Multizone Catalytic Reforming Process

1. Field of the Invention

This invention relates to an improved process for the conversion of hydrocarbons, and more specifically for the catalytic reforming of gasoline-range hydrocarbons.

2. General Background

The catalytic reforming of hydrocarbon feedstocks in the gasoline range is an important commercial process, practiced in nearly every significant petroleum refinery in the world to produce aromatic intermediates for the petrochemical industry or gasoline components with high resistance to engine knock. The widespread removal of lead antiknock additive from gasoline and the rising demands of high-performance internal-combustion engines are increasing the need for gasoline "octane", or knock resistance of the gasoline component. The catalytic reforming unit must operate at higher severities in order to meet these increased octane needs. This trend creates a need for more effective reforming catalysts and catalyst combinations.

The multi-functional catalyst composite employed in catalytic reforming contains a metallic hydrogenation-dehydrogenation component on a porous, inorganic oxide support which provides acid sites for cracking and isomerization. Catalyst composites comprising platinum on highly purified alumina are particularly well known in the art. Those of ordinary skill in the art are also aware of metallic modifiers, such as rhenium, iridium, tin, and germanium which improve product yields or catalyst life in platinum-catalyst reforming operations.

The composition of the catalyst, feedstock properties, and selected operating conditions affect the relative importance and sequence of the principal reactions: dehydrogenation of naphthenes to aromatics, dehydrocyclization of paraffins, isomerization of paraffins and naphthenes, hydrocracking of paraffins to light hydrocarbons, and formation of coke which is deposited on the catalyst. Naphthene dehydrogenation takes place principally in the first catalyst zones, while hydrocracking is largely accomplished in later catalyst zones. High yields of desired gasoline-range products are favored by the dehydrogenation, dehydrocyclization, and isomerization reactions.

The performance of catalysts employed in the catalytic reforming of naphtha range hydrocarbons is measured principally by three parameters:

(1) Activity is a measure of the ability of the catalyst to convert hydrocarbon reactants to products at a designated severity level, with severity level representing a combination of reaction conditions: temperature, pressure, contact time, and hydrogen partial pressure. Activity typically is designated as the octane number of the pentanes and heavier ("C.sub.5.sup.+ ") product stream from a given feedstock at a given severity level, or conversely as the temperature required to achieve a given octane number.

(2) Selectivity refers to the yield of petrochemical aromatics or C.sub.5.sup.+ product from a given feedstock at a particular activity level.

(3) Stability refers to the rate of change of activity or selectivity per unit of time or of feedstock processed. Activity stability generally is measured as the rate of change of operating temperature per unit of time or of feedstock to achieve a given C.sub.5.sup.+ product octane, with a lower rate of temperature change corresponding to better activity stability, since catalytic reforming units typically operate at relatively constant product octane. Selectivity stability is measured as the rate of decrease of C.sub.5.sup.+ product or aromatics yield per unit of time or of feedstock.

Higher catalyst activity is required to meet the need for high octane gasoline components at reasonable operating conditions, and improved catalyst selectivity becomes more important as higher operating severities reduce the yield of desired product.

Higher operating severities also accelerate the deactivation of the catalyst. The principal cause of deactivation of a dual-function catalyst in a catalytic reforming operation is the aforementioned formation of coke on the surface of the catalyst. Alternative approaches to reactivation of the catalyst are well known to those skilled in the art. Regeneration of the catalyst may be carried out during a periodic shutdown of the unit, i.e., a "semiregenerative" operation, or by isolation and regeneration of individual reactors, i.e., a "swingreactor" system. In a "continuous" operation, catalyst is withdrawn by means of a slowly moving bed, regenerated, reactivated, and returned to the reactors. The "hybrid" system is a combination of regeneration techniques, in which a reactor associated with continuous catalyst regeneration is added to an existing fixed-bed system. The reactants may contact the catalyst in individual reactors in either upflow, downflow, or radial flow fashion, with the radial flow mode being preferred.

The problem facing workers in this area of the art, therefore, is to develop catalyst systems with improved activity, selectivity, and stability for a variety of feedstocks, product requirements, and reactor systems. This problem has become more challenging due to the aforementioned increase in required catalytic reforming severity. Multi-catalyst-zone systems, in which different catalyst composites are employed in the sequential zones of the reactor system, are of increasing interest as a solution to the problem. The activity, selectivity, and stability characteristics of individual catalyst composites are complementary to the specific reactions occurring in the different zones of the multi-zone system.

There are numerous references to multi-catalyst-zone systems in the prior art. Several metallic modifiers have been disclosed, in addition to the well-known rhenium, for incorporation into platinum-containing catalysts in different zones of a multi-zone system. Most of these modifiers are employed in the second or terminal zone of the system, in contrast to the present invention.

For example, U.S. Pat. No. 3,772,183 discloses a second-zone reforming catalyst comprising gallium and a hydrogenation component, notably platinum, on a porous refractory inorganic oxide support. The catalyst of the first reforming zone may be any suitable reforming catalyst in the art, notably comprising platinum and rhenium on alumina. U.S. Pat. Nos. 3,772,184; 4,134,823; and 4,325,808 also disclose gallium, as well as other promoters, on second-zone reforming catalysts.

U.S. Pat. No. 3,791,961 teaches platinum-indium on a porous support as a "tail zone" catalyst for the conversion primarily of paraffins in the feedstock. The initial zone uses a conventional naphthene dehydrogenation catalyst, notably comprising platinum and rhenium. U.S. Pat. Nos. 3,684,693 and 4,613,423 also teach the use of indium as a promoter in the tail reactor. U.S. Pat. No. 4,174,271 teaches an increasing concentration of a variety of promoters, notably indium and including germanium, toward the last reaction zone. U.S. Pat. No. 4,588,495 discloses tin, indium, or tellurium as promoters in other than the first reactor for a catalyst containing platinum and notably indium; the first reactor catalyst comprises conventional platinum and rhenium on a carrier to produce aromatics and minimize paraffins cracking.

In contradistinction to the platinum-germanium catalyst of the first catalyst zone of the present invention, the aforementioned prior art discloses catalyst promoters for the second or tail catalyst zones. Thus, these prior art promoters are directed toward catalyst activity, selectivity, or stability in a different section of the catalyst bed than that of the present invention.

