# Patent

## Title
Novel iron oxide catalysts

## Abstract

This application is a division of copending application Ser. No. 526,940, filed Nov. 25, 1974 now U.S. Pat. No. 3,929,623.

## Background
This invention relates to a hydrocarbon reforming process utilizing a lead/chloride/alumina catalyst.

It has long been known to use an alumina base containing platinum and a halogen for the reforming of gasoline fractions such as the higher boiling part of the straight run gasoline contained naturally in crude oil and the heavy gasoline fraction boiling between about 180 to 400.degree. F in a full range gasoline produced by cat cracking. These materials inherently have a research octane number (RON) clear of less than about 90 and must be reformed to produce a product having a higher RON by increasing the aromatic content of the reformate. One of the factors which has limited the use of catalytic reforming has been the excessive formation of light gases such as methane, ethane, propane, ethylene, propylene and butenes. Thus there is a need for an inexpensive catalyst system which is effective in producing large amounts of aromatics so as to raise the RON without significant formation of light gases. Hydrogenationdehydrogenation catalysts, for example, are undersirable since in the presence of hydrogen they would cause hydrogenation of the olefins contained in the gasoline to paraffins thus resulting in the production of gasoline having lowered RON values rather than higher values.

It is an object of this invention to provide an improved catalyst for reforming relatively low octane gasoline fractions;

IT IS A FURTHER OBJECT OF THIS INVENTION TO PROVIDE AN IMPROVED ISOMERIZATION PROCESS TO PRODUCE RELATIVELY HIGH OCTANE GASOLINE;

IT IS YET A FURTHER OBJECT OF THIS INVENTION TO PROVIDE AN INEXPENSIVE CATALYST WHICH IS EFFECTIVE IN PRODUCING HIGH OCTANE PRODUCTS; AND

IT IS STILL YET A FURTHER OBJECT OF THIS INVENTION TO AVOID THE PRODUCTION OF LARGE AMOUNTS OF LIGHT GASES.

In accordance with this invention a relatively low octane gasoline fraction is passed over a catalyst consisting essentially of a chlorided alumina base modified by the addition of 0.01 to 5 weight percent lead calculated as PbO based on the weight of said catalyst.

The base for use in the catalyst of this invention can be any active alumina of the type known in the art. The preferred material is gamma-alumina having a specific surface area of from 100 to 500 square meters per gram, a specific pore volume of about 0.1 to 1 cc per gram, and an apparent bulk density of about 0.6 to 1 grams per cc. Other suitable aluminas included eta and theta alumina. Small quantities (up to about 0.5 weight percent) of other refractory inorganic oxides such as silica, magnesia, zirconia, etc. may also be present in admixture with the alumina as well as lesser amounts (i.e., about 0.1 weight percent or less) of such metals (as the oxide) as iron, sodium, and calcium. In addition, minor quantities of sulfur, ranging from about 0.5 to 4 weight percent (calculated as SO.sub.3) may also be present.

The alumina must be chlorided preferably by treating with aqueous solutions of HCl so as to give chlorine in an amount within the range of 0.1 to 5 weight percent calculated as hydrogen chloride based on the weight of the catalyst. Gaseous HCl or ammonium chloride can also be used.

The third component of the catalyst system is lead which is present in an amount within the range of 0.01 to 5 weight percent of lead calculated as PbO based on the weight of catalyst. The lead can be added to the chlorided support, for example, in the form of any convenient salt which is thereafter converted to PbO by heating in air, for example. Water soluble salts of lead in the plus two valence state such as lead nitrate and lead acetate are preferred.

The catalyst of this invention represents a different class of catalysts from the platinum-containing catalysts of the prior art. In addition with this distinct new class of catalyst of this invention, it is essential that the halogen be a chloride. Accordingly, the catalyst is described as consisting essentially of the alumina base, the chloride, and the lead so as to define this distinction from the prior art catalyst systems containing a platinum group metal either alone or with a fluoride.

The hydrocarbons used in the process of this invention comprise olefins, paraffins and naphthenes which are usually present in thermally and catalytically cracked gasolines. The gasolines are substantially olefinic in nature and generally contain at least 25 volume percent olefin and frequently contain 40 percent or more olefins. The gasoline can be a full boiling range material having an initial ASTM boiling range between about 60.degree. F and about 100.degree. F and an end point between about 250.degree. F and about 450.degree. F or it can be a narrow fraction selected from within this boiling range. It is presently preferred to use such a narrow fraction within this range which has an initial boiling point between about 160.degree. F and about 200.degree. F with an end point between about 375.degree. F and about 425.degree. F.

The catalyst can be calcined prior to use by heating in air at 600.degree. to 1200.degree. F, preferably 850.degree.-1000.degree. F, for 0.1 to 50, preferably 1 to 5, hours or an oxygen-containing gas such as air can be passed over the catalyst while it is in the reactor as the reactor is being brought up to temperature thus eliminating the necessity for a separate calcination step.

The operating conditions used in the process of this invention are varied but are such that the octane rating of the gasoline is substantially improved. Temperatures between about 600.degree. F and about 1200.degree. F, more preferably about 800.degree. F to about 1100.degree. F, most preferably 900.degree. to 1050.degree. F, are employed. Within these temperature ranges, liquid hourly space velocities ranging from about 0.1 to about 20, more preferably from about 1 to about 6 are used. Pressures in the isomerization zone range from about 0 to 100 psig. If hydrogen is used the hydrocarbonhydrogen mole ratio will range from about 0.25 to 10.

