Hydrocarbon Conversion Process

This invention relates to a hydrocarbon conversion process utilizing a supported iridium catalyst and, more particularly, to process utilizing an iridium catalyst wherein there is improved distribution of iridium on an inorganic oxide support.

Catalysts comprising platinum, for example, platinum-on-alumina, are well known and widely used for reforming of naphthas in order to produce high octane gsolines. Iridium has been proposed for use in catalytic reforming as a promoter for platinum-containing catalysts. Thus, U.S. Pat. No. 2,848,377 discloses reforming with a catalyst consisting of platinum and iridium on an alumina support. In U.S. Pat. No. 3,554,902, a particular reforming process is also disclosed using a platinum and iridium supported catalyst similar to the catalyst of U.S. Pat. No. 2,848,377.

A particular problem associated with preparing supported iridium catalyst is to obtain a substantial homogeneous dispersion of iridium on the support carrier. Thus, in Netherlands Patent Application No. 71/02303, a process for the preparation of a platinum-iridium supported catalyst is disclosed which improves upon the catalyst methods of manufacture disclosed in U.S. Pat. No. 2,848,337. As set forth in the Netherlands Application, one of the problems associated with the preparation of a platinum-iridium supported catalyst is the referred to selective absorption phenomena which occurs during the impregnation of the carrier by the solution containing the active catalyst elements, for example, platinum and iridium. For example, the generally used ammonium salts such as the chloroplatinate or the other salts of ammonium or the chloroiridate, lead to the formation of agglomerates of the metals there by producing catalysts having significant activity loss.

It is an object of this invention to provide an improved process for the preparation of a supported iridium catalyst. It is a further object of this invention to provide an improved hydrocarbon conversion process utilizing such improved iridium catalyst. Other objects will be apparent from the following description.

It has now been found that an improved hydrocarbon conversion process can be obtained utilizing a supported iridium catalyst prepared by a process which comprises impregnating an alumina-containing support with a liquid medium containing a decomposable solubilized iridium compound, maintaining the pH of the liquid medium during impregnation of the support in the range of from 3 to 6, preferably from about 3.5 to about 5, with a base selected from ammonium hydroxide, a lower alkyl amine, and mixtures thereof to yield an iridium-alumina composite comprising from about 0.01 to about 1 weight % of iridium and subjecting the resulting iridium-alumina composite to drying, calcination and reduction.

In the preparation of the catalyst utilized in the process of this invention, the alumina-containing support is impregnated with the iridium-containing liquid medium preferably containing a platinum or palladium metal component, preferably platinum. The metals are present in the liquid medium, i.e., as in an aqueous solution, at a sufficient concentration to provide the desired quantity of iridium and platinum metal in the finished catalyst. In general, the temperature of impregnation is from about ambient to about 212.degree.F., more preferably from about 140.degree.F. to about 200.degree.F. The temperature of the liquid medium is maintained at level sufficient to solubilize substantially all of the iridium compound, preferably all of the iridium compound. The impregnation of the alumina-containing support can be at a pressure of from about 0.01 to about 100 atmospheres, more preferably from about 0.01 to about 0.1 atmospheres. The use of a pressure below atmospheric pressure is particularly advantageous in the process of this invention. It is essential that the liquid medium is adjusted to a pH of from about 3 to 6 prior to contact with the alumina-containing support. The base material, e.g., ammonium hydroxide and/or lower alkyl amine, is added to the liquid medium at a concentration sufficient to provide the requisite pH for the liquid medium. As set forth above, it is preferred to use co-impregnation of the alumina-containing support with the iridium and platinum compounds. However, it is contemplated within the scope of this invention that the alumina-containing support can be a catalyst comprising platinum-on-alumina. In such cases, the platinum in general exists in the reduced form. It is, therefore, preferred that the platinum-on-alumina containing support be subjected to oxidizing conditions followed by the impregnation with the iridium compound utilizing the process of this invention. Alternatively, sequential impregnation can be utilized to prepare the iridium composite with either type metal compound being utilized as the first metal. If the metals are sequentially added to the alumina support as, for example, by sequential impregnation, the carrier containing the first metal compound added can be dried and calcined prior to addition of the second metal compound. Thereafter, the carrier containing both metals can be dried and calcined. In any event, the iridium-alumina containing composite is prepared according to the process of this invention.