U.S. Pat. No. 4,167,473 teaches the application of dissimilar catalyst particles in a plurality of catalyst zones, wherein the catalyst particles are downwardly movable via gravity flow. Numerous catalytic modifiers including germanium are listed in the specification. This represents a system for catalyst reactivation such as the aforementioned "continuous" or "hybrid" systems, wherein catalyst is continuously withdrawn from the reactor, regenerated, reactivated, and returned to the catalyst system.

U.S. Pat. No. 3,729,408 teaches the addition of a Group IB metal, preferably copper, to a catalyst in the initial reaction zone comprising platinum on a refractory oxide support. This catalyst greatly increases the selectivity of conversion of alkylcyclopentanes to aromatics. As is well known to those of ordinary skill in the art, however, conversion of alkylcyclopentanes to aromatics is very high in modern catalytic reforming units operating at high reformer severities and the utility of this invention therefore is limited.

U.S. Pat. No. 4,663,020 discloses a first catalyst comprising tin and at least one platinum group metal on a solid catalyst support. The second catalyst notably comprises platinum-rhenium, showing overall greater petrochemical aromatics than with either catalyst alone. However, the relatively low stability of platinum-tin catalysts is well known. Platinum-tin catalysts are applied commercially in catalytic reforming units with continuous catalyst regeneration, realizing the yield advantages of the catalyst while compensating for its relatively low stability, in contrast to the present invention.

Reforming catalysts containing germanium are well known in the prior art. For example, U.S. Pat. No. 3,578,584 describes a catalyst comprising germanium, a platinum group metal, and a halogen on a porous carrier material particularly useful in the reforming of a gasoline fraction.

The benefits of staging catalyst with a germanium-containing catalyst in the first zone have not been described in the prior art. Where the art has recognized the application of a promoter in platinum-containing first-zone catalyst, the development appears to be particularly applicable in systems including continuous catalyst regeneration. The discovery of the surprising yield improvements from the use of a first-zone catalyst containing germanium are notably applicable in semi-regenerative and cyclic catalytic reforming units, where germanium-containing catalysts are commercially proven.

It is an object of the present invention to provide an improved process for the catalytic reforming of hydrocarbons. A corollary objective of the invention is to increase the yield of petrochemical aromatics or gasoline product from the reforming of gasoline-range hydrocarbons.

This invention is based on the discovery that a multi-catalyst-zone reforming process employing an initial catalytic composite comprising platinum, germanium and halogen on a solid catalyst support and a terminal catalytic composite having the essential absence of germanium and comprising platinum, halogen and a metal promoter on a solid catalyst support demonstrates surprising yield improvements over a single-catalyst system.

One embodiment of the present invention is directed toward the catalytic reforming of a hydrocarbon feedstock by: (a) reacting said feedstock and hydrogen in an initial catalyst zone with an initial catalytic composite comprising platinum, germanium, a refractory inorganic oxide, and a halogen: and (b) further reacting the resultant effluent in a terminal catalyst zone with a terminal catalytic composite having the essential absence of germanium and comprising platinum, a refractory inorganic oxide, a halogen, and a metal promoter.

In a preferred embodiment, the refractory inorganic oxide of the initial and terminal catalytic composites comprises alumina.

In a highly preferred embodiment, the halogen of the initial and terminal catalytic composites comprises a chlorine component.

In an even more highly preferred embodiment, the metal promoter of the terminal catalytic composite is rhenium.

In an alternative embodiment, the refractory inorganic oxide of the initial and terminal catalytic composites comprises alumina, the halogen of the initial and terminal composites comprises a chlorine component, and the promoter of the terminal composite comprises rhenium and indium.

In an alternative embodiment, the refractory inorganic oxide of the initial and terminal catalyst composites comprises alumina, the halogen of the initial and terminal composites comprises a chlorine compound, and the metal promoter of the terminal composite comprises surface-impregnated metal components selected from the group consisting of rhodium, ruthenium, cobalt, nickel, iridium, and mixtures thereof.

In an alternative embodiment, the initial catalyst zone comprises at least first and intermediate catalyst zones, wherein the first catalytic composite consists essentially of platinum, germanium, a refractory inorganic oxide and the intermediate catalytic composite comprises platinum, germanium, a refractory inorganic oxide, a halogen, and a metal promoter selected from rhenium, rhodium, ruthenium, cobalt, nickel, and iridium, and mixtures thereof.

These as well as other objects and embodiments will become apparent upon reading of the detailed description of the invention.

FIG. 1 is a graphical depiction of the selectivity, activity, and stability of a multi-zone system of the present invention in comparison to the same catalysts tested individually. Initial yeild of C.sub.5.sup.+ product at equivalent operating severity and the decline of C.sub.5.sup.+ product yield with catalyst age are compared. Initial temperature requirement for equivalent severity and the increase in temperature required to maintain severity with catalyst age also are compared.

FIG. 2 is a graphical depiction of the selectivity, activity and stability of a multi-zone system of the present invention in comparison to a mixture of catalysts having the same composition, an option which is not of the present invention. Again, initial C.sub.5.sup.+ product yield, yield decline, initial temperature, and required temperature increase are compared at equivalent operating severity.

FIG. 3 is a graphical depiction of the yield of C.sub.5.sup.+ product from a multi-zone system of the present invention having a lower chloride level on the first catalytic composite than on the second catalytic composite. Results are compared over a range of product octane numbers with a multi-zone system having essentially the same chloride level on both catalysts and with a single-catalyst test.

To reiterate briefly, one embodiment of the present invention is directed toward the catalytic reforming of a hydrocarbon feedstock by: (a) reacting said feedstock and hydrogen in an initial catalyst zone with an initial catalytic composite comprising platinum, germanium, a refractory inorganic oxide, and a halogen; and (b) further reacting the resultant effluent in a terminal catalyst zone with a terminal catalytic composite having the essential absence of germanium and comprising platinum, a refractory inorganic oxide, a halogen, and a metal promoter.

The catalytic reforming process is well known in the art. The hydrocarbon feedstock and a hydrogen-rich gas are preheated and charged to a reforming zone containing typically two to five reactors in series. Suitable heating means are provided between reactors to compensate for the net endothermic heat of reaction in each of the reactors.

