WO2007030298A1 - Catalytically inactive heat generator and improved dehydrogenation process - Google Patents

Catalytically inactive heat generator and improved dehydrogenation process Download PDF

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Publication number
WO2007030298A1
WO2007030298A1 PCT/US2006/032441 US2006032441W WO2007030298A1 WO 2007030298 A1 WO2007030298 A1 WO 2007030298A1 US 2006032441 W US2006032441 W US 2006032441W WO 2007030298 A1 WO2007030298 A1 WO 2007030298A1
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Prior art keywords
secondary component
alumina
catalyst
heat
dehydrogenation
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PCT/US2006/032441
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French (fr)
Inventor
Vladimir Fridman
Jay S. Merriam
Michael A. Urbancic
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Sud-Chemie Inc.
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Priority to PL06801910T priority Critical patent/PL1933978T3/en
Priority to CN2006800319966A priority patent/CN101252989B/en
Priority to EP06801910.8A priority patent/EP1933978B1/en
Publication of WO2007030298A1 publication Critical patent/WO2007030298A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/32—Manganese, technetium or rhenium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/24—Chromium, molybdenum or tungsten
    • B01J23/26—Chromium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/72—Copper
    • B01J35/19—
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
    • C07C5/321—Catalytic processes
    • C07C5/322—Catalytic processes with metal oxides or metal sulfides
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/02—Boron or aluminium; Oxides or hydroxides thereof
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/02—Boron or aluminium; Oxides or hydroxides thereof
    • C07C2521/04—Alumina
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • C07C2521/08—Silica
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/10—Magnesium; Oxides or hydroxides thereof
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
    • C07C2521/12—Silica and alumina
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the alkali- or alkaline earth metals or beryllium
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the alkali- or alkaline earth metals or beryllium
    • C07C2523/04—Alkali metals
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/06—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of zinc, cadmium or mercury
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • C07C2523/24—Chromium, molybdenum or tungsten
    • C07C2523/26—Chromium
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • C07C2523/32—Manganese, technetium or rhenium
    • C07C2523/34—Manganese
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
    • C07C2523/72—Copper
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
    • C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
    • C07C2523/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36
    • C07C2523/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • C07C2523/889—Manganese, technetium or rhenium
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2529/00—Catalysts comprising molecular sieves
    • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/584—Recycling of catalysts

Definitions

  • the present development relates to an improved dehydrogenation catalyst bed system for olefin production utilizing classical processing techniques.
  • the catalyst system comprises a chromia/alumina dehydrogenation catalyst that further includes physically mixing the catalyst with at least one other component that is catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but that generates heat after being exposed to reducing and/or to oxidizing reaction conditions.
  • Dehydrogenation of aliphatic hydrocarbons to produce their complementary olefins is a well-known process.
  • an aliphatic hydrocarbon such as propane
  • a dehydrogenation catalyst bed where the hydrocarbon is dehydrogenated to its complementary olefin, such as propylene
  • the olefin is flushed from the bed
  • the catalyst is regenerated and reduced, and the cycle is repeated.
  • the CATOFIN® dehydrogenation process is an adiabatic, cyclic process. Each cycle includes a catalyst reduction step, a dehydrogenation step, a step to purge the remaining hydrocarbon from the reactor, and finally a regeneration step with air. Following this, the cycle begins again with the reduction step.
  • the dehydrogenation reaction is highly endothermic. Therefore, during the dehydrogenation step the temperature at the top of the catalyst bed decreases by as much as 100 0 C. This decrease in temperature causes a decrease in paraffin conversion.
  • the reactor In order to reheat the catalyst bed and remove coke that has deposited on the catalyst during the dehydrogenation step, the reactor is purged of hydrocarbon and then undergoes a regeneration step with air heated to temperatures of up to 700 0 C. Heat is provided to the bed by the hot air that passes through the bed and also by the combustion of the coke deposits on the catalyst. Reduction of the catalyst, with a reducing gas such as hydrogen, prior to dehydrogenation step, also provides some additional heat.
  • the hot air flows from the top of the catalyst bed to the bottom, and the regeneration cycle is relatively short, so there is a tendency for the top of the bed to be hotter than the bottom of the bed.
  • the lower temperature in the bottom of the bed does not allow full utilization of the catalyst and thus the yield is lower that what would be otherwise expected.