The final unreduced catalyst, prepared by a method set forth above, is generally dried at a temperature of from about 200.degree.F. to about 600.degree.F. for a period of from about 2 to 24 hours or more and finally calcined at a temperature of about 600.degree.F. to about 1500.degree.F., more preferably from about 700.degree.F. to about 1500.degree.F., and still more preferably from about 700.degree.F. to about 1100.degree.F. for a period of from about 1 hour to about 20 hours and preferably from about 1 hour to about 5 hours.

The resultant calcined catalyst is generally subjected to reduction prior to use in the conversion of hydrocarbons. This step as previously noted is designed to insure chemical reduction of at least a portion of the metallic components.

The reducing media in general contacts the calcined catalyst at a temperature of about 800.degree.F. to about 1200.degree.F., at a pressure in the range from about 0 psig. to about 500 psig. and for a period of time of about 0.5 to 10 hours or more and in any event, for a time which is effective to chemically reduce at least a portion, preferably a major portion, of each of the metallic components, i.e., platinum or palladium metal and iridium component, of the catalyst. By chemical reduction is meant the lowering of oxidation states of the metallic components below the oxidation state of the metallic component in the unreduced catalyst. For example, the unreduced catalyst may contain iridium salts in which the iridium has an oxidation state which can be lowered or even reduced to elemental iridium by contacting the unreduced catalyst with hydrogen. This reduction treatment is preferably performed in situ (i.e., in the reaction zone in which it is to be used), as part of a start-up operation using fresh unreduced catalyst.

The essential constituent of the catalyst is iridium. This component may be present as an elemental metal, as a chemical compound, such as the oxide, sulfide or halide, or in a physical or chemical association with the inorganic oxide support and/or the other components of the catalyst. Generally, the iridium component is utilized in an amount which results in a catalyst composite containing from about 0.01 to about 1 percent, preferably from about 0.025 to about 0.50 percent, by weight or iridium calculated as the elemental metal. The iridium component may be incorporated in the catalyst at any stage in the preparation of the catalyst. As stated above, the procedure for incorporating the iridium component involves the impregnation of the support or its precursor, either in the form of a sol or gel, before, during or after the time platinum or palladium or mixtures thereof are added. The impregnation solution is, in general, an aqueous solution suitable solubilized iridium salt such as chloroiridic acid, iridium tetrachloride, the ammonium complexes such as ammonium chloroiridate, iridium tribromide, iridium trichloride and ammonium chloroiridite. It is preferred to use chloroiridic acid as the source of iridium for the preparation of the supported catalysts. In general, the iridium component can be impregnated either prior to, simultaneously with, or after the platinum or palladium metal component is added to the support. However, it has been found the best results are achieved when the iridium component is impregnated simultaneously with the platinum or palladium component. A preferred impregnation solution contains chloroplatinic acid and chloroiridic acid.

The combined weight of the iridium component plus the platinum and/or palladium component in the catalytic composite may be within the range of from about 0.1 to about 4 percent by weight, preferably from about 0.2 to about 2.0 percent by weight and, more preferably, from about 0.3 to about 1.0 percent by weight, calculated on an elemental basis.

Typical examples of alkyl amine bases which can be utilized to prepare the catalyst utilized in the process of this invention, are represented by the following structural formula: ##STR1## wherein R, R.sub.1 and R.sub.2 are selected from the group consisting of hydrogen, alkyl containing from 1 to 6 carbon atoms, preferably 1 to 2 carbon atoms and cycloalkyl, provided, however, that not more than two R groups are hydrogen and R and R.sub.1 can, together with the nitrogen atom, form a heterocyclic ring containing from 5 to 6 aliphatic carbon atoms. Typical examples of such amines are methyl amine, ethyl amine, t-butyl amine, diethyl amine, triethyl amine, tri-n-butyl amine, cyclohexyl amine, and piperidine.