The individual initial and terminal catalyst zones respectively containing the initial and terminal catalytic composites are typically located in separate reactors, although it is possible that the catalyst zones could be separate beds in a single reactor. Each catalyst zone may be located in two or more reactors with suitable heating means provided between reactors as described hereinabove, for example with the initial catalyst zone located in the first reactor and the terminal catalyst zone in three subsequent reactors. The segregated catalyst zones also may be separated by one or more reaction zones containing a catalyst composite having a different composition from either of the catalyst composites of the present invention.

The initial catalyst zone may be divided into first and intermediate catalyst zones containing, respectively, first and intermediate catalytic composites having different compositions. The first and intermediate catalyst zones are typically located in different reactors, although it is possible that the catalyst zones could be separate beds in a single reactor. Each of the first and intermediate catalyst zones may be located in two or more reactors with suitable heating means provided between reactors as described hereinabove. Generally, the intermediate catalytic composite will be formulated to mitigate coke formation and catalyst deactivation. It is specifically contemplated, without limiting the present invention, that the intermediate catalytic composite will contain a metal promoter known to those of ordinary skill in the art to inhibit coke formation and deactivation. Such promoters include, for example, rhenium, rhodium, ruthenium, cobalt, nickel and iridium.

The reactants may contact the catalyst in individual reactors in either upflow, downflow, or radial flow fashion, with the radial flow mode being preferred. The catalyst is contained in a fixed-bed system or a moving-bed system with associated continuous catalyst regeneration. The preferred embodiment of the current invention is a fixed-bed system. Alternative approaches to reactivation of the catalyst are well known to those skilled in the art:

The entire unit is operated to maintain activity by gradually increasing temperature to maintain product octane number, finally shutting the unit down for catalyst regeneration and reactivation.

Individual reactors are individually isolated by manifolding arrangements as the contained catalyst becomes deactivated, and the catalyst in the isolated reactor is regenerated and reactivated while the other reactors remain on-stream.

Catalyst is continuously withdrawn from the reactors by means of a slowly moving bed, and the catalyst is regenerated and reactivated before being returned to the reactors. This system permits higher operating severity and maintains high catalyst activity by reactivating each catalyst particle over a period of a few days.

Semiregenerative and continuous reactors are contained in the same unit. Usually this is effected by adding a continuous reactor to an existing semiregenerative process unit to provide for higher severity operation with improved selectivity. The preferred embodiment of the current invention is a "semiregenerative" or "swing-reactor" system; these may be incorporated into a "hybrid" system.

Effluent from the reforming zone is passed through a cooling means to a separation zone, typically maintained at about 0.degree. to 65.degree. C., wherein a hydrogen-rich gas is separated from a liquid stream commonly called "unstabilized reformate". The resultant hydrogen stream can then be recycled through suitable compressing means back to the reforming zone. The liquid phase from the separation zone is typically withdrawn and processed in a fractionating system in order to adjust the butane concentration, thereby controlling front end volatility of the resulting reformate.

The hydrocarbon feed stream that is charged to this reforming system will comprise naphthenes and paraffins that boil within the gasoline range. The preferred charge stocks are naphthas consisting principally of naphthenes and paraffins, although, in many cases, aromatics also will be present. This preferred class includes straight-run gasolines, natural gasolines, synthetic gasolines, and the like. As an alternative embodiment, it is frequently advantageous to charge thermally or catalytically cracked gasolines or partially reformed naphthas. Mixtures of straight-run and cracked gasoline-range naphthas can also be used to advantage. The gasoline-range naphtha charge stock may be a full-boiling gasoline having an initial boiling point of from about 40.degree.-70.degree. C. and an end boiling point within the range of from about 160.degree.-220.degree. C., or may be a 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 100.degree.-200.degree. C. In some cases, it is also advantageous to charge pure hydrocarbons or mixtures of hydrocarbons that have been recovered from extraction units--for example, raffinates from aromatics extraction or straight-chain paraffins-- which are to be converted to aromatics.

It is generally preferred to utilize the present invention in a substantially water-free environment. Essential to the achievement of this condition in the reforming zone is the control of the water level present in the charge stock and the hydrogen stream which is being charged to the zone. Best results are ordinarily obtained when the total amount of water entering the conversion zone from any source is held to a level less than 50 ppm and preferably less than 20 ppm, expressed as weight of equivalent water in the charge stock. In general, this can be accomplished by careful control of the water present in the charge stock and in the hydrogen stream. The charge stock can be dried by using any suitable drying means known to the art such as a conventional solid adsorbent having a high selectivity for water; for instance, sodium or calcium crystalline aluminosilicates, silica gel, activated alumina, molecular sieves, anhydrous calcium sulfate, high surface area sodium, and the like adsorbents. Similarly, the water content of the charge stock may be adjusted by suitable stripping operations in a fractionation column or like device. In some cases, a combination of adsorbent drying and distillation drying may be used advantageously to effect almost complete removal of water from the charge stock. Preferably, the charge stock is dried to a level corresponding to less than 20 ppm of H.sub.2 O equivalent.

It is preferred to maintain the water content of the hydrogen stream entering the hydrocarbon conversion zone at a level of about 10 to about 20 volume ppm or less. In the cases where the water content of the hydrogen stream is above this range, this can be conveniently accomplished by contacting the hydrogen stream with a suitable desiccant such as those mentioned above at conventional drying conditions.

It is a preferred practice to use the present invention in a substantially sulfur-free environment. Any control means known in the art may be used to treat the hydrocarbon feedstock which is to be charged to the reforming reaction zone. For example, the feedstock may be subjected to adsorption processes, catalytic processes, or combinations thereof. Adsorption processes may employ molecular sieves, high surface area silica-aluminas, carbon molecular sieves, crystalline aluminosilicates, activated carbons, high surface area metallic containing compositions, such as, nickel or copper, and the like. It is preferred that these charge stocks be treated by conventional catalytic pretreatment methods such as hydrorefining, hydrotreating, hydrodesulfurization, etc., to remove substantially all sulfurous, nitrogenous and water-yielding contaminants therefrom, and to saturate any olefins that may be contained therein. Catalytic processes may employ traditional sulfur reducing catalyst formulations known to the art including refractory inorganic oxide supports containing metals selected from the group comprising Group VI-B, Group II-B, and Group VIII of the Periodic Table (see Cotton and Wilkinson, Advanced Inorganic Chemistry, (3rd Ed., 1972)).

