DEHYDROGENATION PROCESS AND CATALYST

Abstract: Alkanes are dehydrogenated to alkenes, for example n-bu­ tane to n-butenes by contact with a catalyst comprising a silicalite and a platinum group metal the catalyst being substan­ tially free of alkali and alkaline earth metals. The selectivity of the product to butenes is improved by either presulphiding the catalyst or by passing a minor amount of a sulphur-containing compound with the alkane feed. The catalyst can be prepared by either forming the silicalite in the presence of the platinum group metal or alternatively contacting preformed silicalite with a solution of a platinum group metal.

Description: The present invention relates to a process for catalytically dehydrogenating hydrocarbons, to a novel dehydrogenation catalyst and to a process for producing the dehydrogenation catalyst. Dehydrogenation is an important commercial process because of the great demand for olefins for the manufacture of a wide variety of chemical products such as detergents, high octane gasolines, pharmaceuticals, plastics, synthetic rubbers and many other chemical products. To be commercially successful a dehydrogenation catalyst must satisfy at least three requirements, namely high activity, high selectivity and good stability. Activity is a measure of the catalyst's ability to convert dehydrogenatable hydrocarbons into products at a specified severity level, the severity level being a measure of the reaction conditions, ie temperature, pressure, contact time etc, employed. Selectivity is a measure of the catalyst's ability to convert dehydrogenatable hydrocarbons into a desired product or products relative to the amount of hydrocarbon charged or converted. Stability is a measure of the rate of change with time of the activity and selectivity factors. Heterogeneous catalysts comprising platinum group metals for the dehydrogenation of liquid or gaseous hydrocarbons have been previously described. Representative of the prior art relating to platinum group metal catalysts are US Patents Nos. 3,531,543; 3,745,112; 3,892,657; 3,909,451; 4,101,593; 4,210,769; 4,329,258; 4,363,721; 4,438,288 and British Patent No. 1,499,297. Generally, in addition to the platinum group metal, there is employed a porous support and an additional component specifically selected for the purpose of improving the activity and/or selectivity and/or stability of the catalyst. The additional component is typically an alkali metal or an alkaline earth metal. A large number of porous supports are reported. These include (1) activated carbon, coke, or charcoal; (2) silica or silica gel, silicon carbide, clays and silicates; (3) ceramics, porcelain, crushed firebrick, bauxite; (4) refractory inorganic oxides such as alumina, titania, zirconia and the like; (5) crystalline zeolite silicates; (6) spinels; and (7) combinations of the foregoing. USP 4 438 288 describes a dehydrogenation process employing, as catalyst, a platinum group metal and an alkali or alkaline earth component, on a porous support material. Amongst the porous support materials disclosed is silicalite. It has now been found that dehydrogenation catalysts comprising a platinum group metal and substantially free of an alkali and alkaline earth metal supported on a silicalite can exhibit not only a high activity and selectivity but also improved stability as compared with prior art catalysts. Accordingly, the present invention provides a process for the dehydrogenation of a C₂ to C₁₀ paraffin to yield an alkene product which process comprises dehydrogenating the paraffin in the presence of a dehydrogenation catalyst, characterised in that the catalyst is substantially free of alkali and alkaline earth metals and comprises an effective amount of a platinum group metal on a silicalite support. Preferably, the catalyst also contains sulphur in an amount effective to improve the selectivity of the process to alkenes. In a further aspect of the present invention, there is provided a catalyst suitable for the dehydrogenation of C₂ to C₁₀ paraffins to alkenes, which is substantially free of alkali and alkaline earth metals and comprises an effective amount of a platinum group metal on a silicalite support, together with sulphur in an amount within the range from 0.1 to 1% by weight. Preferably the catalyst is also substantially free of all metals other than the platinum group metal. The term substantially free does not exclude trace amounts of metals that occur as impurities in ordinary commercially available materials. The paraffin is preferably a C₃ to C₆, paraffin. Examples of suitable paraffinic hydrocarbons include ethane, propane, n-butane, isobutane, n-pentane, isopentane, n-hexane, 2-methylpentane, 3-methylpentane, 2,2-dimethylbutane, n-heptane. The term paraffin is intended to include substituted paraffins for example ethyl benzene which upon dehydrogenation yields styrene. As regards the catalyst, the platinum group metal may suitably be at least one of platinum, ruthenium, iridium, rhodium or palladium and is preferably platinum. The metal is preferably present, at least in part, in elemental form. The catalyst may suitably contain up to 10%, preferably up to 5%, even more preferably from 0.01 to 2% by weight of the platinum group metal. Silicalite is one form of crystalline silica polymorph and the term silicalite has been designated by Union Carbide. Silicalite can exist in a number of different structural forms depending upon the route by which it is prepared. Thus, one form (silicalite I) is described in US Patent No. 4,061,724 which relates to a silica polymorph consisting of crystalline silica which after calcination in air at 600°C for one hour has a characteristic X-ray powder diffraction pattern similar to that of ZSM-5. Another form (silicalite II) is described in a publication in Nature , 280 , 664-665 (1979) by D.M. Bibby, N.B. Milestone and L.P. Aldridge. Structurally, silicalite II has the same relationship to ZSM-11 as silicalite I has to ZSM-5. It has been proposed that silicalite I, for example, merely represents an extreme end member of the ZSM-5 type of aluminosilicate zeolite. Without wishing to join this controversy in any way, silicalites utilisable as catalyst components in the operation of the present invention may contain minor amounts of impurities, such as aluminium and/or gallium, within the framework thereof. As previously mentioned, it is an advantage of the catalyst as used in the process of the present invention that no additional alkali metal or alkaline earth metal components are necessary for the performance of the invention. The risk of side reactions, such as cracking, and oligomerisation as a result of the acidic nature of certain of the prior art co-metals is reduced without the need to incorporate alkali metals. Catalyst preparation is thereby simplified. The catalyst may suitably be prepared by any of the known techniques for preparing catalysts. These include impregnation, precipitation or gelation. Thus, the invention provides a process for the preparation of a novel catalyst according to the invention, which comprises either forming the silicalite in the presence of a platinum group metal or contacting preformed silicalite with an aqueous solution of a platinum group metal and drying the product, and contacting the catalyst with a sulphur-containing compound to deposit sulphur on the catalyst. A suitable method, for example, comprises impregnating a silicalite with a soluble thermally decomposable compound of the platinum group metal. A mineral acid, for example nitric acid, may be added to the impregnation solution in order to facilitate better the dispersion of the metallic component(s). Furthermore, it is generally preferred to impregnate the silicalite after it has been calcined. The catalyst composition may if desired be sulphided and/or halogenated in known manner. At some stage after impregnation it will be necessary to decompose thermally decomposable platinum group metal compounds and preferably to activate reductively the catalyst composition. We have found a method of preparation of platinum group metal-containing catalysts which renders them particularly useful in the dehydrogenation of dehydrogenatable hydrocarbons. Accordingly, in another aspect the present invention provides a process for the production of a platinum group metal-containing dehydrogenation catalyst which process comprises forming a hydrogel comprising water, a soluble source of a platinum group metal, a source of silica and an organic nitrogen-containing compound and thereafter crystallising the hydrogel at elevated temperature; and, where the catalyst comprises sulphur, contacting the catalyst with a sulphur-containing compound to deposit sulphur on the catalyst. Of the platinum group metals, platinum is preferred. The metal may suitably be added in the form of a salt or complex thereof. Platinum, for example, may suitably be added in the form of tetramine platinum dihydroxide or dihalide, for example dichloride. Suitable sources of silica include, for example, sodium silicate, silica hydrosol, silica gel, silica sol