  • the coke distribution in the catalyst bed which is not easily controlled, affects the amount of heat added at each location and the resulting catalyst bed temperature profile. These factors make control of the temperature profile in the bed difficult.
  • the reactor contains a physical mixture of a chromia/alumina catalyst and an "inert".
  • the volume ratio between the "inert” material and the catalyst depends on a number of factors including the type of hydrocarbon feed being used in the dehydrogenation process. For example, for a propane feed the "inert" material equal to about 50% of the total catalyst volume, whereas for an isobutane feed the volume of the "inert" can be as low as about 30% of the total catalyst bed volume.
  • the “inert” is typically a granular, alpha-alumina material of similar particle size to the catalyst that is catalytically inactive with respect to dehydrogenation or side reactions such as cracking or coking, but that has a high density and high heat capacity, so it can be used to store additional heat in the bed. The additional heat is then used during the dehydrogenation step.
  • the "inert” is not capable of producing heat during any stage of the process.
  • the present development is a dehydrogenation catalyst bed system comprising a conventional chromia/alumina dehydrogenation catalyst that further includes at least one component that is catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but that generates heat after being exposed to reducing and/or to oxidizing reaction conditions.
  • the heat-generating inert component has a similar density and heat capacity to alpha-alumina.
  • the catalyst system comprises a chromia/alumina catalyst physically mixed with a heat- generating inert component comprising copper oxide supported on alumina wherein the copper oxide comprises at least about 8 wt% of the heat-generating inert component.
  • the catalyst bed system of the present invention is intended for use in aliphatic hydrocarbon dehydrogenation reaction processes, and similar adiabatic non-oxidative dehydrogenation processes, specifically for the production of olefins.
  • the catalyst bed system utilized in the process is a chromia/alumina dehydrogenation catalyst that further comprises a heat-generating component that is inert with respect to the dehydrogenation reaction or side reactions such as cracking or coking.
  • the equipment used for the dehydrogenation process includes a reactor bed wherein the bed defines a top section and a bottom section.
  • a catalyst is physically mixed with an inert, such as granular alpha- alumina, and the catalyst plus inert is then loaded into the reactor bed.
  • An aliphatic hydrocarbon is fed into the catalyst bed as a gas feed at a preselected flow rate and such that the feed initially contacts the top section of the bed and exits after contact with the bottom section.
  • the aliphatic hydrocarbon is propane and the target product is propylene.
  • the process generally follows the typical "Houdry" process as described in U.S. Patent 2,419,997.
  • the Houdry process includes a series of stages wherein the catalyst bed is evacuated, reduced with hydrogen and evacuated, then an aliphatic hydrocarbon is introduced and dehydrogenated, then the catalyst bed is steam purged and regenerated, and the cycle is repeated starting with the reduction stage.
  • a catalyst generally has one or more active components dispersed on or compounded with a carrier or support. The support provides a means for increasing the surface area of the catalyst.
  • Patent 3,488,402 (issued to Michaels et al., and incorporated herein by reference) .
  • the M02 catalyst comprises "alumina, magnesia, or a combination thereof, promoted with up to about 40% of an oxide of a metal" of Group 4, Group 5 or Group 6.
  • Group 4", “Group 5" and “Group 6” refer to the new IUPAC format numbers for the Periodic Table of the Elements.
  • the active dehydrogenation catalyst is then physically mixed with a first inert material.
  • This first inert material may be any material that is catalytically inactive with respect to dehydrogenation or side reactions, such as cracking or coking, and that has a high density and high heat capacity, but that is not capable of producing heat during any stage of the process.
  • an exemplary first inert material is a granular, alpha-alumina material of similar particle size to the catalyst.
  • the volume ratio between the first inert material and the catalyst depends on a number of factors including the type of hydrocarbon feed being used in the dehydrogenation process. In the present application, no particular volume ratio is prescribed, but rather the user may adjust the ratio as appropriate for the intended use.
  • the catalyst and the first inert material is then further physically combined with at least one secondary component.
  • the secondary component must be catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but must generate heat after being exposed to reducing and/or to oxidizing reaction conditions.
  • the secondary component comprises a heat-generating inert material and a carrier capable of supporting the heat-generating inert material.
  • exemplary carriers for the secondary component include, but are not limited to, aluminum oxide, aluminas, alumina monohydrate, boehmite, pseudo-boehmite, alumina trihydrate, gibbsite, bayerite, alumina-silica, transition aluminas, alpha- alumina, silica, silicate, aluminates, calcined hydrotalcites, zeolites, zinc oxide, chromium oxides, magnesium oxides and combinations thereof.
  • the heat-generating inert material may be selected from copper, chromium, molybdenum, vanadium, cerium, yttrium, scandium, tungsten, manganese, iron, cobalt, nickel, silver, bismuth and combinations thereof.
  • the heat-generating inert material comprises from 1 wt% to 40 wt% of the total secondary component weight. In a more preferred embodiment, the heat generating inert material comprises from 4 wt% to 20 wt% of the total secondary component weight; and in a most preferred embodiment, the amount of heat-generating inert material is from 6 wt% to 10 wt% of the total secondary component weight.
  • the secondary component may further comprise a promoter, such as an alkali, an alkaline earth metal, lithium, sodium, potassium, rubidium, cesium, beryllium, magnesium, calcium, strontium, barium and a combination thereof.
  • the secondary component is prepared by essentially the same methods known in the art for preparing a supported catalyst.
  • the secondary component may be prepared by precipitation of the secondary component carrier with the heat-generating inert material, or by impregnation of the secondary component carrier with the heat-generating inert material. Promoters may further be added with the heat-generating inert material, or may be otherwise added to the secondary component via methods known in the art for the addition of promoters.
  • a representative preparation is alumina trihydrate (gibbsite) is pelletized as approximately 3/16" pellets, and then the gibbsite is calcined at 55O 0 C for 4 hours, and the calcined material is then impregnated with a saturated solution of copper nitrate, and the impregnated material is dried for 4 hours at 250 0 C and is then calcined at from 500 0 C to 1400°C.
  • alumina trihydrate gibbsite
  • the catalyst bed system is then prepared by physically mixing or combining the catalyst, the first inert material and the secondary component. More specifically, the desired amount of catalyst is defined, and then is mixed with a predetermined amount of the first inert material and a predetermined amount of the secondary component.
  • the amount of first inert material is essentially equal to the amount of inert material that would normally be combined with the catalyst less the amount of secondary component to be added. That is, the secondary component is added in such a manner as to be a complete or partial substitution for the first inert material.
  • the secondary component does not affect the amount of catalyst added nor the relative ratio of catalyst to inert material in the resultant catalyst bed.
  • the volume of catalyst used equals 25% to 75% of the volume of the first inert material plus secondary component or
  • volume of the secondary component to be used should be equal to 20 to 100% of the volume of the first inert material plus secondary component or
  • the mixture is then loaded into the reactor in the same manner as traditional dehydrogenation catalysts are loaded.
  • the catalyst bed is evacuated and reduced with hydrogen.
  • the secondary component in the reactor bed generates additional heat that passes into the alumina-supported chromium oxide catalyst portion of the reactor bed.
  • an aliphatic hydrocarbon is fed into the catalyst bed and is dehydrogenated upon contact with the alumina-supported chromium oxide catalyst portion of the reactor bed.
  • the alumina-supported chromium oxide catalyst portion of the bed has been essentially pre-heated by the secondary component, the alumina-supported chromium oxide catalyst demonstrates improved conversion relative to a reactor bed that does not include the secondary component.
  • the catalyst bed is steam purged and regenerated, and the cycle is repeated starting with the reduction stage.
  • the secondary component may also generate additional heat.
  • the secondary component is selected such that no significant negative effect on selectivity is observed.
  • the catalyst bed system of the present invention is intended for use in an adiabatic non-oxidative cyclic dehydrogenation process.
  • the catalyst bed system differs from the catalyst bed systems of the prior art by requiring that the catalyst comprise a heat-generating component that is inert with respect to the dehydrogenation reaction or side reactions such as cracking or coking. It is understood that the composition of the catalyst and the specific processing conditions may be varied without exceeding the scope of this development.

