SOLID STRONG ACID CATALYST

Abstract: A solid strong acid catalyst useful for hydrocarbon reactions, especially for the skeletal isomerization of paraffi­ nic hydrocarbons is provided by supporting sulfate (SO₄) and at least one Group VIII metal on a support consisting of a hydroxide or oxide of a Group IV metal or Group III metal or a mixture thereof and then calcining and stabilizing the catalyst.

Description: This invention relates to a solid strong acid catalyst and more particularly, it is concerned with a solid strong acid catalyst in which sulfate (SO₄) and Group VIII metals of the Periodic Table are supported on a hydroxide or oxide of zirconium and a process for the production of the same. The chemical reactions carried out in the petroleum refining and petrochemical industry include catalytic cracking, catalytic reforming, hydrodesulfurization, isomerization, alkylation of aliphatic and aromatic hydrocarbons and polymerization and it has been recognized as regards catalysts used for such reactions that the acid property thereof is one of the important factors for reactivity. In the field of the so-called C₁ chemistry using methanol or synthesis gas as a raw material, wherein various studies or developments have eagerly been made lately, solid acid catalysts, typical of which are metal silicates, play an important role, as is well known in the art. Generally, it is considered that there is an optimum value in the solid acid strength required for a certain reaction and on the other hand, it is also known that when using a "superacid" defined as a stronger acid than 100% sulfuric acid (Cf. "Superacids and Superbases" by Kozo Tanabe and Ryoji Noyori, published by Kodansha Scientific (1980)), skeletal isomerization reactions of paraffins proceed even at room temperature. However, the solid superacid catalysts of the prior art have the drawbacks that large amounts of by-products consisting predominantly of cracked products are formed in addition to the desired product and the active sites are poisoned by carbonaceous by-products so that the catalyst life is shortened so as to be impracticable. In actual fact, therefore, evaluation of the activity of the catalyst has been carried out by prolonging the contact time largely to increase the efficiency using a reaction test apparatus of closed cycle system. It would be desirable to provide a solid strong acid catalyst with the long life and with less formation of by-products. US-A-4 465 788 describes an olefin oligimerization catalyst containing nickel sulfate on a porous support, which is activated by calcining in an oxidising atmosphere, followed by an inert gas treatment at a lower but elevated temperature. However, the catalyst is not strongly acidic. Furthermore, the reaction temperatures at which this catalyst is used, e.g. 260 o C, is relatively high. DE-A-1 443 496 describes a catalyst for hydrocatalytic treatment of hydrocarbons comprising a hydrogenating/dehydrogenating component, a water-free neutral metal sulfate or water-free cobalt sulfate and an inactive support. The catalyst described is not a strong acid catalyst. According to the present invention there is provided a solid strong acid catalyst consisting essentially of a sulfate (SO₄²⁻) and at least one Group VIII metal, supported on a support consisting essentially of at least one hydroxide or oxide of zirconium, wherein the Group VIII metal is supported in a proportion of 0.01 to 10 parts by weight to 100 parts by weight of the support. Also provided by the present invention is a process for the production of a solid strong acid catalyst as defined above which process comprises incorporating or applying at least one Group VIII metal and sulfate or a precursor of sulfate in or to a support consisting essentially of a hydroxide or an oxide of zirconium and then calcining and stabilizing. In the present invention, Group VIII metals and sulfate (SO₄) or a precursor of sulfate (SO₄) is incorporated or applied in or to the support. Group VIII metals include nickel, platinum, ruthenium, rhodium, palladium, osmium and iridium, and the Group VIII metals may be as compounds thereof, and can be incorporated in or applied to the support in conventional manner, for example, by the impregnation method or ion