and silicic acid. A preferred source of silica is an aqueous colloidal dispersion of silica particles. A suitable commercially available source of silica is LUDOX (RTM) Colloidal Silica supplied by Du Pont. The organic nitrogen-containing compound may suitably be an amine, for example diethylamine or 1,6-diaminohexane, or a tetraalkyl ammonium compound, for example tetrapropylammonium hydroxide or tetrabutylammonium hydroxide. In addition to water, the hydrogel may if desired contain an alcohol, for example methanol or ethanol. The proportions in which the water, silica source and organic nitrogen-containing compound are present in the hydrogel may suitably be such as to form one of the structurally distinct forms of silicalite. These proportions are disclosed in the aforesaid US Patent No. 4,061,724 and the article in Nature, 280 , 664-665 (1979), which are incorporated herein by reference. The amount of the platinum group metal source may suitably be such as to provide up to 10% by weight, preferably up to 5% by weight, even more preferably between 0.01 and 2% by weight of the platinum group metal in the final catalyst composition. Crystallisation may suitably be effected at a temperature greater than 100°C, preferably in the range from 140 to 220°C. The pressure may suitably be autogenous, that is the pressure generated within a closed vessel at the temperature employed. The crystallisation period will depend upon a number of factors including the rate of stirring and the temperature. Typically, within the preferred temperature range the crystallisation period may suitably be from 1 to 4 days. The catalyst may be recovered, suitably by filtration or centrifugation, and washed, suitably with water at a temperature in the range, for example, of from 15 to 95°C. Finally, the catalyst composition is preferably activated, suitably by a thermal treatment, for the purpose of decomposing thermally decomposable compounds. The thermal treatment may suitably be effected in the presence of an inert gas, for example nitrogen, or air. Alternatively, or in addition, the catalyst may be reductively activated by heating in the presence of a reducing gas, for example hydrogen. It is possible to combine the thermal treatment and the reductive treatment into a single operation. It is preferred to subject catalyst compositions for use according to the present invention to a presulphiding treatment for the purpose of incorporating into the composition at least 0.01% w/w and suitably up to 1% w/w sulphur calculated on an elemental basis. Suitably the presulphiding treatment may be effected by heating the composition, suitably at a temperature in the range from about 300 to 800°C, for example about 550°C, in the presence of a sulphur-containing compound such as hydrogen sulphide, organic sulphides, e.g. tertiary nonyl polysulphide, or low molecular weight mercaptans. Preferably the sulphiding treatment is carried out in the presence of hydrogen. A typical sulphiding gas composition comprises 1% hydrogen sulphide and hydrogen. From time to time during the dehydrogenation process it may be beneficial to repeat the sulphiding treatment. More preferably the sulphiding is carried out continuously using a feed of hydrogen sulphide diluted with hydrogen, nitrogen or the dehydrogenatable hydrocarbon feed. Alternatively, or in addition, the catalyst composition may be activated by halogenation in known manner. As regards the process of the invention, dehydrogenation conditions comprise a temperature in the range from 300 to 800°C and, a pressure in the range from 0.01 to 10 bar. Since the dehydrogenation of hydrocarbons is an endothermic reaction and conversion levels are limited by chemical equilibrium, it is desirable in order to achieve high conversion to operate at high temperatures and low hydrogen partial pressures. Under severe conditions it is difficult to maintain high activity and selectivity for long periods of time because undesirable side reactions such as aromatisation, cracking, isomerisation and coke formation increase. Reaction conditions within the aforesaid ranges should be chosen with regard to maximising activity, selectivity and stability. A diluent may be employed in the process. Suitable diluents include hydrogen, steam, methane, ethane and carbon dioxide, hydrogen being preferred. The product from the process of the invention comprises dehydrogenated hydrocarbons, unconverted dehydrogenatable hydrocarbons and hydrogen. It is preferred to recover hydrogen from the product. The hydrogen so-obtained may be utilised