As set forth above, it is preferred that the iridium-alumina containing support contain at least one platinum group metal selected from platinum and palladium. The platinum and palladium component may exist within the final unreduced catalyst at least in part as a compound such as an oxide, sulfide, halide and the like, or in the elemental state. Generally, the amount of the platinum or palladium component present in the final catalyst is small compared to the quantities of the other components combined therewith. The platinum or palladium generally has from about 0.5 to about 3.0 percent, preferably from about 0.10 to about 1.0 percent, by weight of the catalyst calculated on an elemental basis. Excellent results are obtained when the catalyst contains from 0.2 to about 0.9 percent by weight of the platinum group metal.

The platinum or palladium may be incorporated in the catalyst by the contacting of the alumina support and/or alumina hydrogel and/or alumina sol or gel at any stage in its preparation, either after or before calcination of the alumina hyrogel. The preferred method for adding the platinum or palladium to the alumina support involves the utilization of a water-soluble compound of the platinum or palladium to impregnate the alumina support prior to calcination. For example, platinum may be added to the support by comingling the uncalcined inorganic oxide support with an aqueous solution of chloroplatinic acid. Other water-soluble compounds of platinum may be employed as impregnation solutions, including, for example, ammonium chloroplatinate and platinum chloride. The utilization of a platinum-chlorine compound, such as chloroplatinic acid, is preferred since it facilitates the incorporation of both the platinum component and a minor quantity of a halogen component.

An optional component of the catalyst utilized in the present invention is a halogen component. Although the precise chemistry of the association of the halogen component with the inorganic oxide support is not entirely known, it is customary in the art to refer to the halogen component as being combined with the support, or with the other ingredients of the catalyst. This combined halogen may be fluorine, chlorine, bromine, and mixtures thereof. Of these, fluorine and, particularly, chlorine are preferred for the purposes of the present invention. The halogen may be added to the support in any suitable manner, either during preparation of the support, or before or after the addition of the catalytically active metallic components. For example, at least a portion of the halogen may be added at any stage of the preparation of the support, or to the calcined catalyst support, as an aqueous solution of an acid such as hydrogen fluoride, hydrogen chloride, hydrogen bromide and the like or as a substantially anhydrous gaseous stream of these halogen-containing components. The halogen component, or a portion thereof, may be composited with the support during the impregnation of the latter with the platinum group component and/or iridium component, for example, through the utilization of a mixture of chloroplatinic acid and/or chloroiridic acid and hydrogen chloride. In another situation, an alumina hydrosol which can be utilized to form the alumina component may contain halogen and thus contribute at least a portion of the halogen component to the final composite. For purposes of the present invention, when the catalyst support, for example, alumina derived from hydrous alumina, e.g., alumina monohydrate, is used in the form of an extrudate, and platinum is added before extrusion, it is preferred to add the major portion of the halogen component to the otherwise fully composited calcined catalyst by contacting this catalyst with a substantially anhydrous stream of halogen-containing gas. When the catalyst is prepared by impregnating calcined, formed alumina, for example, spheres produced by the oil drop method, it is preferred to impregnate the support simultaneously with the platinum group metal, iridium component and halogen. In any event, the halogen will be added in such a manner as to result in a fully composited catalyst that contains from about 0.1 to about 1.5 percent and preferably from about 0.5 to about 1.3 percent by weight of halogen calculated on an elemental basis. During processing, i.e., the period during which hyrocarbon is being converted, the halogen content of the catalyst can be maintained at or restored to the desired level by the addition of halogen-containing compounds, such as carbon tetrachloride, ethyl trichloride, t-butyl chloride and the like, to the hydrocarbon charge stock before entering the reaction zone.