exchange method. The quantity of Group VIII metals to be supported is 0.01 to 10 parts by weight per 100 parts by weight of the support, since if less than 0.01 part by weight, the catalytic effect of the Group VIII metal is decreased and the stability of the activity tends to be insufficient, while if more than 10 parts by weight, the acid strength is lowered thereby decreasing the conversion. As the sulfate, for example, there can be used sulfuric acid, e.g. in a concentration of 0.01 to 10 N, preferably 0.1 to 5 N or ammonium sulfate, e.g. in a concentration of 0.1 to 10 mols. As the precursor of sulfate, for example, there can be used materials capable of forming sulfate after calcining, e.g. hydrogen sulfide, sulfur dioxide and sulfur- and halo-containing compounds such as fluorosulfonic acid, sulfuryl chloride or thionyl chloride, or a mixture thereof. According to the present invention, introduction of the Group VIII metal and sulfate may be carried out by any known method, for example. For example, a Group VIII metal is introduced or applied to the support, which is then treated with an agent containing sulfate, calcined and stabilized, thus preparing a solid strong acid catalyst. Group VIII metals, for example, platinum can be introduced or applied by an aqueous solution of chloroplatinic acid or tetrammine platinum complex and thereafter, a sufficient catalytic property can be given by only a drying treatment prior to the treatment with a sulfate-containing agent. At the same time, as the sulfate-containing agent, sulfuric acid with a concentration of 0.01 to 10 N, preferably 0.1 to 5 N or ammonium sulfate with a concentration of 0.1 to 10 mols may be used in a quantity of 1 to 10 times as much as the catalyst by weight, and other compounds capable of forming sulfate after a calcining treatment, such as hydrogen sulfide, sulfur dioxide and sulfuryl chloride can of course be used with similar effects. Introduction of Group VIII metals and sulfate can be also carried out by the use of at least one sulfate of a Group VIII metal. The sulfate of Group VIII metals include, for example, nickel sulfate, platinum sulfate, palladium sulfate, ruthenium sulfate and nickel ammonium sulfate. The sulfates of Group VIII metals can be incorporated or applied by any method, e.g. impregnation using an aqueous solution, for example, nickel sulfate. After incorporating or applying a Group VIII metal, calcination in air can be carried out at a temperature of, for example, 50 to 550 o C, preferably 100 to 400 o C for, e.g., 1 to 24 hours, but for the present invention, it is important for good results to effect a calcining and stabilizing treatment at a temperature of 450 to 800 o C, preferably 500 to 650 o C for 0.5 to 10 hours in an oxidizing atmosphere after the treatment with the sulfate-containing agent. According to this procedure a part of the sulfate introduced into the support is reduced. However, the remaining sulfate may be incorporated in a proportion of 0.1 to 25 parts by weight to 100 parts by weight of the support to have an interaction with support materials. Thus, the catalyst is given a strong acidity. When the calcining and stabilizing treatment is carried out in a reducing atmosphere, the catalytic activity is lowered to a great extent probably due to change of the bonding state of the sulfate on the Group VIII metal or compound thereof, or to reduction and decomposition thereof. This is not favourable. In another embodiment of the present invention, the support can be subjected firstly to the treatment with a sulfate-containing agent and then to incorporation or application of a Group VIII metal as it is or after a calcining treatment at a temperature of 50 to 600 o C. After the Group VIII metal is incorporated or applied, it is necessary to calcine and stabilize the catalyst at a temperature of e.g. 450 to 800 o C for e.g. 0.5 to 10 hours in an oxidizing atmosphere. Catalysts prepared in this way may exhibit an excellent catalytic activity under flow of hydrogen. That is to say, it is considered that a Group VIII metal acts as a center of supplying active hydrogen for solid strong acid sites formed of sulfate and a metal oxide surface. Before use of this catalyst, a reduction procedure at lower than 400 o C was preferred, but is not always necessary for this catalyst. Through this procedure, there is found no generation of hydrogen sulfide, etc. due to reduction of sulfate under flowing of hydrogen. Thus, it is assumed that sulfate is firmly bound with the catalyst surface by effecting the calcining and stabilizing treatment in the final step of the process for preparing the catalyst, and a stable strong acid catalyst may thus be formed. The catalyst prepared according to the process of the present invention is useful for various reactions, in particular, isomerization of hydrocarbons. That is, various useful products can selectively be obtained by the use of the catalyst according to the present invention for skeletal isomerization of paraffinic hydrocarbons, isomerization of cyclic compounds, e.g. obtaining cyclohexane from methylcyclopentane, isomerization of aromatic compounds, e.g. obtaining p-xylene from m-xylene. The above described isomerization reactions are preferably carried out at a reaction temperature of 400 °C or lower, since if the reaction is carried out at a temperature of higher than 400 °C, in particular, in the presence of hydrogen, sulfate (SO₄) tends to be decomposed to lower the acid strength of the catalyst so that the isomerization does not proceed as at a lower temperature. The catalyst of the present invention which is highly active at a lower temperature is particularly useful for skeletal isomerization reaction of light petroleum fractions in order to obtain higher octane number products because the thermodynamic equilibrium of light paraffinic hydrocarbons shows that the presence of higher octane number components - highly branched paraffins - are advantageous at a lower temperature. In the skeletal isomerization reaction described above according to the present invention, for example, a feed oil of an octane number of 60-70 containing 50 to 80 % of paraffinic hydrocarbons such as n-pentane and n-hexane, known as light naphtha fractions, can selectively be converted into a useful oil as a gasoline fraction of an octane number of 80-90 in the presence of a catalyst of the present invention at a temperature of 400 °C or lower, preferably 70 to 250 °C, a pressure of 1 to 50 bar, a liquid space velocity of 0.5 to 10 hr⁻¹ and a hydrogen to feed oil molar ratio of 1 to 10. In this case, better results can be obtained by subjecting the catalyst to a reducing treatment at a temperature of 100 to 400 °C immediately before use for the purpose of stabilizing the activity, i.e. reducing a supported metal compound to the metal and activating strong acid sites. The following examples are given in order to illustrate the present invention in greater detail without limiting the same. Example 1 900 g of commercially available zirconium oxychloride (manufactured by KANTO CHEMICAL CO., LTD.) was dissolved in 7000 g of pure water and the pH was adjusted to 10 by adding a suitable amount of aqueous ammonia to form a precipitate. The precipitate was aged for a whole day and night, filtered, washed and dried to obtain 300 g of Support A (Zr(OH)₄). Support A was impregnated with aqueous solutions of chloroplatinic acid, palladium chloride, nickel nitrate, ferric nitrate, cobalt nitrate, ruthenium chloride and rhodium chloride respectively, dried at 110 °C for a whole day and night, added to 650 g of 1 N sulfuric acid, the excess of which was separated by filtration, and calcined at 600 °C for 3 hours to obtain Catalysts 1 to 7. The solid acid strength was determined by the titration method using a Hammett indicator in a benzene solvent to obtain results as shown in Table 1. Comparative Example 1 Support A prepared in an analogous manner to Example 1 was immersed in an aqueous solution of chloroplatinic acid with such a concentration as to give 0.5 part by weight as platinum metal per 100 parts by weight of the support weight, dried at 110 °C and calcined at 600 °C for 3 hours to obtain Comparative Catalyst 1. The solid acid strength was determined by the titration method using a Hammett indicator in a benzene solvent to obtain results as shown in Table 1. Comparative Example 2 Support A prepared in an analogous manner to Example 1 was dried at 110 °C, added to 1 N sulfuric acid the excess of which was then separated by filtration, dried at 110 °C and then calcined at 600 °C for 3 hours to obtain Comparative Catalyst 2. The solid acid strength was determined by the titration method using a Hammett indicator in a benzene solvent to obtain results as shown in Table 1. Example 2 300 g of Support A of Example 1 was added to 650 g of 1 N sulfuric acid the excess of which was separated by filtration, dried at 110 °C for one day and night to give Support G and then calcined at 600 °C for 3 hours to prepare Support H. Supports G and H were respectively immersed in an aqueous solution of chloroplatinic acid with such a concentration as to give 0.5 part by weight as platinum metal to 100 parts by weight of the support, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 13 and 14. Support G was immersed in aqueous solutions of palladium chloride, rhodium chloride and ruthenium chloride respectively, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 15, 16 and 17 each having 0.5 part by weight of palladium, rhodium and ruthenium per 100 parts by weight of the support. Support G was immersed in aqueous solutions of ferric nitrate, cobalt nitrate and nickel nitrate respectively, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 18, 19 and 20 supporting each 2 parts by weight of ferric oxide, cobalt oxide and nickel oxide per 100 parts by weight of the support. The solid acid strength was determined by the titration method using a Hammett indicator in a solvent of benzene to obtain results as shown in Table 2. Catalyst No. Composition pKa Value of Hammett Indicator -3.0 -5.6 -8.2 -11.4 -12.7 13 Pt/SO₄/ZrO₂ + + + + + 14 Pt/SO₄/ZrO₂ + + + + + 15 Pd/SO₄/ZrO₂ + + + + + 16 Rh/SO₄/ZrO₂ + + + + + 17 Ru/SO₄/ZrO₂ + + + + + 18 Fe₂O₃/SO₄/ZrO₂ + + + + + 19 CoO/SO₄/ZrO₂ + + + + + 20 NiO/SO₄/ZrO₂ + + + + + Example 3 Support A of Example 1 was immersed in an aqueous solution of nickel sulfate with such a concentration as to give 5.0 parts by weight as nickel metal to 100 parts by weight of the support, dried at 110 °C for a whole day and night and then calcined at 550 °C, 600 °C, 650 °C, 700 °C and 800 °C for 3 hours to prepare Catalysts 25 to 29. Support A of Example 1 was immersed in an aqueous solution of palladium sulfate, aqueous sulfuric acid solution of chloroplatinic acid and aqueous sulfuric acid solution of rhodium chloride, dried at 110 °C for a whole day and night and then calcined at 575 °C for 3 hours to prepare Catalysts 32 to 34 supporting respectively 0.5, 0.01 and 0.5 part by weight of palladium, platinum and rhodium per 100 parts by weight of the support. The solid acid strength was determined by the titration method using a Hammett indicator in a solvent of benzene to obtain results as shown in Table 3. Example 4 300 g of Support A of Example 1 was immersed in an aqueous solution of chloroplatinic acid, palladium chloride, nickel nitrate, ferric nitrate, cobalt nitrate, ruthenium chloride or rhodium chloride, dried at 110 °C for a whole day and night, added to 500 ml of a solution of sulfuryl chloride (reagent chemical grade, manufactured by WAKO PURE CHEMICAL INDUSTRIES, LTD.), dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 35 to 41. The solid acid strength thereof was measured by the titration method using a Hammett indicator in a solvent of benzene to obtain results as shown in Table 4. Comparative Example 3 Support A of Example 1 was immersed in an aqueous solution of commercially available sulfuryl chloride (manufactured by WAKO PURE CHEMICAL INDUSTRIES, LTD.), dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Comparative Catalyst 3. The solid acid strength was measured by the titration method using a Hammett indicator in a benzene solvent to obtain results as shown in Table 4. Example 5 300 g of Support A of Example 1 was immersed in 600 ml of a solution of commercially available sulfuryl chloride (reagent chemical grade, manufactured by WAKO PURE CHEMICAL INDUSTRIES, LTD.), dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Support J. Support I and J were immersed respectively in an aqueous solution of chloroplatinic acid with such a concentration as to give 0.5 part by weight as platinum metal to 100 parts by weight of the support, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 47 and 48. Support I was immersed in aqueous solutions of palladium chloride, rhodium chloride and ruthenium chloride respectively, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours to prepare Catalysts 49 to 51 each supporting 0.5 part by weight of palladium, rhodium and ruthenium per 100 parts by weight of the support. Furthermore, Support I was immersed in aqueous solutions of ferric nitrate, cobalt nitrate and nickel nitrate respectively, dried at 110 °C for a whole day and night and then calcined at 600 °C for 3 hours, thus preparing Catalysts 52 to 54 supporting respectively 2 parts by weight of iron oxide, cobalt oxide and nickel oxide per 100 parts by weight of the support. The solid acid strength thereof was determined by the titration method using a Hammett indicator in a benzene solvent to obtain results as shown in Table 5. Catalyst No. Composition pKa Value of Hammett Indicator -3.0 -5.6 -8.2 -11.4 -12.7 47 Pt/SO₂Cl₂ /ZrO₂ + + + + + 48 Pt/SO₂Cl₂/ZrO₂ + + + + + 49 Pd/SO₂Cl₂/ZrO₂ + + + + + 50 Rh/SO₂Cl₂/ZrO2 + + + + + 51 Ru/SO₂Cl₂/ZrO₂ + + + + + 52 Fe₂O₃/SO₂Cl₂/ZrO₂ + + + + + 53 CoO/SO₂Cl₂/ZrO₂ + + + + + 54 NiO/SO₂Cl₂/ZrO₂ + + + + + Example 6 Skeletal Isomerization of n-Pentane Catalysts 1, 13, 26, 27, 29, 35 and 47 prepared in Examples 1 to 5 and Comparative Catalysts 1 to 3 prepared in Comparative Examples 1 to 3 were respectively shaped in pellets with a diameter of 0.59-1.00 mm. Using these catalysts, hydroisomerization reaction of n-pentane was carried out in a high pressure flow reactor with a length of 22 cm and inner diameter of 1 cm under the following reaction conditions: Temperature 200 °C Total Pressure 10 bar H₂/n-Pentane Molar Ratio 5/1 mol/mol Liquid Space Velocity 1.5 ml n-pentane/ml catalyst/hr The composition of the reactor outlet gas was continuously analyzed by gas chromatography to obtain results shown in Table 6. It will clearly be understood from Table 6 that catalysts prepared according to the present invention are excellent catalysts having higher activities for the skeletal isomerization of n-pentane and longer catalyst life, which result from the presence of Group VIII metals and sulfate. Example 7 Skeletal Isomerization of n-Pentane Hydroisomerization reaction of n-pentane was carried out using Catalysts 2, 3, 6 and 7 under the similar reaction conditions to Example 6. The results are shown in Table 7. Catalyst No. Composition Reactor Outlet Gas Composition (wt %) Methane, Ethane, Propane, Butane i-Pentane n-Pentane Hexane, etc. 2 SO₄/Pd/ZrO₂ 4 68 25 3 3 SO₄/Ni/ZrO₂ 4 65 29 2 6 SO₄/Ru/ZrO₂ 0.5 34 65 0.5 7 SO₄/Rh/ZrO₂ 11 55 31 3 Example 8 Skeletal Isomerization of n-Hexane Using Catalysts 1 and 35, each being shaped in pellets with a diameter of 0.59-1.00 mm, hydroisomerization reaction of n-hexane was carried out in a high pressure flow reactor with a length of 22 cm and inner diameter of 1 cm under the following reaction conditions. Before the reaction, the catalysts were subjected to reduction with hydrogen at 300 °C for 2 hours to stabilize the catalytic activity. The amounts of sulfate supported on Catalysts 1 and 35 were 6.5 and 18.5 % by weight on the fresh catalysts, and 6.3 and 17.2 % by weight on the used catalysts, respectively. Temperature 180, 200, 220 and 250 °C Total Pressure 5, 10 and 15 bar H₂/n-Hexane Molar Ratio 5/1 mol/mol Liquid Space Velocity 0.38, 0.75, 1.0, 1.5 and 2.0 ml n-hexane/ml catalyst/hr The composition of the reactor outlet gas was analyzed by gas chromatography to obtain results as shown in Tables 8 and 9, in which: Total Conversion (%) = 100 - Outlet Gas Composition of Unreacted n-Hexane (wt %) Isomer Selectivity (%) Example 9 Isomerization of Hydrocarbons 200 mg of each of Catalysts 1, 2, 26, 35, 36 and 37 was packed in a pulse reactor and isomerization reaction was carried out in a helium stream by feeding 1 ml of N₂ gas containing 10 % of n-butane, 1 µl of liquid methylcyclopentane or liquid m-xylene, thus obtaining results shown in Table 10, in which the ratios of conversion, decomposition and isomerization are defined as follows: Catalyst No. Feed Hydrocarbons Reaction Temperature (°C) Conversion(%) Decomposition (%) Isomerization (%) 1 n-butane 200 60.8 31.1 62.3 methylcyclopentane 200 24.0 8.3 69.2 m-xylene 150 45.6 53.9 32.5 2 n-butane 200 53.0 20.8 72.1 methylcyclopentane 200 23.4 7.7 71.4 m-xylene 150 39.1 43.5 44.0 26 n-butane 200 57.2 25.7 67.1 methylcyclopentane 200 24.6 7.3 68.3 m-xylene 150 34.2 27.5 56.7 35 n-butane 200 55.4 28.3 58.6 methylcyclopentane 200 22.7 10.2 67.7 m-xylene 150 38.3 50.3 34.9 36 n-butane 200 58.2 18.8 70.0 methylcyclopentane 200 23.9 8.0 68.2 m-xylene 150 42.1 42.1 46.0 37 n-butane 200 36.3 20.5 70.3 methylcyclopentane 200 20.5 3.2 72.9 m-xylene 150 30.0 38.0 48.3 Example 10 Cracking of n-Pentane 200 mg of each powder of Catalysts 13 to 20, 32 to 34 and 47 to 54 was packed in a pulse reactor and cracking reaction of n-pentane was carried by feeding 1 µl of n-pentane to the reactor at 300 °C in helium stream. The outoet gas composition of the pulse reactor was analyzed by gas chromatography to obtain results shown in Table 11: Catalyst No. Reactor Outlet Gas Composition (wt %) Propane, Butane i-Pentane n-Pentane Hexane and Others 13 87 6 6 1 14 83 4 12 1 15 73 9 17 1 16 85 6 8 1 17 77 7 15 1 18 77 8 14 1 19 78 8 13 1 20 78 8 13 1 32 87 5 7 1 33 30 42 22 6 34 83 6 10 1 47 90 5 5 0 48 85 4 10 1 49 76 8 15 1 50 84 7 8 1 51 79 7 13 1 52 75 9 15 1 53 80 7 12 1 54 78 8 13 1 Example 11 Alkylation of Hydrocarbons 60 g of each of Catalysts 13 and 47 was charged in an autoclave of 300 ml, into which a mixed liquid of isobutane and cis-2-butene (isobutane to cis-2-butene weight ratio: 10 : 1) was introduced in an amount of 1.5 times the weight of the catalyst, and after closing the reaction system, the mixture was reacted at a reaction temperature of 60 °C and a pressure of 16 kg/cm²G for 5 hours. After the reaction, the product was taken and analyzed to obtain results as shown in Table 12: Example 12 10 g of Support A of Example 1 was immersed in an aqueous solution of chloroplatinic acid with such a concentration as to give 0.5 part by weight as platinum metal to 100 parts by weight of the support, dried at 110 °C for a whole day and night, then treated with N₂ gas containing 20 % of SO₂ flowing at a rate of 50 Nl.hr at 300 °C for 3 hours and calcined at 550 °C for 1 hour to prepare Catalyst 67. 200 mg of Catalyst 67 was packed in a pulse reactor and isomerization reaction of n-butane was then carried out by feeding 1 ml of N₂ gas containing 10 % of n-butane to the pulse reactor at 300 °C in helium stream. The outlet gas of the pulse reactor was subjected to analysis by gas chromatography to obtain a conversion of 52.0 % and isomerization of 60.5 % (defined similarly to Example 9). Example 13 Isomerization of methylcyclopentane Catalyst 1 was shaped in pellets with a diameter of 0.59 to 1.00 mm. Using this catalyst, hydroisomerization reaction of methylcyclopentane was carried out in a high pressure flow reactor with a length of 22 cm and an inner diameter of 1 cm under the following reaction conditions: Temperature 200 °C Total Pressure 10 bar H₂/Methylcyclopentane Molar Ratio 5/1 mol/mol Liquid Space Velocity 1.5 ml methylcyclopentane/ml catalyst/hr The composition of the reactor outlet gas was analyzed by gas chromatography to obtain methylcyclopentane 48 wt %, cyclohexane 24 wt % and other hydrocarbons 28 wt %. Thus, it is apparent from this result that the catalyst of the present invention is also useful for the isomerization reaction of methylcyclopentane to cyclohexane. Example 14 Catalyst 35 of Example 4 was further calcined at 600 °C for 3 hours to prepare Catalyst 68, which powder was shaped in pellets with a diameter of 0.59 to 1.00 mm. Hydroisomerization reaction of n-pentane was carried out in an analogous manner to Example 6 except using this Catalyst 68 and changing the reaction temperature to 140 °C and the H₂/n-pentane molar ratio to 1.5/1 mol/mol. Analysis of the reactor outlet gas was continuously carried out by gas chromatography to give compositions of; methane, ethane, propane and butane 2.5 wt %, i-pentane 72.8 wt %, n-pentane 21.2 wt % and hexane 3.4 wt % after 5 hours from the start of the reaction, and methane, ethane, propane and butane 1.0 wt %, i-pentane 72.4 wt %, n-pentane 25.4 wt % and hexane 1.1 wt % after 98 hours from the start of the reaction. Thus, it will be apparent that by the present invention there may be provided a catalyst excellent in low temperature activity as well as durability.

Claims: A solid strong acid catalyst consisting essentially of a sulfate (SO₄²⁻) and at least one Group VIII metal, supported on a support consisting essentially of at least one hydroxide or oxide of zirconium, wherein the Group VIII metal is supported in a proportion of 0.01 to 10 parts by weight to 100 parts by weight of the support. A solid strong acid catalyst as claimed in Claim 1, wherein the Group VIII metal is one or more of nickel, platinum, iron, cobalt, ruthenium, rhodium, palladium, osmium and iridium. A process for the production of a solid strong acid catalyst as claimed in Claim 1 or Claim 2 which process comprises incorporating or applying at least one Group VIII metal and sulfate or a precursor of sulfate in or to a support consisting essentially of a hydroxide or an oxide of zirconium and then calcining and stabilizing. A process as claimed in Claim 3 wherein the sulfate is sulfuric acid or ammonium sulfate. A process as claimed in Claim 3 wherein the precursor of sulfate is hydrogen sulfide or sulfur dioxide, or is sulfuryl chloride, thionyl chloride, fluorosulfonic acid or a mixture thereof. A process as claimed in any one of Claims 3 to 5 wherein the calcining and stabilizing are carried out at a temperature of from 450 o to 800 o C. A process as claimed in any one of Claims 3 to 6 wherein after calcining and stabilizing sulfate is incorporated or applied in a proportion of 0.1 to 25 parts by weight to 100 parts by weight of the support. A process as claimed in any one of Claims 3 to 7 wherein the incorporating or applying of the Group VIII metal is carried out by impregnation or ion exchange. A process as claimed in any one of Claims 3 to 9 wherein the sulfate is incorporated or applied by the use of 0.01 to 10 N sulfuric acid or 0.1 to 10 mol ammonium sulfate in a quantity of 1 to 10 times the weight of the catalyst. A process as claimed in any one of Claims 3 to 9 wherein the Group VIII metal sulfate is one or more of nickel sulfate, platinum, sulfate, palladium sulfate, ruthenium sulfate or nickel ammonium sulfate. The use of a catalyst as claimed in Claim 1 or Claim 2 or of a catalyst prepared by a process as claimed in any one of Claims 3 to 10 for catalysing hydrocarbon isomerisation, paraffinic hydrocarbon skeletal isomerisation, hydrocarbon cracking or hydrocarbon alkylation.

Inventors: BABA, SHIEGO C/O YOKKAICHI RESEARCH, IMAI, TETSUYA C/O HIROSHIMA TECHNICAL INSTITUTE, KAWAMURA, TAKAHIRO YOKKAICHI RESEARCH, KIMURA, TSUGUO, KOUSAKA, KAZUO, LIDA, KOZO C/O HIROSHIMA TECHNICAL INSTITUTE, MINATO, YOSHIHIRO, SHIBATA, YUKIO YOKKAICHI RESEARCH, TAKAOKA, HIDEO YOKKAICHI RESEARCH, YOKOYAMA, NARUO HIROSHIMA TECHNICAL INSTITUTE
Applicants: RESEARCH ASSOCIATION FOR UTILIZATION OF LIGHT OIL
Application year: 1985
Main classification: B01J27
IPC codes: C07C5, C07C2, C10G45, B01J27, C07C4