Operating conditions used for the reforming process of the present invention include a pressure selected within the range of about 100 to 7000 kPa (abs), with the preferred pressure being about 350 kPa to 4250 kPa (abs). Particularly good results are obtained at low pressure, namely a pressure of about 350 to 2500 kPa. Reforming conditions include a temperature in the range from about 315.degree. to about 600.degree. C. and preferably from about 425.degree. to about 565.degree. C. As is well known to those skilled in the reforming art, 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. Ordinarily, the temperature then is thereafter slowly increased during the run to compensate for the inevitable deactivation that occurs to provide a constant octane product.

The reforming conditions in the present invention also typically include sufficient hydrogen to provide an amount of about 1 to about 20 moles of hydrogen per mole of hydrocarbon feed entering the reforming zone, with excellent results being obtained when about 2 to about 10 moles of hydrogen are used per mole of hydrocarbon feed. Likewise, the liquid hourly space velocity (LHSV) used in reforming is selected from the range of about 0.1 to about 10 hr.sup.-1, with a value in the range of about 1 to about 5 hr.sup.-1 being preferred.

The present invention as reviewed relates to a multi-catalyst-zone process for the catalytic reforming of hydrocarbons in which the initial catalytic composite comprises platinum, germanium and halogen on a solid catalyst support and the terminal catalytic composite has the essential absence of germanium and comprises platinum, halogen and a metal promoter on a solid catalyst support. Each of the catalysts required in the process of this invention employs a porous carrier material or support having combined therewith catalytically effective amounts of the required metals and a halogen component.

Considering first the refractory support utilized in the present invention, it is preferred that the material be a porous, adsorptive, high-surface area support having a surface area of about 25 to about 500 m.sup.2 /g. The porous carrier material should also be uniform in composition and relatively refractory to the conditions utilized in the hydrocarbon conversion process. By the term "uniform in composition", it is meant that the support be unlayered, has no concentration gradients of the species inherent to its composition, and is completely homogeneous in composition. Thus, if the support is a mixture of two or more refractory materials, the relative amounts of these materials will be constant and uniform throughout the entire support. It is intended to include within the scope of the present invention carrier materials which have traditionally been utilized in dual-function hydrocarbon conversion catalysts such as: (1) refractory inorganic oxides such as alumina, titanium dioxide, zirconium dioxide, chromium oxide, zinc oxide, magnesia, thoria, boria, silica-alumina, silica-magnesia, chromia-alumina, alumina-boria, silica-zirconia, etc.; (2) ceramics, porcelain, bauxite; (3) silica or silica gel, silicon carbide, clays and silicates including those synthetically prepared and naturally occurring, which may or may not be acid treated, for example attapulgus clay, diatomaceous earth, fuller's earth, kaolin, kieselguhr, etc.; (4) crystalline zeolitic aluminosilicates, such as naturally occurring or synthetically prepared mordenite and/or faujasite, either in the hydrogen form or in a form which has been treated with multivalent cations; and (5) combinations of one or more elements from one or more of these groups.

The preferred refractory inorganic oxide for use in the present invention is alumina. Suitable alumina materials are the crystalline aluminas known as the gamma-, eta-, and theta-alumina, with gamma- or eta-alumina giving best results. The preferred refractory inorganic oxide will have an apparent bulk density of about 0.3 to about 1.01 g/cc and surface area characteristics such that the average pore diameter is about 20 to 300 angstroms, the pore volume is about 0.1 to about 1 cc/g, and the surface area is about 100 to about 500 m.sup.2 /g.

Although alumina is the preferred refractory inorganic oxide, a particularly preferred alumina is that which has been characterized in U.S. Pat. Nos. 3,852,190 and 4,012,313 as a by-product from a Ziegler higher alcohol synthesis reaction as described in Ziegler's U.S. Pat. No. 2,892,858. For purposes of simplification, such an alumina will be hereinafter referred to as a "Ziegler alumina". Ziegler alumina is presently available from the Vista Chemical Company under the trademark "Catapal" or from Condea Chemie GMBH under the trademark "Pural." This material is an extremely high purity pseudoboehmite which, after calcination at a high temperature, has been shown to yield a high purity gamma-alumina. This alumina powder may be formed into a material according to any of the techniques known to those skilled in the catalyst carrier material forming art. Spherical carrier material particles may be formed, for example, from this Ziegler alumina by: (1) converting the alumina powder into an alumina sol by reaction with a suitable peptizing acid and water and thereafter dropping a mixture of the resulting sol and a gelling agent into an oil bath to form spherical particles of an alumina gel which are easily converted to a gamma-alumina carrier material by known methods; (2) forming an extrudate from the powder by established methods and thereafter rolling the extrudate particles on a spinning disk until spherical particles are formed which can then be dried and calcined to form the desired particles of spherical carrier material; and (3) wetting the powder with a suitable peptizing agent and thereafter rolling the particles of the powder into spherical masses of the desired size. This alumina powder can also be formed in any other desired shape or type of carrier material known to those skilled in the art such as rods, pills, pellets, tablets, granules, extrudates, and like forms by methods well known to the practitioners of the catalyst material forming art. The preferred type of carrier material for the present invention is a cylindrical extrudate generally having a diameter of about 0.8 to 3.2 mm (especially 1.6 mm) and a length to diameter ratio of about 1:1 to about 5:1, with 2:1 being especially preferred. The especially preferred extrudate form of the carrier material is preferably prepared by mixing the alumina powder with water and suitable peptizing agents such as nitric acid, acetic acid, aluminum nitrate, and the like material until an extrudable dough is formed. The amount of water added to form the dough is typically sufficient to give a loss on ignition (LOI) at 500.degree. C. of about 45 to 65 mass %, with a value of 55 mass % being especially preferred. On the other hand, the acid addition rate is generally sufficient to provide 2 to 7 mass % of the volatile-free alumina powder used in the mix, with a value of 3 to 4 mass % being especially preferred. The resulting dough is then extruded through a suitably sized die to form extrudate particles. These particles are then dried at a temperature of about 260.degree. to about 427.degree. C. for a period of about 0.1 to 5 hours and thereafter calcined at a temperature of about 480.degree. to 816.degree. C. for a period of 0.5 to 5 hours to form the preferred extrudate particles of the Ziegler alumina refractory inorganic oxide. It is preferred that the refractory inorganic oxide comprise substantially pure Ziegler alumina having an apparent bulk density of about 0.6 to about 1 g/cc and a surface area of about 150 to 280 m.sup.2 /g (preferably 185 to 235 m.sup.2 /g, at a pore volume of 0.3 to 0.8 cc/g).