Abstract

An improved dehydrogenation catalyst bed system for olein production utilizing classical processing techniques is disclosed. The catalyst bed system comprises a dehydrogenation catalyst comprising an active component selected from an oxide of a metal of Group 4 or Group 5 or Group 6 and combinations thereof and a support selected from aluminum oxide, aluminas, alumina monohydrate, alumina trihydrate, alumina-silica, transition aluminas, alpha- alumina, silica, silicate, aluminates, calcined hydrotalcites, zeolites and combinations thereof mixed with a first inert material selected from any material that is catalytically inactive when subjected to reaction conditions that can effect dehydrogenation of olefins and that has a high density and high heat capacity and that is not capable of producing heat during any stage of the dehydrogenation process, and the dehydrogenation catalyst plus the first inert material then being physically mixed with a secondary component comprising a heat-generating inert material and a carrier capable of supporting the heat-generating inert material, wherein the secondary component is catalytically inert with respect to dehydrogenation reactions or to cracking or to coking and generates heat after being exposed to reducing and/or to oxidizing reaction conditions.

Description

Title
CATALYTICALLY INACTIVE HEAT GENERATOR AND IMPROVED DEHYDROGENATION PROCESS
Background
The present development relates to an improved dehydrogenation catalyst bed system for olefin production utilizing classical processing techniques. Specifically, the catalyst system comprises a chromia/alumina dehydrogenation catalyst that further includes physically mixing the catalyst with at least one other component that is catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but that generates heat after being exposed to reducing and/or to oxidizing reaction conditions.
Dehydrogenation of aliphatic hydrocarbons to produce their complementary olefins is a well-known process. In the typical Houdry CATOFIN® process, an aliphatic hydrocarbon, such as propane, is passed through a dehydrogenation catalyst bed where the hydrocarbon is dehydrogenated to its complementary olefin, such as propylene, the olefin is flushed from the bed, the catalyst is regenerated and reduced, and the cycle is repeated. (See, for example, U.S. Patent 2,419,997 and incorporated herein by reference.) The CATOFIN® dehydrogenation process is an adiabatic, cyclic process. Each cycle includes a catalyst reduction step, a dehydrogenation step, a step to purge the remaining hydrocarbon from the reactor, and finally a regeneration step with air. Following this, the cycle begins again with the reduction step.
The dehydrogenation reaction is highly endothermic. Therefore, during the dehydrogenation step the temperature at the top of the catalyst bed decreases by as much as 1000C. This decrease in temperature causes a decrease in paraffin conversion.
In order to reheat the catalyst bed and remove coke that has deposited on the catalyst during the dehydrogenation step, the reactor is purged of hydrocarbon and then undergoes a regeneration step with air heated to temperatures of up to 7000C. Heat is provided to the bed by the hot air that passes through the bed and also by the combustion of the coke deposits on the catalyst. Reduction of the catalyst, with a reducing gas such as hydrogen, prior to dehydrogenation step, also provides some additional heat.
During regeneration, the hot air flows from the top of the catalyst bed to the bottom, and the regeneration cycle is relatively short, so there is a tendency for the top of the bed to be hotter than the bottom of the bed. The lower temperature in the bottom of the bed does not allow full utilization of the catalyst and thus the yield is lower that what would be otherwise expected. Also, the coke distribution in the catalyst bed, which is not easily controlled, affects the amount of heat added at each location and the resulting catalyst bed temperature profile. These factors make control of the temperature profile in the bed difficult.
In the conventional HOUDRY CATOFIN® process, the reactor contains a physical mixture of a chromia/alumina catalyst and an "inert". The volume ratio between the "inert" material and the catalyst depends on a number of factors including the type of hydrocarbon feed being used in the dehydrogenation process. For example, for a propane feed the "inert" material equal to about 50% of the total catalyst volume, whereas for an isobutane feed the volume of the "inert" can be as low as about 30% of the total catalyst bed volume.
The "inert" is typically a granular, alpha-alumina material of similar particle size to the catalyst that is catalytically inactive with respect to dehydrogenation or side reactions such as cracking or coking, but that has a high density and high heat capacity, so it can be used to store additional heat in the bed. The additional heat is then used during the dehydrogenation step. However, the "inert" is not capable of producing heat during any stage of the process.
Since dehydrogenation is a highly endothermic reaction, a constant challenge related to the Houdry process, and similar adiabatic non-oxidative dehydrogenation processes, has been to identify a commercially feasible means for improving the heat addition to the unit without using a catalytically active material that produces large quantities of unwanted side products. Thus, it would be advantageous to identify a catalyst additive that has a heat capacity and density comparable to the currently used alumina "inert", and that does not participate to any great extent in the dehydrogenation reaction or side reactions such as cracking or coking, and that can be physically mixed with the catalyst before loading, but that generates heat as needed during the operation. Summary of the Invention
The present development is a dehydrogenation catalyst bed system comprising a conventional chromia/alumina dehydrogenation catalyst that further includes at least one component that is catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but that generates heat after being exposed to reducing and/or to oxidizing reaction conditions. In an exemplary embodiment, the heat-generating inert component has a similar density and heat capacity to alpha-alumina. In a further exemplary embodiment, the catalyst system comprises a chromia/alumina catalyst physically mixed with a heat- generating inert component comprising copper oxide supported on alumina wherein the copper oxide comprises at least about 8 wt% of the heat-generating inert component.
Detailed Description of the Preferred Embodiment The catalyst bed system of the present invention is intended for use in aliphatic hydrocarbon dehydrogenation reaction processes, and similar adiabatic non-oxidative dehydrogenation processes, specifically for the production of olefins. The catalyst bed system utilized in the process is a chromia/alumina dehydrogenation catalyst that further comprises a heat-generating component that is inert with respect to the dehydrogenation reaction or side reactions such as cracking or coking.
The equipment used for the dehydrogenation process includes a reactor bed wherein the bed defines a top section and a bottom section. In commercial practice, a catalyst is physically mixed with an inert, such as granular alpha- alumina, and the catalyst plus inert is then loaded into the reactor bed. An aliphatic hydrocarbon is fed into the catalyst bed as a gas feed at a preselected flow rate and such that the feed initially contacts the top section of the bed and exits after contact with the bottom section. For the purposes of example herein, the aliphatic hydrocarbon is propane and the target product is propylene.
For exemplary purposes only, the process generally follows the typical "Houdry" process as described in U.S. Patent 2,419,997. The Houdry process includes a series of stages wherein the catalyst bed is evacuated, reduced with hydrogen and evacuated, then an aliphatic hydrocarbon is introduced and dehydrogenated, then the catalyst bed is steam purged and regenerated, and the cycle is repeated starting with the reduction stage. As is known in the art, a catalyst generally has one or more active components dispersed on or compounded with a carrier or support. The support provides a means for increasing the surface area of the catalyst. Several compositions for dehydrogenation catalysts have been taught in the prior art, such as the catalyst taught in U.S. Patent 3,488,402 (issued to Michaels et al., and incorporated herein by reference) . The M02 catalyst comprises "alumina, magnesia, or a combination thereof, promoted with up to about 40% of an oxide of a metal" of Group 4, Group 5 or Group 6. (The terms "Group 4", "Group 5" and "Group 6" refer to the new IUPAC format numbers for the Periodic Table of the Elements. Alternative terminology, known in the art, includes the old IUPAC labels "Group IV A," "Group VA" and "Group VI-A", respectively, and the Chemical Abstract Services version of numbering as "Group IVB, " "Group VB" and "Group VI-B", respectively.) Recommended carriers for dehydrogenation catalysts include aluminum oxide, aluminas, alumina monohydrate, alumina trihydrate, alumina-silica, transition aluminas, alpha-alumina, silica, silicate, aluminates, calcined hydrotalcites, zeolites and combinations thereof. For the present application, the catalyst may be prepared by any standard method known in the art, such as taught in U.S. Patent Application 20040092391, incorporated herein in its entirety by reference.
The active dehydrogenation catalyst is then physically mixed with a first inert material. This first inert material may be any material that is catalytically inactive with respect to dehydrogenation or side reactions, such as cracking or coking, and that has a high density and high heat capacity, but that is not capable of producing heat during any stage of the process. For the present application, an exemplary first inert material is a granular, alpha-alumina material of similar particle size to the catalyst. As is known in the art, the volume ratio between the first inert material and the catalyst depends on a number of factors including the type of hydrocarbon feed being used in the dehydrogenation process. In the present application, no particular volume ratio is prescribed, but rather the user may adjust the ratio as appropriate for the intended use.
In the present invention, the catalyst and the first inert material is then further physically combined with at least one secondary component. The secondary component must be catalytically inert with respect to dehydrogenation or side reactions such as cracking or coking but must generate heat after being exposed to reducing and/or to oxidizing reaction conditions.
More specifically, the secondary component comprises a heat-generating inert material and a carrier capable of supporting the heat-generating inert material. Exemplary carriers for the secondary component include, but are not limited to, aluminum oxide, aluminas, alumina monohydrate, boehmite, pseudo-boehmite, alumina trihydrate, gibbsite, bayerite, alumina-silica, transition aluminas, alpha- alumina, silica, silicate, aluminates, calcined hydrotalcites, zeolites, zinc oxide, chromium oxides, magnesium oxides and combinations thereof.
The heat-generating inert material may be selected from copper, chromium, molybdenum, vanadium, cerium, yttrium, scandium, tungsten, manganese, iron, cobalt, nickel, silver, bismuth and combinations thereof. The heat-generating inert material comprises from 1 wt% to 40 wt% of the total secondary component weight. In a more preferred embodiment, the heat generating inert material comprises from 4 wt% to 20 wt% of the total secondary component weight; and in a most preferred embodiment, the amount of heat-generating inert material is from 6 wt% to 10 wt% of the total secondary component weight. Optionally, the secondary component may further comprise a promoter, such as an alkali, an alkaline earth metal, lithium, sodium, potassium, rubidium, cesium, beryllium, magnesium, calcium, strontium, barium and a combination thereof.
The secondary component is prepared by essentially the same methods known in the art for preparing a supported catalyst. For example, and without limitation, the secondary component may be prepared by precipitation of the secondary component carrier with the heat-generating inert material, or by impregnation of the secondary component carrier with the heat-generating inert material. Promoters may further be added with the heat-generating inert material, or may be otherwise added to the secondary component via methods known in the art for the addition of promoters. A representative preparation, without limitation, is alumina trihydrate (gibbsite) is pelletized as approximately 3/16" pellets, and then the gibbsite is calcined at 55O0C for 4 hours, and the calcined material is then impregnated with a saturated solution of copper nitrate, and the impregnated material is dried for 4 hours at 2500C and is then calcined at from 5000C to 1400°C.
The catalyst bed system is then prepared by physically mixing or combining the catalyst, the first inert material and the secondary component. More specifically, the desired amount of catalyst is defined, and then is mixed with a predetermined amount of the first inert material and a predetermined amount of the secondary component. The amount of first inert material is essentially equal to the amount of inert material that would normally be combined with the catalyst less the amount of secondary component to be added. That is, the secondary component is added in such a manner as to be a complete or partial substitution for the first inert material. The secondary component does not affect the amount of catalyst added nor the relative ratio of catalyst to inert material in the resultant catalyst bed. In an exemplary embodiment, without limitation, the volume of catalyst used equals 25% to 75% of the volume of the first inert material plus secondary component or
(vol. catalyst) / (vol. first inert material + vol. secondary component) = 0.25 to 0.75. The volume of the secondary component to be used should be equal to 20 to 100% of the volume of the first inert material plus secondary component or
(vol. secondary component) / (vol . first inert material + vol. secondary component) = 0.20 to
1.0.
The mixture is then loaded into the reactor in the same manner as traditional dehydrogenation catalysts are loaded.
In an improved Houdry process, the catalyst bed is evacuated and reduced with hydrogen. During this stage, the secondary component in the reactor bed generates additional heat that passes into the alumina-supported chromium oxide catalyst portion of the reactor bed. Then an aliphatic hydrocarbon is fed into the catalyst bed and is dehydrogenated upon contact with the alumina-supported chromium oxide catalyst portion of the reactor bed. Because the alumina-supported chromium oxide catalyst portion of the bed has been essentially pre-heated by the secondary component, the alumina-supported chromium oxide catalyst demonstrates improved conversion relative to a reactor bed that does not include the secondary component. The catalyst bed is steam purged and regenerated, and the cycle is repeated starting with the reduction stage. During the regeneration step, the secondary component may also generate additional heat. In a preferred embodiment, the secondary component is selected such that no significant negative effect on selectivity is observed.
The catalyst bed system of the present invention is intended for use in an adiabatic non-oxidative cyclic dehydrogenation process. The catalyst bed system differs from the catalyst bed systems of the prior art by requiring that the catalyst comprise a heat-generating component that is inert with respect to the dehydrogenation reaction or side reactions such as cracking or coking. It is understood that the composition of the catalyst and the specific processing conditions may be varied without exceeding the scope of this development.

Claims

What is claimed is :
1. In a catalyst bed system for use in adiabatic non- oxidative dehydrogenation processes comprising an oxide of chromium on alumina dehydrogenation catalyst mixed with a granular, alpha-alumina material having a similar particle size to said catalyst, the improvement comprising physically mixing said dehydrogenation catalyst plus said alpha-alumina material with a secondary component comprising a heat- generating inert material selected from the group consisting of copper, manganese and combinations thereof, and a carrier, wherein said secondary component is catalytically inert with respect to dehydrogenation reactions or to cracking or to coking and generates heat after being exposed to reducing and/or to oxidizing reaction conditions.
2. The catalyst bed system of Claim 1 wherein said secondary component carrier is selected from aluminum oxide, aluminas, alumina monohydrate, boehmite, pseudo-boehmite, alumina trihydrate, gibbsite, bayerite, alumina-silica, transition aluminas, alpha-alumina, silica, silicates, aluminates, calcined hydrotalcites, zeolites, zinc oxide, chromium oxides, magnesium oxides and combinations thereof.
3. The catalyst bed system of Claims 1 or 2 wherein said heat-generating inert material comprises from 1 wt% to 40 wt% of the total secondary component weight, preferably from 4 wt% to 20 wt%, and most preferably from 6 wt% to 10 wt% of the total secondary component weight.
4. The catalyst bed system of any of Claims 1-3 wherein said secondary component further comprises a promoter selected from an alkali, an alkaline earth metal, lithium, sodium, potassium, rubidium, cesium, beryllium, magnesium, calcium, strontium, barium and combinations thereof.
5. The catalyst bed system of any of Claims 1-4 wherein said catalyst, said alpha-alumina material and said secondary component have a volume relationship defined by the equation:
(vol. catalyst) / (vol . alpha-alumina material + vol. secondary component) = 0.25 to 0.75 and wherein said alpha-alumina material and said secondary component have a volume relationship defined by the equation: (vol. secondary component) / (vol. alpha-alumina material + vol. secondary component) = 0.20 to
1.0.
6. A catalyst bed system for use in adiabatic non- oxidative dehydrogenation processes comprising a dehydrogenation catalyst comprising an active component selected from an oxide of a metal of Group 4, Group 5, Group 6 and combinations thereof and a support selected from aluminum oxide, aluminas, alumina monohydrate, alumina trihydrate, alumina-silica, transition aluminas, alpha- alumina, silica, silicates, aluminates, calcined hydrotalcites, zeolites and combinations thereof mixed with a first inert material selected from any material that is catalytically inactive when subjected to reaction conditions that can effect dehydrogenation of olefins and that has a high density and high heat capacity and that is not capable of producing heat during any stage of the dehydrogenation process, the improvement comprising physically mixing said dehydrogenation catalyst plus said first inert material with a secondary component comprising a heat-generating inert material and a carrier capable of supporting the heat- generating inert material, wherein said secondary component is catalytically inert with respect to dehydrogenation reactions or to cracking or to coking and generates heat after being exposed to reducing and/or to oxidizing reaction conditions.
7. The catalyst bed system of Claim β wherein said heat-generating inert material is selected from copper, chromium, molybdenum, vanadium, cerium, yttrium, scandium, tungsten, manganese, iron, cobalt, nickel, silver, bismuth and combinations thereof.
8. The catalyst bed system of Claims 6 or 7 wherein said heat-generating inert material comprises from 1 wt% to 40 wt% of the total secondary component weight.
9. The catalyst bed system of any of Claims 6-8 wherein said catalyst, said first inert material and said secondary component have a volume relationship defined by the equation:
(vol. catalyst) / (vol. first inert material + vol. secondary component) = 0.25 to 0.75 and wherein said first inert material and said secondary component have a volume relationship defined by the equation: (vol. secondary component) / (vol. first inert material + vol. secondary component) = 0.20 to
1.0.
10. The catalyst bed system of any of Claims 1-9 wherein said secondary component is prepared by precipitation of said secondary component carrier with said heat-generating inert material or by impregnation of the secondary component carrier with the heat-generating inert material .
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