elsewhere or recycled to the dehydrogenation process as diluent. Depending upon the use to which the dehydrogenated hydrocarbon is to be put, it may be separated from the unconverted dehydrogenatable hydrocarbon. The separated unconverted hydrocarbons may then be recycled to the process. Water or a material decomposable to water under dehydrogenation conditions, for example an alcohol, aldehyde, ether or ketone, may be admixed with the dehydrogenatable hydrocarbon either continuously or intermittently if so desired. The invention will now be further illustrated by reference to the following Examples. In the Examples and Comparison Tests the terms used are defined as follows:- In Examples 1 to 3 reference will be made to X-ray diffraction patterns, the data relating to which is given in Tables 1 to 3. The specific values in the Tables were determined using copper K-alpha radiation and a computer controlled step scan. The peak heights, I, and their position as a function of 2-theta, where theta is the Bragg angle, were read from the diffractometer output. From this output the relative intensities, (I/I max) x 100, where I max is the intensity of the strongest peak, and d the interplanar spacing in Angstroms, corresponding to the recorded peaks were calculated. It will be understood by those skilled in the art that the X-ray diffraction pattern of the silicalite may vary in the values of (I/I max) x 100 and the d-spacing, depending for example upon whether the specimen sample is calcined, partially calcined, or uncalcined, upon the calcination temperature, upon the sample preparation and upon the particle size and shape. Example 1 (i) Preparation of Platinum on Silicalite Catalyst : formation of silicalite in the presence of platinum 23.4g of a 2.9% by weight tetramine platinum dihydroxide, Pt(NH₃)₄ (OH)₂, in aqueous solution was added to 10g of distilled water. With stirring 25g of a 20% by weight tetrapropylammonium hydroxide (TPAOH) (as silicalite-forming template) solution in water was added, followed by 70g of silica sol containing 40% silica (LUDOX (RTM) AS 40, ammonia stabilised). The resultant gel had the molar composition:- 0.5Pt(NH₃)₄(OH)₂:1.4 NH₃:5.3 TPAOH:100SiO₂:1127H₂O The gel was heated at 190°C in a pressure vessel for 48 hours under autogenous pressure. It was then cooled, filtered, washed with distilled water and dried at 100°C. The X-ray diffraction pattern of the product is shown in Table 1. (ii) Activation of Catalyst The product obtained in (i) above was pressed into tablets, broken into granules and sieved to pass 8 but not 36 mesh (BSS). The granules (approximate size 5 cm³) were packed into a tubular quartz reactor which was 450 mm in length and 15 mm inner diameter. The reactor had a coaxial thermocouple well of approximately 3 mm outer diameter. The catalyst granules were sandwiched between two regions (each of 35 cm³) of inert beads. A mixture of nitrogen and air approximately 1:3 by volume was passed over the composition at the rate of 600 cm³/minute. The temperature was raised to 650°C in a 30 minutes step and kept at that temperature for at least 30 minutes to remove the tetrapropyl ammonium ions and decompose the platinum complex. The catalyst was then flushed with nitrogen and the temperature reduced to near the desired reaction temperature. Example 2 (i) Preparation of Platinum on Silicalite Catalyst : formation of silicalite in the presence of platinum Example 1 (i) was repeated except that the gel composition was:- 0.44Pt(NH₃)₄(OH)₂:1.4 NH₃:5.3 TPAOH:100SiO₂:950H₂O The gel was heated at 200°C in a pressure vessel for 48 hours under the autogenous pressure. It was then cooled and the product treated as in Example 1. The X-ray diffraction pattern is shown In Table 2. (ii) Activation of Catalyst The composition obtained in (i) above was activated in the manner described in Example 1 (ii). Example 3 (i) Preparation of Platinum on Silicalite Catalyst : impregnation of preformed silicalite with platinum 600g of an aqueous solution containing 20% by weight tetrapropylammonium hydroxide (TPAOH) was added with stirring to 2000g of silica sol containing 40% by weight silica (LUDOX (RTM) AS 40, ammonia stabilised). The resultant gel had the composition:- 4.4 TPAOH : 1.4NH₃:100SiO₂:700H₂O The gel was heated at 175°C for 72 hours in a pressure vessel under autogenous pressure. The vessel was cooled and the product was filtered, washed with distilled water and dried at 100°C. The X-ray diffraction pattern of the product is shown in Table 3. 