One essential ingredient of the initial and the terminal catalytic composites is a dispersed platinum component. This platinum component may exist within the final catalytic composite as a compound such as an oxide, sulfide, halide, oxyhalide, etc., in chemical combination with one or more of the other ingredients of the composite or as an elemental metal. Best results are obtained when substantially all of this component is present in the elemental state and it is uniformly dispersed within the carrier material. This component may be present in the final catalyst composite in any amount which is catalytically effective, but relatively small amounts are preferred. In fact, the platinum component generally will comprise about 0.01 to about 2 mass % of the final catalytic composite, calculated on an elemental basis. Excellent results are obtained when the catalyst contains about 0.05 to about 1 mass % of platinum.

This platinum component may be incorporated into the catalytic composite in any suitable manner, such as coprecipitation or cogelation, ion-exchange, or impregnation, in order to effect a uniform dispersion of the platinum component within the carrier material. The preferred method of preparing the catalyst involves the utilization of a soluble, decomposable compound of platinum to impregnate the carrier material. For example, this component may be added to the support by commingling the latter with an aqueous solution of chloroplatinic acid. Other water-soluble compounds of platinum may be employed in impregnation solutions and include ammonium chloroplatinate, bromoplatinic acid, platinum dichloride, platinum tetrachloride hydrate, platinum dichlorocarbonyl dichloride, dinitrodiaminoplatinum, etc. The utilization of a platinum chloride compound, such as chloroplatinic acid, is preferred since it facilitates the incorporation of both the platinum component and at least a minor quantity of the halogen component in a single step. Best results are obtained in the preferred impregnation step if the platinum compound yields complex anions containing platinum in acidic aqueous solutions. Hydrogen chloride or the like acid is also generally added to the impregnation solution in order to further facilitate the incorporation of the halogen component and the distribution of the metallic component. In addition, it is generally preferred to impregnate the carrier material after it has been calcined in order to minimize the risk of washing away the valuable platinum compounds; however, in some cases, it may be advantageous to impregnate the carrier material when it is in a gelled state.

A second essential constituent of the initial catalytic composite is a germanium component. This component may in general be present in the composite in any catalytically available from such as the elemental metal, a compound such as the oxide, hydroxide, halide, oxyhalide, aluminate, or in chemical combination with one or more of the other ingredients of the catalyst. Although it is not intended to restrict the present invention by this explanation, it is believed that best results are obtained when the germanium component is present in the composite in a form wherein substantially all of the germanium moiety is in an oxidation state above that of the elemental metal such as in the form of germanium oxide or germanium oxyhalide or germanium halide or in a mixture thereof and the subsequently described oxidation and reduction steps that are preferably used in the preparation of the instant catalytic composite are specifically designed to achieve this end. The term "germanium oxyhalide" as used herein refers to a coordinated complex of germanium, oxygen, and halogen which are not necessarily present in the same relationship for all cases covered herein. This germanium component can be used in any amount which is catalytically effective, with good results obtained, on an elemental basis, with about 0.05 to about 5 mass % germanium in the catalyst. Best results are ordinarily achieved with about 0.01 to about 1 mass % germanium, calculated on an elemental basis. The preferred atomic ratio of germanium to platinum group metal for this catalyst is about 0.1:1 to about 20:1.

This germanium component is preferably incorporated in the catalytic composite in any suitable manner known to the art to result in a relatively uniform dispersion of the germanium moiety in the carrier material, such as by coprecipitation or cogelation, or coextrusion with the porous carrier material, ion exchange with the gelled carrier material, or impregnation of the porous carrier material either after, before, or during the period when it is dried and calcined. Methods which result in non-uniform germanium distribution are within the scope of the present invention. It is intended to include within the scope of the present invention all conventional methods for incorporating and simultaneously distributing a metallic component in a catalytic composite in a desired manner, and the particular method of incorporation used is not deemed to be an essential feature of the present invention. One method of incorporating the germanium component into the catalytic composite involves cogelling or coprecipitating the germanium component in the form of the corresponding hydrous oxide or oxyhalide during the preparation of the preferred carrier material, alumina. This method typically involves the addition of a suitable sol-soluble or sol-dispersible germanium compound such as germanium tetrachloride, germanium oxide, and the like to the alumina hydrosol and then combining the germanium-containing hydrosol with a suitable gelling agent and dropping the resulting mixture into an oil bath, etc., as explained in detail hereinbefore. Alternatively, the germanium compound can be added to the gelling agent. After drying and calcining the resulting gelled carrier material in air, there is obtained an intimate combination of alumina and germanium oxide and/or oxychloride. One preferred method of incorporating the germanium component into the catalytic composite involves utilization of a soluble, decomposable compound of germanium to impregnate the porous carrier material. In general, the solvent used in this impregnation step is selected on the basis of the capability to dissolve the desired germanium compound and to hold it in solution until it is evenly distributed throughout the carrier material without adversely affecting the carrier material or the other ingredients of the catalyst--for example, a suitable alcohol, ether, acid, and the like solvents. One preferred solvent is an aqueous, acidic solution. Thus, the germanium component may be added to the carrier material by commingling the latter with an aqueous acidic solution of suitable germanium salt, complex, or compound such as germanium oxide, germanium tetrachloride, germanium tetraethoxide, germanium difluoride, germanium tetrafluoride, germanium di-iodide, ethylgermanium oxide, tetraethylgermanium, and the like compounds. A particularly preferred impregnation solution comprises an anhydrous alcoholic solution of germanium tetrachloride, germanium trifluoride chloride, germanium dichloride difluoride, ethyltriphenylgermanium, tetramethylgermanium, and the like compounds. Suitable acids for use in the impregnation solution are: inorganic acids such as hydrochloric acid, nitric acid, and the like, and strongly acidic organic acids such as oxalic acid, malonic acid, citric acid, and the like. In general, the germanium component can be impregnated either prior to, simultaneously with, or after the platinum group component is added to the carrier material. However, excellent results are obtained when the germanium component is impregnated simultaneously with the platinum group component.