The alumina-containing support utilized in the catalyst comprises a major amount of alumina. Any of the forms of alumina suitable as supports, for example, in reforming, can be utilized. Furthermore, alumina can be prepared by a variety of methods satisfactory for the purposes of this invention. The preferred alumina material should be a porous, adsorptive support having a surface area of from about 25 m.sup.2 /gm. to about 600 m.sup.2 /gm. or more. The alumina comprises a major proportion, preferably at least about 80 percent, and more preferably at least 90 percent, by weight of the catalyst. The more preferred catalyst support, or base, is an alumina derived from hydrous alumina, particularly gamma alumina, when formed as pellets and calcined, has an apparent bulk density of from about 0.40 gm./cc. to about 0.85 gm./cc., pore volume of from about 0.45 ml./gm. to about 0.55 ml./gm., and surface area of from about 100 m.sup.2 /gm. to about 500 m.sup.2 /gm. As stated above, the alumina support may contain, in addition, minor proportions of other well-known refractory inorganic oxides such as silica, zirconia, magnesia and the like. However, the preferred support is substantially pure alumina derived from hydrous alumina.

The alumina support may be synthetically prepared in any suitable manner and may be activated prior to use by one or more treatments including drying, calcination, steaming and the like. The alumina may be formed in any desired shape such as spheres, pills, cakes, extrudates, powers, granules and the like. For example, the alumina base can be shaped into spheres by means of the well-known oil-drop method. If the spheroidal particles are calcined, the resulting product is a hard, porous alumina gel. When the catalyst used in the present invention is to be made in the form of spheres by means of the oil-drop method, it is preferred to add the additional essential components of the catalyst, i.e., platinum group metal, iridium and, optionally, halogen, after calcination of the spheroidal particles.

The hydrocarbon conversion process utilizing the catalyst prepared by the above process includes by way of example reforming, hydrocracking, isomerization, dehydrogenation, hydrogenation, hydrodesulfurization, cyclization, alkylation, polymerization, cracking, hydroisomerization and the like. The hydrocarbon conversion process of the present invention involves contacting a hydrocarbon feed with a catalyst comprising at least one of the iridium supported catalysts as set forth above. As a result of this contacting, at least a portion of the hydrocarbon feed is chemically converted to different, and often more valuable products. The conditions at which the contacting takes place are, of course, dependent upon the particular application involved. However, in each application, the conditions used are conventional, well known in the art and, therefore, need not be listed here in detail. In many cases, the processes using these catalysts involve the simultaneous occurrence of more than one reaction. An example of this type of process is reforming, wherein a hydrocarbon feed stream comprising paraffins and naphthenes is subjected to conditions which promote dehydrogenation of naphthenes to aromatics, dehydrocyclization of paraffins to aromatics, isomerization of paraffins and naphthenes, hydrocracking of naphthenes and paraffins and the like reactions to produce a high octane or aromatic-rich product stream. Another example of a process in which more than one reaction occurs simultaneously is hydrocracking, wherein catalysts are used to promote selective hydrogenation and cracking of high molecular weight unsaturated materials, selective hydrocracking of high molecular weight materials and other like reactions to produce a generally lower boiling, more valuable product stream. Yet another example of a process utilizing these catalysts is an isomerization process, wherein, for example, a hydrocarbon fraction which is relatively rich in straight-chain paraffin components is contacted with the catalyst to produce an output stream rich in isoparaffin compounds.

When the catalyst described herein is used in reforming operation, the reforming system may comprise a reforming zone containing at least one fixed bed of catalyst previously characterized. This reforming zone may be one or more separate reactors with suitable heating means there between to compensate for the net endothermic nature of the reactions that take place in each catalyst bed. The hydrocarbon feed stream that is charged to the reforming system will comprise hydrocarbon fractions containing naphthenes and paraffins the boil within the gasoline range. A preferred class of charge stocks includes straight run gasolines, natural gasolines, synthetic gasolines and the like. On the other hand, it is frequently advantageous to charge thermally or catalytically cracked gasolines or higher boiling fractions thereof, called heavy naphthas. Mixtures of straight run and cracked gasolines can also be used to advantage. The gasoline charge stock may be a full boiling range gasoline having an initial boiling point of from about 50.degree.F. to about 150.degree.F. and an end boiling point within the range of from about 325.degree.F. to about 425.degree.F., or may be selected fraction thereof which generally will be a higher boiling fraction commonly referred to as a heavy naphtha -- for example, a naphtha boiling in the range of about C.sub.7 to about 400.degree.F. In some cases, it is also advantageous to charge pure hydrocarbons or mixtures of hydrocarbons that have been extracted from hydrocarbon distillates -- for example, a straight-chain paraffin -- which are to be converted to aromatics. It is preferred that these charge stocks be treated by conventional pretreatment methods, if necessary, to remove substantially all sulfurous and nitrogenous contaminants therefrom.