10g of the product was mixed with 400g of an aqueous solution containing 20% by weight nitric acid. The slurry was stirred at room temperature for 1 hour. The solid was filtered, washed with distilled water and dried at 100°C. It was then calcined at 600°C for 48 hours. The solid was mixed with 15 cm³ of an aqueous solution containing 260 mg of tetramine platinum dihydroxide, Pt(NH₃)₄(OH)₂ , to form a paste which was mixed vigorously. The paste was dried at 100°C. (ii) Activation of Catalyst The composition obtained in (i) above was activated in the manner of Example 1 (ii). Example 4 The activated catalyst of Example 2 was sulphided by contact with a stream of 1% hydrogen sulphide in hydrogen at the rate of 120 cm³/minute for 30 minutes at 550°C. Example 5 The activated catalyst of Example 3 was sulphided by contact with a stream of 1% hydrogen sulphide in hydrogen at the rate of 120 cm³/minute for 45 minutes at 550°C. Comparison Test 1 (This is a Cr₂O₃/Al₂O₃ catalyst typical of the prior art) 73.6g of aluminium nitrate nonahydrate, Al(NO₃)₃.9H₂O, and 19.2g of chromium nitrate nonahydrate, Cr(NO₃)₃.9H₂O, were dissolved in 1 litre of distilled water. With stirring the pH of the solution was adjusted to a value between 8 and 9 by adding aqueous ammonia. The resultant precipitate was washed with distilled water and dried at 100°C. The dried product was sieved to pass through 8 but not 36 mesh (BSS). The composition was activated in the manner described in Example 1 (ii). B. CATALYST TESTING Example 6 The activated catalyst produced in Example 1 was tested for n -butane (99.9% purity) dehydrogenation at an oven temperature of 498°C. The test conditions and the results are shown in Table 4. Example 7 The procedure of Example 6 was repeated except that the oven temperature was 560°C. The test conditions and the results are shown in Table 5. Example 8 A feed of n -butane (99.9% purity) was passed over the activated catalyst produced in Example 2 at a WHSV of 6.0 hours⁻¹ and at a temperature of 505°C for 5 minutes. The catalyst was then flushed with nitrogen and propane gas (containing 0.9% w/w ethane and 0.9% w/w isobutane) which was passed over the catalyst at a WHSV of 4.6 hours⁻¹ and a temperature of 505°C for 68 minutes. The catalyst was flushed with nitrogen and reactivated in air as described in Example 1 (ii). It was then tested for the dehydrogenation of n -butane at an oven temperature of 503°C. The test conditions and the results are given in Table 6A. After time on stream (TOS) = 128 minutes the feeding of n-butane was discontinued and the catalyst was treated with 1% hydrogen sulphide in hydrogen at the rate of 120 cm³/minute for 30 minutes. The n-butane feed was then re-established. The test conditions and the results are given in Table 6B. Example 9 The catalyst tested in Example 8 was reactivated in the manner described in Example 1 (ii) in air at 650°C. It was then flushed with nitrogen and sulphided by treatment with 1% hydrogen sulphide in hydrogen at a rate of 120 cm³/minute for 30 minutes. The catalyst was then tested for the dehydrogenation of n-butane at an oven temperature of 507°C. The test conditions and the results are given in Table 7. Example 10 A feed of n-butane was passed over the sulphided catalyst of Example 4 at a WHSV of 6.4 hours⁻¹ for 30 minutes. The n -butane flow was then stopped and propane feed (containing 0.9% w/w ethane and 0.9% w/w isobutane) was passed over the catalyst to test its propane dehydrogenation activity. The test conditions and the results are given in Table 8. Example 11 The catalyst of Example 5 was tested for the dehydrogenation of n -butane at an oven temperature of 505°C. The test conditions and the results are given in Table 9. Comparison Test 2 The catalyst of Comparison Test 1 was tested for the dehydrogenation of n -butane at an oven temperature of 508°C. The test conditions and the results are given in Table 10. Comparison Test 3 Comparison Test 2 was repeated except that the oven temperature was 561°C. The test conditions and the results are given in Table 11. Comparison of the results in Tables 6A and 6B demonstrates the improvement in selectivity to butenes obtained by the sulphiding treatment of the catalyst. The conversion is reduced by the treatment but the overall effect is beneficial, since the reduced conversion can be overcome by recycling. Example 12 (i) Preparation of Catalyst A catalyst containing 0.6% by weight platinum on silicalite-I was prepared as described in Example 3(i). (ii) Activation of Catalyst The catalyst was formed into granules and packed into a reactor as described