Advances in dehydrogenation catalysis
First Claim
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1. A regenerable catalyst useful in the dehydrogenation of hydrocarbons, said catalyst comprising a primary catalytic component that comprises one or more elements selected from the group consisting of:
- platinum, rhodium, iridium, palladium, ruthenium, and osmium deposited on a solid support comprising porous alumina, wherein said regenerable catalyst has a surface area greater than 100 m2/g, a volume of pores with diameters below 60 Angstrom units that is less than 0.05 cm3/g, a volume of pores with diameters in the range of 60-350 Angstrom units that is greater than 0.50 cm3/g, and wherein the volume of pores with diameters in the range of 60-350 Angstrom units is greater than about 70% of the total contained pore volume.
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Abstract
Provided herein are supported catalysts and processes useful in the dehydrogenation of hydrocarbons. Catalysts made according to the invention possess a unique pore size distribution which provides a favorable balance of selectivity, activity, and thermal stability. In a preferred form of the invention, catalysts made in accordance of the invention are regenerable. Detergent range paraffins may be converted to monoolefins using a catalyst and process provided by the invention.
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Citations
86 Claims
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1. A regenerable catalyst useful in the dehydrogenation of hydrocarbons, said catalyst comprising a primary catalytic component that comprises one or more elements selected from the group consisting of:
- platinum, rhodium, iridium, palladium, ruthenium, and osmium deposited on a solid support comprising porous alumina, wherein said regenerable catalyst has a surface area greater than 100 m2/g, a volume of pores with diameters below 60 Angstrom units that is less than 0.05 cm3/g, a volume of pores with diameters in the range of 60-350 Angstrom units that is greater than 0.50 cm3/g, and wherein the volume of pores with diameters in the range of 60-350 Angstrom units is greater than about 70% of the total contained pore volume.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A catalyst useful in the dehydrogenation of hydrocarbons, said catalyst comprising:
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a) a primary catalytic component that comprises one or more elements selected from the group consisting of;
platinum, rhodium, iridium, palladium, ruthenium, and osmium deposited on a porous alumina catalyst support, andb) an acidity control component comprising at least one element selected from the group consisting of the alkali metals and the alkaline earth metals deposited upon said support, wherein said catalyst has a surface area greater than 100 m2/g, a volume of pores with diameters below 60 Angstrom units that is less than 0.05 cm3/g, a volume of pores with diameters in the range of 60-350 Angstrom units that is greater than 0.50 cm3/g, and wherein the volume of pores with diameters in the range of 60-350 Angstrom units is greater than about 70% of the total contained pore volume. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42)
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43. A catalyst useful in the dehydrogenation of hydrocarbons, said catalyst comprising:
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a) a primary catalytic component that comprises one or more elements selected from the group consisting of platinum, rhodium, iridium, palladium, ruthenium, and osmium deposited on a porous alumina catalyst support, and b) an activator component comprising one or more elements selected from the group consisting of;
scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, silver, lanthanum, hafnium, tantalum, tungsten, rhenium, and gold deposited upon said support,wherein said catalyst has a surface area greater than 100 m2/g, a volume of pores with diameters below 60 Angstrom units that is less than 0.05 cm3/g, a volume of pores with diameters in the range of 60-350 Angstrom units that is greater than 0.50 cm3/g, and wherein the volume of pores with diameters in the range of 60-350 Angstrom units is greater than about 70% of the total contained pore volume. - View Dependent Claims (44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62)
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63. A catalyst useful in the dehydrogenation of hydrocarbons, said catalyst comprising:
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a) a primary catalytic component that comprises one or more elements selected from the group consisting of;
platinum, rhodium, iridium, palladium, ruthenium, and osmium deposited on a porous alumina catalyst support;
b) an activator component comprising one or more elements selected from the group consisting of;
scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, silver, lanthanum, hafnium, tantalum, tungsten, rhenium, and gold deposited upon said support; and
c) an acidity control component comprising at least one element selected from the group consisting of the alkali metals and the alkaline earth metals deposited upon said support, wherein said catalyst has a surface area greater than 100 m2/g, a volume of pores with diameters below 60 Angstrom units that is less than 0.05 cm3/g, a volume of pores with diameters in the range of 60-350 Angstrom units that is greater than 0.50 cm3/g, and wherein the volume of pores with diameters in the range of 60-350 Angstrom units is greater than about 70% of the total contained pore volume. - View Dependent Claims (64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86)
a) the primary catalytic component comprises platinum;
b) the activator component is selected from the group consisting of copper, silver, and gold, and in which the activator component is present in an amount between 0.10% and 5.00% by weight based on the total weight of the catalyst, including every hundredth percentage therebetween; and
c) the acidity control component is selected from the group consisting of;
alkali metals and alkaline earth metals, and the acidity control component is present in an amount between 0.001% and 1.000% by weight based on the total weight of the catalyst, including every thousandth percentage therebetween.
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74. A catalyst according to claim 73 wherein the packed bulk density is greater than 0.50 g/cm3.
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75. A catalyst according to claim 73 which contains between 0.02% and 2.00% of platinum by weight based on the total weight of the catalyst, including every hundredth percentage therebetween.
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76. A catalyst according to claim 73 which contains between 0.20% and 1.00% of platinum by weight based on the total weight of the catalyst, including every hundredth percentage therebetween.
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77. A catalyst according to claim 73 which contains between 0.40% and 0.70% of platinum by weight based on the total weight of the catalyst, including every hundredth percentage therebetween.
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78. A catalyst according to claim 73 wherein said acidity control component is potassium, and wherein the acidity control component is present in an amount between 0.10% and 0.60% by weight based on the total weight of the catalyst, including every hundredth percentage therebetween.
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79. A catalyst according to claim 74 which contains between 1.00% and 3.00% of copper by weight based upon the total weight of the catalyst, including every hundredth percentage therebetween.
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80. A catalyst according to claim 75 which contains between 1.00% and 3.00% of copper by weight based upon the total weight of the catalyst, including every hundredth percentage therebetween.
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81. A catalyst according to claim 73 wherein the catalyst is regenerable and the cycle length reduction attributable to a first regeneration of the catalyst is not greater than 50% of the length of the first cycle.
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82. A catalyst according to claim 73 wherein the catalyst is regenerable and the cycle length reduction attributable to a first regeneration of the catalyst is not greater than 35% of the length of the first cycle.
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83. A catalyst according to claim 73 wherein the catalyst is regenerable and the cycle length reduction attributable to a first regeneration of the catalyst is not greater than 20% of the length of the first cycle.
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84. A catalyst according to claim 73 in which the catalyst exists in the form of spheroids having diameters is in the range of between 1.0 millimeters and 4.0 millimeters, including every tenth millimeter therebetween.
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85. A catalyst according to claim 73 in which the catalyst exists in the form of an extrudate with its longest length dimension in the range of between 1.0 millimeters and 10.0 millimeters, including every tenth millimeter therebetween.
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86. A catalyst according to claim 73 wherein the surface area is within the range of 135 to 150 m2/g, including every integral m2/g therebetween, the volume of pores with diameters below 60 Angstrom units is less than 0.02 cm3/g, the volume of pores with diameters in the range of 60-350 Angstrom units is in the range of 0.60-0.80 cm3/g, including every hundredth cm3/g therebetween, and the volume of pores with diameters in the range of 60-350 Angstrom units is greater than 80% of the total contained pore volume.
Specification