In the reforming embodiment of the present invention, the pressure utilized is selected in the range of from about 50 psig. to about 1000 psig., with the preferred pressure being from about 100 psig. to about 600 psig. Reforming operations may be conducted at the more preferred pressure range of from about 200 psig. to about 400 psig. to achieve substantially increased catalyst life before regeneration.

For optimum reforming results, the temperature in the reaction zone should preferably be within the range of from about 700.degree.F. to about 1100.degree.F. more preferably in the range of from about 800.degree.F. to about 1050.degree.F. The initial selection of the temperature within this broad range is made primarily as a function of the desired octane of the product reformate, considering the characteristics of the charge stock and of the catalyst. The temperature may then be slowly increased during the run to compensate for the inevitable deactivation that occurs, to provide a constant octane product.

In accordance with the reforming process of the present invention, sufficient hydrogen is supplied to provide from about 2.0 to about 20 moles of hydrogen per mole of hydrocarbon entering the reaction zone, with excellent results being obtained when from about 5 to about 10 moles of hydrogen are supplied per mole of hydrocarbon charge stock. Likewise, the weight hourly space velocity, i.e., WHSV, used in reforming may be in the range from about 0.5 to about 10.0 with a value in the range from about 2.0 to about 5.0 being preferred. In addition, the catalyst can be sulfided prior to contact with the feed in the reaction zone utilizing conventional presulfiding processes.

As stated above, the conditions utilized in the numerous hydrocarbon conversion embodiments of the present invention are those customarily used in the art for the particular reaction, or combination of reactions, that is to be effected. For instance, alkylaromatics and paraffin isomerization conditions include: a temperature of about 32.degree.F. to about 1,000.degree.F. and preferably about 75.degree.F. to about 600.degree.F.; a pressure of atmospheric to about 100 atmospheres; a hydrogen to hydrocarbon mole ratio of about 0.5:1 to about 20:1 and a LHSV (calculated on the basis of equivalent liquid volume of the charge stock contacted with the catalyst per hour divided by the volume of conversion zone containing catalyst) of about 0.2 hr..sup.-.sup.1 to 10 hr..sup.-.sup.1. Dehydrogenation conditions include: a temperature of about 700.degree. to about 1,250.degree.F., a pressure of about 0.1 to about 10 atmospheres, a liquid hourly space velocity of about 1 to 40 hr..sup.-.sup.1 and a hydrogen to hydrocarbon mole ratio of about 1:1 to 20:1. Likewise, typically hydrocracking conditions include: a pressure of about 500 psig. to about 3,000 psig.; a temperature of about 400.degree.F. to about 900.degree.F.; a LHSV of about 0.1 hr..sup.-.sup.1 to about 10 hr..sup.-.sup.1 ; and hydrogen circulation rates of about 1000 to 10,000 SCF per barrel of charge.

In the hydrocarbon conversion process, the charge stock will be of the conventional type customarily used for the particular kind of hyrocarbon conversion being effected. For example, in a typical insomerization embodiment the charge stock can be a paraffinic stock rich in C.sub.4 to C.sub.8 normal paraffins, or a normal butane-rich stock, or an n-hexane-rich stock, or a mixture of xylene isomers, etc. In a dehydrogenation embodiment, the charge stock can be any of the known dehydrogenatable hydrocarbons such as an aliphatic compound containing 2 to 30 carbon atoms per molecule, a C.sub.4 to C.sub.30 normal paraffin, a C.sub.8 to C.sub.12 alkylaromatic, a naphthene and the like. In hydrocracking embodiments, the charge stock will be typically a gas oil, heavy cracked cycle oil, etc. In addition alkylaromatic and naphthenes can be conveniently isomerized by using the catalyst of the present invention. Likewise, pure hydrocarbons or substantially pure hydrocarbons can be converted to more valuable products by using the above catalyst of the present invention in any of the hydrocarbon conversion processes, known to the art, that use such a catalyst.