In alternative embodiments, the initial catalytic composite or intermediate catalytic composite comprises platinum, rhenium, and germanium. In these alternative embodiments, platinum and germanium components are incorporated into the carrier material as described hereinabove. Prior to incorporation of the rhenium component, the platinum and germanium-containing composite may be oxidized at from about 370.degree. C. to about 600.degree. C. as described hereinafter in more detail. Distilled water preferably is injected into the air stream in the oxidation step to adjust the halogen content of the composite. The halogen-content of the platinum- and germanium-containing composite should be from about 0.1 to about 10 mass % before addition of the rhenium component, with the preferred range being from about 0.1 to about 1.0 mass % halogen.

The rhenium component preferably is incorporated into the catalytic composite utilizing a soluble, decomposable rhenium compound. Rhenium compounds which may be employed include ammonium perrhenate, sodium perrhenate, potassium perrhenate, potassium rhenium oxychloride, potassium hexachlororhenate (IV), rhenium chloride, rhenium heptoxide, and the like compounds. Best results are obtained when an aqueous solution of perrhenic acid is employed in impregnation of the rhenium component.

Rhenium is a preferred metal promoter of the terminal catalytic composite. The terminal catalytic composite has an essential absence of germanium, characterized as less than about 0.05 mass % germanium on an elemental basis. The platinum and rhenium components of the terminal catalytic composite may be composited with the refractory inorganic oxide in any manner which results in a preferably uniform distribution of these components such as coprecipitation, cogelation, coextrusion, ion exchange or impregnation. Alternatively, non-uniform distributions such as surface impregnation are within the scope of the present invention. The preferred method of preparing the catalytic composite involves the utilization of soluble decomposable compounds of platinum and rhenium for impregnation of the refractory inorganic oxide in a relatively uniform manner. For example, the platinum and rhenium components may be added to the refractory inorganic oxide by commingling the latter with an aqueous solution of chloroplatinic acid and thereafter an aqueous solution of perrhenic acid. Other water-soluble compounds or complexes of platinum and rhenium may be employed in the impregnation solutions. Typical platinum compounds include ammonium chloroplatinate, bromoplatinic acid, platinum trichloride, platinum tetrachloride hydrate, platinum dichlorocarbonyl dichloride, dinitrodiaminoplatinum, sodium tetranitroplatinate (II), etc. Decomposable rhenium compounds which may be employed include ammonium perrhenate, sodium perrhenate, potassium perrhenate, potassium rhenium oxychloride, potassium hexachlororhenate (IV), rhenium chloride, rhenium heptoxide, and the like compounds. The utilization of a platinum halogen compound, such as chloroplatinic acid, is preferred since it facilitates the incorporation of both the platinum component and at least a minor quantity of the halogen component in a single step. It is further preferred that an aqueous solution of perrhenic acid be employed in impregnation of the rhenium component.

As heretofore indicated, any procedure may be utilized in compositing the platinum component and rhenium component with the refractory inorganic oxide as long as such method is sufficient to result in relatively uniform distributions of these components. Accordingly, when an impregnation step is employed, the platinum component and rhenium component may be impregnated by use of separate impregnation solutions or, as is preferred, a single impregnation solution comprising decomposable compounds of platinum component and rhenium component. In fact, excellent results are obtained with a one-step impregnation procedure using an aqueous acidic solution containing chloroplatinic acid, perrhenic acid, and hydrochloric acid to impregnate a calcined refractory inorganic oxide comprising alumina. It should be noted that irrespective of whether single or separate impregnation solutions are utilized, hydrogen chloride, nitric acid, or the like acid may be also added to the impregnation solution or solutions in order to further facilitate uniform distribution of the platinum and rhenium components throughout the refractory inorganic oxide. Additionally, it should be indicated that it is generally preferred to impregnate the refractory inorganic oxide after it has been calcined in order to minimize the risk of washing away valuable platinum and rhenium compounds; however, in some cases, it may be advantageous to impregnate refractory inorganic oxide when it is in a gelled, plastic dough or dried state. If two separate impregnations solutions are utilized in order to composite the platinum component and rhenium component with the refractory inorganic oxide, separate oxidation and reduction steps may be employed between application of the separate impregnation solutions. Additionally, halogen adjustment steps may be employed between application of the separate impregnation solutions. Such halogenation steps will facilitate incorporation of the catalytic components and halogen component into the refractory inorganic oxide.

Irrespective of its exact formation, the dispersion of platinum component and rhenium component must be sufficient so that the platinum component comprises, on an elemental basis, from about 0.01 to about 2 mass % of the finished catalytic composite. Additionally, there must be sufficient rhenium component present to comprise, on an elemental basis, from about 0.01 to about 5 mass % of the finished composite.

Indium is an alternative metal promoter of the platinum-rhenium terminal catalytic composite of the present invention. The indium is incorporated into the catalyst composite by a second dispersion of an indium component over the first uniform dispersion of platinum component and rhenium component. It is to be understood that by the phrase "a second dispersion of indium component thereover", it is meant a second application of indium component over the first uniform dispersion of platinum and rhenium component, said second dispersion being formed by contacting the platinum-and rhenium-containing refractory inorganic oxide with indium in a manner which results in a dispersion thereof throughout the refractory inorganic oxide.

At least one oxidation step is required prior to addition of the second dispersion of indium component. The oxidation step acts to assure fixation of the platinum component and rhenium component so that the uniform dispersion thereof is retained, and said oxidation step may be immediately followed by halogen adjustment step. Additionally, a reduction step may be employed either prior to or subsequent to the oxidation step. A reduction step may also follow the halogen adjustment step. Any suitable decomposable indium compound may be utilized to incorporate the indium component into the catalytic composite. Impregnation is a particularly suitable means of contacting the indium with the refractory inorganic oxide. In general, the solvent used in such an impregnation step is selected on the basis of the capability to dissolve the desired indium compound and is preferably an aqueous, acidic solution. Thus, the indium component may be added to the refractory inorganic oxide by commingling the latter with an aqueous, acidic solution of suitable indium salt or suitable compound of indium such as indium tribromide, indium perchlorate, indium trichloride, indium trifluoride, indium nitrate, indium sulfate, and the like compounds. A particularly preferred impregnation solution comprises an acidic solution of indium trichloride in water. Following impregnation of the second dispersion of indium component, the resulting composite may then be subjected to an oxidation step followed by a halogen adjustment step and subsequent reduction step. Irrespective of the exact method of forming the second dispersion, sufficient (rhenium+indium) components should be contained therein to comprise, on an elemental basis, from about 0.01 to about 5 mass % of the finished composite.

An alternative metal promoter of the terminal or intermediate catalytic composite of the present invention is a surface-impregnated metal component selected from the group consisting of rhodium, ruthenium, cobalt, nickel, iridium, and mixtures thereof. It is to be understood that as utilized herein, the term "surface-impregnated" means that at least 80% of the surface-impregnated component is located within the exterior surface of the catalyst particle. The term "exterior surface" is defined as the outermost layer of the catalyst, preferably that which comprises the exterior 50% of the catalyst volume. By "layer" is meant a stratum of substantially uniform thickness.

A metal component is considered surface-impregnated when the average concentration of said metal component within the exterior surface of the catalyst is at least 4 times the average concentration of the same metal component in the remaining interior portion of the catalyst. Alternatively, a metal component is said to be surface-impregnated when the average atomic ratio of the metal component to the uniformly dispersed platinum component is at least 4 times greater in magnitude within the exterior surface of the catalyst than it is within the remaining interior portion. A catalytic composite comprising a surface-impregnated metal component is described in U.S. Pat. No. 4,677,094, which is incorporated by reference into this specification.

As previously stated, the surface-impregnated metal is selected from the group consisting of rhodium, ruthenium, cobalt, nickel, iridium, and mixtures thereof. The surface-impregnated metal component may be present in the composite as an elemental metal or in chemical combination with one or more of the other ingredients of the composite, or as a chemical compound of the metal such as the oxide, oxyhalide, sulfide, halide, and the like. The metal component may be utilized in the composite in any amount which is catalytically effective, with the preferred amount being about 0.01 to about 2 mass % thereof, calculated on an elemental metal basis. Typically, best results are obtained with about 0.05 to about 1 mass % of surface-impregnated metal. Additionally, it is within the scope of the present invention that beneficial results may be obtained by having more than one of the above-named metals surface-impregnated on the catalyst.

The surface-impregnated component may be incorporated into the catalytic composite in any suitable manner which results in the metal component being concentrated in the exterior surface of the catalyst support in the preferred manner. In addition, it may be added at any stage of the preparation of the composite--either during preparation of the carrier material or thereafter--and the precise method of incorporation used is not deemed to be critical so long as the resulting metal component is surface-impregnated as the term is used herein. A preferred way of incorporating this component is an impregnation step wherein the porous carrier material containing uniformly dispersed platinum is impregnated with a suitable metal-containing aqueous solution. It is also preferred that no "additional" acid compounds are to be added to the impregnation solution. In a particularly preferred method of preparation the carrier material containing platinum is subjected to oxidation and halogen stripping procedures, as is explained hereinafter, prior to the impregnation of the surface-impregnated metal components. Aqueous solutions of water soluble, decomposable surface-impregnated metal compounds are preferred, including hexaminerhodium chloride, rhodium carbonylchloride, rhodium trichloride hydrate, ammonium pentachloroaquoruthenate, ruthenium trichloride, nickel chloride, nickel nitrate, cobaltous chloride, cobaltous nitrate, iridium trichloride, iridium tetrachloride and the like compounds.

It is contemplated in the present invention that the terminal catalytic composite may contain other metallic modifiers in addition to or instead of the aforementioned rhenium, indium, rhodium, ruthenium, cobalt, nickel, and iridium. Such modifiers are known to those or ordinary skill in the art and include but are not limited to tin, gallium, and thallium. Catalytically effective amounts of such modifiers may be incorporated into the catalyst composite in any suitable manner known to the art.

As heretofore indicated, it is necessary to employ at least one oxidation step in the preparation of the catalyst. The conditions employed to effect the oxidation step are selected to convert substantially all of the metallic components within the catalytic composite to their corresponding oxide form. The oxidation step typically takes place at a temperature of from about 370.degree. to about 600.degree. C. An oxygen atmosphere is employed typically comprising air. Generally, the oxidation step will be carried out for a period of from about 0.5 to about 10 hours or more, the exact period of time being that required to convert substantially all of the metallic components to their corresponding oxide form. This time will, of course, vary with the oxidation temperature employed and the oxygen content of the atmosphere employed.

In addition to the oxidation step, a halogen adjustment step may also be employed in preparing the catalyst. As heretofore indicated, the halogen adjustment step may serve a dual function. First, the halogen adjustment step aids in formation of the first uniform dispersion of platinum and rhenium component and the second dispersion of indium component. Additionally, since the catalyst of the instant invention comprises a halogen component, the halogen adjustment step can serve as a means of incorporating the desired level of halogen into the final catalytic composite. The halogen adjustment step employs a halogen or halogen-containing compound in air or an oxygen atmosphere. Since the preferred halogen for incorporation into the catalytic composite comprises chlorine, the preferred halogen or halogen-containing compound utilized during the halogen adjustment step is chlorine, HCl, or precursor of these compounds. In carrying out the halogen adjustment step, the catalytic composite is contacted with the halogen or halogen-containing compound in air or an oxygen atmosphere at an elevated temperature of from about 370.degree. to about 600.degree. C. It is further desired to have water present during the contacting step in order to aid in the adjustment. In particular, when the halogen component of the catalyst comprises chlorine, it is preferred to use a mole ratio of water to HCl of about 5:1 to about 100:1. The duration of the halogenation step is typically from about 0.5 to about 5 hours or more. Because of the similarity of conditions, the halogen adjustment step may take place during the oxidation step. Alternatively, the halogen adjustment step may be performed before or after the oxidation step as required by the particular method being employed to prepare the catalyst of the invention. Irrespective of the exact halogen adjustment step employed, the halogen content of the final catalyst should be such that there is sufficient halogen to comprise, on an elemental basis, from about 0.1 to about 10 mass % of the finished composite.

In an alternative embodiment, the halogen content of the initial catalytic composite is lower than that of the terminal catalytic composite. Higher C.sub.5.sup.+ product selectivity has been observed, for example, when the chlorine-component content of catalysts of the present invention were adjusted in this manner. The halogen content of each catalyst may be adjusted in any suitable manner as described hereinabove.

In preparing the catalyst, it is also necessary to employ a reduction step. The reduction step is designed to reduce substantially all of the platinum component and rhenium component to the corresponding elemental metallic states and to ensure a relatively uniform and finely divided despersion of these components throughout the refractory inorganic oxide. It is preferred that the reduction step take place in a substantially water-free environment. Preferably, the reducing gas is substantially pure, dry hydrogen (i.e., less than 20 volume ppm water). However, other reducing gases may be employed such as CO.sub.2, nitrogen, etc. Typically, the reducing gas is contacted with the oxidized catalytic composite at conditions including a reduction temperature of from about 315.degree. to about 650.degree. C. for a period of time of from about 0.5 to 10 or more hours effective to reduce substantially all of the platinum component and any rhenium component to the elemental metallic state. The reduction step may be performed prior to loading the catalytic composite into the hydrocarbon conversion zone or it may be performed in situ as part of a hydrocarbon conversion process start-up procedure. However, if this latter technique is employed, proper precautions must be taken to predry the hydrocarbon conversion plant to a substantially water-free state and a substantially water-free hydrogen-containing reduction gas should be employed.

The terminal catalytic composite may be beneficially subjected to a presulfiding step designed to incorporate sufficient sulfur to comprise, on an elemental basis, from about 0.05 to about 0.5 mass % of the finished composite. The sulfur component may be incorporated into the catalyst by any known technique. For example, the catalytic composite may be subjected to a treatment which takes place in the presence of hydrogen in a suitable sulfur-containing compound such as hydrogen sulfide, lower molecular weight mercaptans, organic sulfides, disulfides, etc. Typically, this procedure comprises treating the reduced catalyst with a sulfiding gas such as a mixture of hydrogen and hydrogen sulfide having about 10 moles of hydrogen per mole of hydrogen sulfide at conditions sufficient to effect the desired incorporation of sulfur, generally including a temperature ranging from about 10.degree. up to about 600.degree. C. or more. It is generally a good practice to perform this sulfiding step under substantially water-free conditions.

The following examples show the advantages of alternative embodiments of the invention, and also provide data for the drawings summarized hereinabove. The examples illustrate the invention without limiting the scope thereof.

Pilot-plant tests were performed to compare results from multi-zone catalysts of the present invention with single-catalyst performance. The initial-zone "Catalyst A" was chlorided platinum-germanium on an extruded alumina support. The terminal-zone "Catalyst B" was a platinum-rhenium catalyst on the same extruded alumina support as Catalyst A. The key parameters of catalyst composition were (mass %):

The same feedstock was used for all comparative tests, and had the following characteristics:

The tests were based on a severity of 98 RON (Research Octane Number) clear C.sub.5.sup.+ product at 1725 kPa (ga) pressure and 2.5 LHSV in all cases. The multi-zone "A/B" was 30% Catalyst A in the initial zone and 70% Catalyst B in the terminal zone. Results were as follows:

The comparative results also are shown in FIG. 1. The multi-zone catalysts demonstrated a selectivity advantage over both single-catalyst operations. FIG. 1 and the data show that the multi-zone catalysts increased this advantage over the catalyst cycle. Activity and stability of the multi-zone catalysts also were more favorable, in terms of lower operating temperature and lower rate of temperature increase required to achieve product octane, than for either single-catalyst operation.

An additional pilot-plant test was performed to investigate whether the multi-zone catalysts of Example I would show an advantage over a mixed loading of the same catalysts. Catalysts A and B of Example I were tested in a 30% A/70% B mixture against the same multi-zone loading of Example I, with 30% Catalyst A in the initial zone and 70% Catalyst B in the terminal zone. The feedstock, severity, and operating conditions were identical to those of Example I.

The results of the test are shown in FIG. 2. The multi-zone loading of the present invention showed a clear advantage over the mixed loading in selectivity, activity, and stability.

The effect of a relatively lower chloride content of the primary catalyst composite was evaluated in pilot-plant tests. Catalyst A" was a platinum-germanium formulation on a spherical alumina support with a chloride content approximately half that of otherwise similar catalysts tested in the pilot plants, such as Catalyst A'. Catalyst B was a platinum-rhenium formulation on extruded alumina support as described hereinabove in Example I. Key composition parameters of the individual catalysts were as follows:

The feedstock was the same as for Example I, and severity varied over a range of about two octane numbers including 98 and 99 RON clear. The multi-zone systems were 20% Catalyst A" or A' in the initial zone and 80% Catalyst B in the terminal zone. Results are summarized for the range of severities in FIG. 3, and were as follows at 98 RON clear, 2030 kPa (ga) pressure and 2.5 LHSV:

The lower-chloride catalyst in the initial catalyst zone demonstrated improved selectivity over catalysts having essentially the same chloride level in both catalyst zones.

Pilot-plant tests were structured to consider the impact of a platinum-rhenium-indium Catalyst C in the terminal zone. The initial-zone Catalyst A' was another formulation of platinum-germanium on an extruded alumina support. The multi-zone catalyst was compared with platinum-rhenium Catalyst B as described hereinabove in Example I. Key composition parameters of the individual catalysts of the test were as follows (mass %):

The feedstock was the same as for Example I, and severity was 98 RON C.sub.5.sup.+ product at 1725 kPa (ga) pressure and 2.5 LHSV. The multi-zone system was 30% Catalyst A'" in the initial zone and 70% Catalyst C in the terminal zone. Results were as follows:

The multi-zone catalyst thus showed a clear advantage over the single catalyst in selectivity, selectivity stability, and activity stability, as well as matching the single catalyst in activity. Thus, considering results over the entire catalyst cycle, the multi-zone catalyst shows an advantage in both selectivity and activity.