in Example 1(ii). Air (600 cm³/minute) was passed over the catalyst and the temperature was raised from ambient to 360°C over 3 hours. The reactor was then flushed with nitrogen for one hour. Hydrogen (600 cm³/minute) was then passed over the catalyst and the temperature raised to 530°C over 2 hours. Catalyst Testing Example 13 A feed of n-butane (WHSV = 4.5 h⁻¹) was cofed with hydrogen containing hydrogen sulphide (50 ppm) (hydrogen concentration ca 2-10% volume:hydrogen sulphide in feed - see Figure) over the catalyst prepared in Example 12 at a bed temperature of 506°C (furnace temperature = 530°C). The results (n-butane conversion; C₄ alkene selectivity; C₄= productivity and hydrogen sulphide concentration) with time on stream are shown in the Figure. This example illustrates the stability and long life of the catalyst. In addition it illustrates the importance of sulphiding the catalyst to maintain high selectivity to C₄ alkenes (see results at 280 and 500 hours on stream). Example 14 The platinum/silicalite catalyst was prepared and activated as described in Example 12 sections (i) and (ii). Catalyst Testing Example 15 In this example isobutane was the feed. A feed of isobutane (WHSV = 4 h⁻¹) was cofed with hydrogen containing hydrogen sulphide (500 ppm) (hydrogen concentration in feed ca 3%:hydrogen sulphide concentration in feed ca 10 ppm) over the catalyst at a bed temperature of 490°C (furnace temperature = 500°C). The isobutane conversion was 30% with a selectivity to isobutene of greater than 95%.

Claims: A process for the dehydrogenation of a C₂ to C₁₀ paraffin to yield an alkene product which process comprises dehydrogenating the paraffin in the presence of a dehydrogenation catalyst characterised in that the catalyst is substantially free of alkali and alkaline earth metals and comprises an effective amount of a platinum group metal on a silicalite support. A process as claimed in claim 1 characterised in that the catalyst contains sulphur in an amount effective to improve the selectivity of the process to alkenes. A process as claimed in claim 2 characterised in that the amount of sulphur is from 0.01 to 1% by weight based on the total weight of catalyst. A process as claimed in any one of the preceding claims characterised in that a sulphur-containing compound is contacted with the catalyst at the same time as the paraffin, the sulphur-containing compound being one which is capable of depositing sulphur on the catalyst under the dehydrogenation conditions. A process as claimed in claim 4 characterised in that the paraffin is a butane. A process as claimed in any one of the preceding claims characterised in that the temperature is from 300 to 800°C and the pressure from 0.1 to 10 bar. A process as claimed in any one of the preceding claims characterised in that the paraffin is isobutane and the paraffin isobutene. A process as claimed in any one of the preceding claims characterised in that there is maintained continuous dehydrogenation process conditions for at least 500 hours with the same catalyst. A catalyst suitable for the dehydrogenation of C₂ to C₁₀ paraffins to alkenes, which is substantially free of alkali and alkaline earth metals and comprises an effective amount of a platinum group metal on a silicalite support, together with sulphur in an amount within the range of from 0.1 to 1% by weight. A catalyst as claimed in claim 9 characterised in that the amount of platinum group metal is from 0.01 to 5%, preferably 0.01 to 1% by weight based on the total weight of catalyst. A catalyst as claimed in claim 10 characterised in that the amount of platinum group metal is from 0.01 to 0.2% by weight. A process for the preparation of a catalyst as claimed in claim 9, which comprises either forming the silicalite in the presence of the platinum group metal or contacting preformed silicalite with an aqueous solution of a platinum group metal and drying the product; and contacting the catalyst with a sulphur-containing compound to deposit sulphur on the catalyst. A process as claimed in claim 12 characterised in that the process comprises forming a hydrogel comprising water, a soluble source of a platinum group metal, a source of silica and an organic nitrogen-containing template under silicalite forming conditions and thereafter crystallising the hydrogel at elevated temperature.

Inventors: BARRI, SAMI A.I. THE BRITISH PETROLEUM CO. P.L.C.
Applicants: THE BRITISH PETROLEUM COMPANY P.L.C.
Application year: 1986
Main classification: C07C5
IPC codes: C07C1, C07C5, C07B61, C07C11, C07C67, B01J29