Maintenance of catalyst activity during use in this process can be aided, if desired, by including 0.001 to about 1 weight percent chloride in the feed in the form of chlorinated hydrocarbons such as carbon tetrachloride, chloroform, ethyl chloride, etc.

The chlorided alumina catalyst used as the control was prepared by crushing a commercially obtained gamma-alumina in the form of 1/8-inch extrudate and screening the material to obtain 10-20 mesh particles. The particles were dried at 215.degree. F for 7 hours in an air oven and to 63.8 g of the cooled dried product was added 31.9 g of 2 weight percent hydrochloric acid solution. The liquid was just taken up by the solid. The resulting mixture was dried for 4 hours at 210.degree.-240.degree. F and then allowed to cool overnight at room temperature in a vacuum desiccator. The calculated amount of chloride impregnated on the catalyst was 0.96 weight percent calculated as HCl and based on the total weight of the catalyst.

The lead-promoted catalyst of this invention was prepared by impregnating 19.1 grams of the chloride alumina with 0.600 grams of Pb(C.sub.2 H.sub.3 O.sub.2).sub.2.sup.. 3H.sub.2 O dissolved in 10 cc of water. The resulting mixture was dried at 215.degree. F for 3 hours. The amount of lead, calculated as PbO, impregnated on the catalyst was 1.94 weight percent based on the total weight of the catalyst.

Each of the catalysts (about 14-15 grams) was individually charged to a reactor at room temperature and the reactor was brought up to operating temperature while nitrogen was passed through the apparatus in the conrol runs and nitrogen plus 1 volume percent oxygen in the invention runs to convert any remaining lead acetate to lead monoxide.

The feed for the runs used in the process of this invention was obtained by fractionating a caustic-washed but not inhibited Kansas City cat cracked full range gasoline to obtain a heavy fraction with a boiling point range from 167.degree. F to 407.degree. F. The full range gasoline had an API gravity of 59.0, a research octane number (RON) clear of 92.3 and a motor octane number (MON) clear of 80.5. The olefin content was approximately 50 LV percent. The heavy fraction obtained had an API gravity of 49.1, RON (clear) of 89.2, a MON (clear) of 79.3 and it consisted of about 63 liquid volume percent of the starting material. The light unused fraction had an API gravity of 80.3, RON (clear) of 95.3 and a MON (clear) of 81.6.

The heavy gasoline fraction was isomerized at several temperatures to illustrate the utility of the lead-promoted catalyst in comparison with the unleaded control catalyst. Analyses of products was made using gas-liquid chromatography. The operating conditions employed and the results obtained are presented in Table 1. __________________________________________________________________________ Catalyst Chlorided Alumina Lead Oxide/Chlorided alumina Run No.           1     2     3     4     5     6 __________________________________________________________________________ Reactor Temp. .degree. F 800   850   900   950   1000  1050 Run Length, Hrs.  4     4     5     5     5     5 Space Rate (vol/vol/hr) 2.93  2.95  3.05  3.01  3.03  3.04 Yields, Wt. % Gas             4.39  5.28  2.08  3.37  3.80  5.99 C.sub.5 + liquid 95.3  94.4  97.6  96.3  95.8  93.8 Coke            0.28  0.30  0.33  0.34  0.43  0.16 Octane Ratings of C.sub.5 + liquid RON (clear)     92.0  91.4  92.6  92.3  92.4  93.2 MON (clear)     81.4  80.9  80.6  80.0  80.6  80.7 Octane No. (RON) .times. Wt. Fraction 87.7  86.3  90.4  88.9  88.5  87.4 Yield __________________________________________________________________________

Inspection of the results shows that with a chorided alumina catalyst, production of cracked material becomes objectionably high at a reactor temperature of about 850, the yield of liquid product is decreasing, the RON (clear) value is decreasing and a relative rating value obtained by multiplying the RON by the weight fraction yield of liquid product is decreasing. Contrasting with these results are those obtained using the lead oxide-promoted chlorided alumina catalyst of the invention. It is clearly seen at temperatures as much as 200.degree. F higher than the best results obtained with the control catalyst operating at 800.degree. F that the invention catalyst is suppressing the formation of cracked gases, thus the yields of the desired product remain higher than those obtained with the control catalyst. Moreover, the RON values of the products, even at 250.degree. F above the best operating temperature of the control catalyst, are higher than the control values. The relative rating values are also significantly higher than the control up to 1000.degree. F reactor temperature and about equal at 1050.degree. F compared to the best control operating at 800.degree. F.

In a subsequent operation, the fraction upgraded by isomerization is blended with the light fraction to obtain a full range gasoline with a higher RON (clear) rating compared to the untreated gasoline.

While this invention has been described in detail for the purpose of illustration, it is not be construed as limited thereby but is intended to cover all changes and modifications within the spirit and scope thereof.

## Claims

1. A platinum-free catalyst consisting essentially of calculated as hydrogen chloride based on the weight of said catalyst; and said catalyst.

2. A catalyst according to claim 1 wherein said base is gamma-alumina.

3. A catalyst according to claim 1 wherein said chlorine is imparted by contacting said alumina with a hydrochloric acid solution.

4. A catalyst according to claim 1 wherein said lead is introduced by impregnating said base with a solution of a lead compound and thereafter contacting said thus impregnated base with air at an elevated temperature to oxidize said lead compound to said PbO.

5. A catalyst according to claim 4 wherein said base is gamma-alumina, and wherein said chlorine is imparted by contacting said alumina with a hydrochloric acid solution.