The following examples illustrate more clearly the preparation of a catalyst for use in the process of the present invention. However, these illustrations are not to be interpreted as specific limitations on this invention.

A commercially available gamma-alumina was utilized to prepare the platinum-iridium supported alumina-contained catalyst. The alumina had a pore volume of 1 cc./gm., a density of 0.50 gm./cc., a surface area of 240 sq. meters and a diameter of 1/2 in. The alumina was in the form of an extrudate.

A solution of deionized water containing 6.87 ml. of chloroplatinic acid (56.17 mg. platinum per ml.), 2.93 ml. of chloroiridic acid (37.43 mg. iridium per ml.) and 5 ml. of dilute hydrochloric acid was adjusted to a pH of 5.5 with ammonium hydroxide. The gamma-alumina (117 gm.) was vacuum impregnated at a temperature of about 190.degree. F. with the iridium-containing aqueous solution. The impregnated alumina was maintained at ambient temperature for a period of 20 hours. The iridium-alumina composite was vacuum dried until free flowing and further dried for a period of 24 hours at a temperature of 230.degree.F. The platinum-iridium alumina was calcined for a period of 3 hours at a temperature of 900.degree.F. in a stream of dry air. The resulting platinum-iridium alumina composite was contacted with hydrogen for a period of 16 hours at 900.degree.F. and atmospheric pressure. The catalyst contained 0.33 weight % platinum and 0.11 weight % iridium.

A platinum-iridium alumina composite was manufactured according to the process of Example I, except the pH of the liquid medium was maintained at 1.0. The resulting platinum-iridium alumina composite contained 0.31 weight % platinum and 0.10 weight % iridium.

A platinum-iridium alumina composite was manufactured according to the process of Example I, except the ammonium hydroxide was added until the pH of the liquid medium was 9.0. The resulting platinum-iridium alumina composite contained 0.34 weight % platinum and 0.11 weight % iridium.

A solution of deionized water containing 6.87 ml. of chloroplatinic acid (56.17 mg. platinum per ml.), 2.93 ml. of chloroiridic acid (37.43 mg. iridium per ml.), 6 ml. of dilute hydrochloric acid, and 2 mg. of ammonium nitrate was prepared. The gamma-alumina (117 gm. ) was vacuum impregnated at a temperature of 190.degree.F. with the iridium-containing aqueous solution. The impregnated alumina was maintained at ambient temperature for a period of 20 hours. The impregnated alumina was vacuum dried until free flowing and further dried for a period of 5 hours at a temperature of 230.degree.F. The platinum-iridium alumina was calcined for a period of 3 hours at a temperature of 900.degree.F. in a stream of dry air. The resulting platinum-iridium alumina composite was contacted with hydrogen for a period of 16 hours at 900.degree.F. and atmospheric pressure. The catalyst contained 0.33 weight % platinum and 0.11 weight % iridium.

The catalysts of Examples I through IV were performance tested as reforming catalysts by contacting the catalysts with a typical mid-continent naphtha feedstock at a temperature of about 950.degree.F., WHSV of 4, a pressure of 300 psig., and a mole ratio of hydrogen to hydrocarbon of from 3:1. The catalyst was subjected to hydrocarbon reforming for about 150 hours. The results of these tests are as follows:

The above results demonstrates a significant increase in the stability of the iridium supported catalyst prepared in manner set forth herein. Thus, the standard aging rate for the catalyst of Example I, was only 0.9, as compared to significantly higher aging rates of platinum-iridium catalyst prepared at pH's of 1 and 9, respectively. In addition, a comparison of the aging rate of Examples I and Iv demonstrates the importance of the base material which is utilized in the process of this invention. Thus, the use of ammonium nitrate as a source of ammonium ion in comparison to ammonium hydroxide showed a significantly higher aging rate.

While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims.