed and treated thermally to enhance its thermal and steam stability.
H-beta zeolite is a high-silica content zeolite having full three dimensional 12-ring pore system.
MCM-22 is a type of zeolite having unique phase and good crystallinity.
ZSM-12 is a type of pentasil zeolite having silica to alumina ratio above 33.

BACKGROUND

Catalytic naphtha reforming is an important industrial process. During the naphtha reforming process, mainly low-octane straight chain alkanes (paraffins), with 6-10 carbon atoms, are reformed into molecules having branched alkanes (isoparaffins) and cyclic naphthenes, which are then partially dehydrogenated to produce high-octane aromatic hydrocarbons such as benzene, toluene and xylenes (BTX) in the reformate. The naphtha feedstock used for catalytic reforming contains naphthenic hydrocarbons, paraffinic hydrocarbons and aromatic hydrocarbons of different carbon numbers. The major reactions in naphtha reforming process include dehydrogenation of naphthenes, dehydrocyclization of paraffins, isomerization of paraffins and hydrocracking. The chemical reactions in reforming process occur in presence of a catalyst and a high partial pressure of hydrogen. The catalysts used for reforming process are usually bifunctional in nature (i.e. having metal function and the acidic function). In a typical reforming process, naphtha is processed over the conventional acidic reforming catalysts where, one or more dehydrogenation metals, i.e. noble metals with stabilizing metal ions are supported on chlorided Al₂O₃.These conventional reforming catalysts comprises platinum alone or along with Re, Ir, Sn or Ge as a promoter metals on gamma alumina support. However, it is observed that reforming of naphtha in the presence of conventional catalysts results in undesired products.
Further, the gamma alumina support of the conventional reforming catalysts consists of corrosive and non-eco-friendly ingredients such as chloride that provides required acidity essential for the process. However, the activity of the conventional catalysts decreases due to the formation and accumulation of coke on the catalyst as well as by sintering of metals on the catalyst surface during the naphtha reforming process.
In the conventional reforming process, the C8 aromatic isomers formed i.e., ethyl benzene (EB), para-xylenes (p-X), meta-xylenes (m-X), and ortho-xylenes (o-X) appear in thermodynamic equilibrium with the product. Generally, the ethyl benzene formed during the conventional reforming takes an idle ride in the post reforming downstream p-xylene recovery unit, thus occupying unit capacity and leading to undesired operating cost.
Therefore, there is a need of a catalyst which reduces the formation of ethylbenzene in the product. Further, there is a need of a catalyst that overcomes the drawbacks associated with the conventional catalyst.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It in an object of the present disclosure to provide a catalyst for reforming of naphtha.
It is another object of the present disclosure to provide a catalyst which possesses dual functionality (i.e. the catalyst can be used for reforming as well as dealkylation).
It is yet another object of the present disclosure to provide a catalyst with optimum acidity for reforming reaction.
It is still another object of the present disclosure to provide a catalyst with reduce corrosive effects on process unit.
It is still another object of the present disclosure to provide an efficient and eco-friendly catalyst.
It is a further object of the present disclosure to ameliorate one or more problems associated with the conventional catalysts or at least provide a useful alternative.
Other objects and advantages of the present disclosure will be more apparent from the following description which is not intended to limit the scope of the present disclosure.

SUMMARY

The present disclosure provides a catalyst for a naphtha reforming process. The catalyst comprises a chloride free zeolite coated alumina support impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal, the thickness of the zeolite coating on the chloride free alumina support ranges from 100 μm to 200 μm.
The zeolite is at least one selected from a group consisting of ZSM-5, mordenite, USY, H-Beta, MCM-22, and ZSM-12.
In accordance with the present disclosure, the zeolite is ZSM-5 comprising SiO₂and Al₂O₃and the ratio of SiO₂to Al₂O₃in ZSM-5 is 15:1.
The active metal is at least one selected from the group consisting of platinum (Pt), palladium (Pd) and nickel (Ni).
The promoter metal is at least one selected from the group consisting of tin (Sn), rhenium (Re) and Iridium (Ir).

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The disclosure will now be described with reference to the accompanying non-limiting drawings:

FIG. 1 illustrates the SEM micrograph of a catalyst in accordance with the present disclosure; wherein the catalyst depicts the thickness of the zeolite coating of size 135 microns.

DETAILED DESCRIPTION

The present disclosure provides a catalyst for a naphtha reforming process. The catalyst of the present disclosure is used for reforming of naphtha.
In a first aspect, the present disclosure provides a catalyst that comprises of a chloride free zeolite coated alumina support impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal. The thickness of the zeolite coating on the chloride free alumina support ranges from 100 μm to 200 μm.
The zeolite is at least one selected from a group consisting of ZSM-5, mordenite, USY, H-Beta, MCM-22, and ZSM-12.
In accordance with one embodiment, the zeolite is ZSM-5 comprising SiO₂and Al₂O₃.
In accordance with one embodiment, the ratio of SiO₂to Al₂O₃in ZSM-5 ranges from 10:1 to 20:1.
In accordance with another embodiment, the ratio of SiO₂to Al₂O₃in ZSM-5 is 15:1.
Examples of the active metals impregnated in the catalyst include platinum (Pt), palladium (Pd) and nickel (Ni).
In accordance with one embodiment, the active metal impregnated in the catalyst is platinum (Pt).
In accordance with another embodiment, the concentration of the platinum (Pt) ranges from 0.01 wt % to 0.75 wt %.
Examples of the promoter metals impregnated in the catalyst include tin (Sn), rhenium (Re) and Iridium (Ir).
In accordance with one embodiment, the metal impregnated in the catalyst is tin (Sn).
In accordance with another embodiment, the concentration of the tin (Sn) ranges from 0.01 wt % to 0.75 wt %.
The alumina support of the conventional catalyst contains chloride which makes the catalyst highly acidic. Due to this, undesired C₁to C₄gaseous products are formed by cracking reaction during the reforming process.
The catalyst of the present disclosure comprises a chloride free alumina support coated with the zeolite and impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal, which provides optimum acidity to the catalyst resulting into lower cracking during the reforming process. This leads in the reduction in formation and accumulation of coke on the catalyst surface, and sintering of metals on the catalyst surface during the reforming process. Due to this, the selectivity and the yield of desired hydrocarbons including desired aromatic compounds are improved.
The present disclosure is further illustrated herein below with the help of the following examples. The examples used herein are intended merely to facilitate an understanding of the ways in which the embodiments herein may be practiced and to further enable those of skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The catalyst of the present disclosure comprises a chloride free zeolite coated alumina support impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal. The thickness of the zeolite coating on the chloride free alumina support is illustrated in the following example:

EXAMPLE

FIG. 1 illustrates the SEM micrograph of a catalyst in accordance with the present disclosure; wherein the catalyst depicts the thickness of the zeolite coating of size 135 microns.
The catalyst of the present disclosure described herein above shows that it overcomes the problems faced by the conventional catalyst.

Technical Advancement

The present disclosure relates to the catalyst. The catalyst has several technical advancements:

- the alumina support of the catalyst does not contain chloride;
- the catalyst has optimum acidity due to presence of chlorine free zeolite layer on the catalyst surface which results into less chain cracking and reduced coke formation during the reforming process.
- the selectivity of desired hydrocarbons is improved; and
- the yield of desired aromatic compounds is improved.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.

Claims

1. A catalyst comprising a chloride free zeolite coated alumina support impregnated with 0.01 wt % to 0.5 wt % active metal and 0.01 wt % to 0.5 wt % promoter metal, wherein the thickness of said zeolite coating on said chloride free alumina support ranges from 100 μm to 200 μm.

2. The catalyst as claimed in claim 1, wherein said zeolite is at least one selected from a group consisting of ZSM-5, mordenite, USY, H-Beta, MCM-22, and ZSM-12.

3. The catalyst as claimed in claim 1, wherein said zeolite is ZSM-5 comprising SiO₂and Al₂O₃.

4. The catalyst as claimed in claim 3, wherein said zeolite is ZSM-5 having the ratio of SiO₂to Al₂O₃ranging from 10:1 to 20:1, preferably 15:1.

5. The catalyst as claimed in claim 1, wherein said active metal is at least one selected from the group consisting of platinum (Pt), palladium (Pd) and nickel (Ni).

6. The catalyst as claimed in claim 1, wherein said active metal is platinum (Pt).

7. The catalyst as claimed in claim 1, wherein said promoter metal is at least one selected from the group consisting of tin (Sn), rhenium (Re) and Iridium (Ir).

8. The catalyst as claimed in claim 1, wherein said promoter metal is tin (Sn).