Selective Hydrogenation Catalyst and Methods of Making and Using Same (Basf Corporation, Chevron Phillips)

CATEGORY: CATALYSTS
PATENT
Selective Hydrogenation Catalyst and Methods of Making and Using Same (Basf Corporation, Chevron Phillips)
Publication numberUS20140005449 A1
Publication type Application
Application number US 14/020,442
Publication date Jan 2, 2014
Inventors
Tin-Tack Peter Cheung, 5 More »
Original Assignee
Basf Corporation, Chevron Phillips Chemical Company Lp
Abstract
A composition comprising a support formed from a high surface area alumina and having a low angularity particle shape; and at least one catalytically active metal, wherein the support has pores, a total pore volume, and a pore size distribution; wherein the pore size distribution displays at least two peaks of pore diameters, each peak having a maximum; wherein a first peak has a first maximum of pore diameters of equal to or greater than about 200 nm and a second peak has a second maximum of pore diameters of less than about 200 nm; and wherein greater than or equal to about 5% of a total pore volume of the support is contained within the first peak of pore diameters.
BACKGROUND
1. Technical Field
The present disclosure relates to the production of unsaturated hydrocarbons, and more particularly to a selective hydrogenation catalyst and methods of making and using same.
2. Background
Unsaturated hydrocarbons such as ethylene and propylene are often employed as feedstocks in preparing value added chemicals and polymers. Unsaturated hydrocarbons can be produced by pyrolysis or steam cracking of hydrocarbons including hydrocarbons derived from coal, hydrocarbons derived from synthetic crude, naphthas, refinery gases, ethane, propane, butane, and the like. Unsaturated hydrocarbons produced in these manners usually contain small proportions of highly unsaturated hydrocarbons such as acetylenes and diolefins that can adversely affect the production of subsequent chemicals and polymers. Thus, to form an unsaturated hydrocarbon product such as a polymer grade monoolefin, the amount of acetylenes and diolefins in the monoolefin stream is typically reduced. For example, in polymer grade ethylene, the acetylene content typically is less than about 2 ppm.
One technique commonly used to reduce the amount of acetylenes and diolefins in an unsaturated hydrocarbon stream primarily comprising monoolefins involves selectively hydrogenating the acetylenes and diolefins to monoolefins. This process is selective in that hydrogenation of the monoolefin and the highly unsaturated hydrocarbons to saturated hydrocarbons is minimized. For example, the hydrogenation of ethylene or acetylene to ethane is minimized. An ongoing need exists for improved selective hydrogenation catalysts.
SUMMARY
Disclosed herein is a composition comprising a support formed from a high surface area alumina and having a low angularity particle shape; and at least one catalytically active metal, wherein the support has pores, a total pore volume, and a pore size distribution; wherein the pore size distribution displays at least two peaks of pore diameters, each peak having a maximum; wherein a first peak has a first maximum of pore diameters of equal to or greater than about 200 nm and a second peak has a second maximum of pore diameters of less than about 200 nm; and wherein greater than or equal to about 5% of a total pore volume of the support is contained within the first peak of pore diameters.
Also disclosed herein is a method of preparing a hydrogenation catalyst comprising shaping a mixture comprising a high surface area alumina, a pore former, and water to form a shaped support, wherein the shaped support comprises a low angularity particle shape; drying the shaped support to form a dried support; calcining the dried support to from a calcined support; contacting the calcined support with a chlorine-containing compound to form a chlorided support; reducing the amount of chloride in the chlorided support to form a cleaned support; and contacting the cleaned support with a Group 10 metal and a Group 1B metal to form a hydrogenation catalyst, wherein a pore size distribution for the hydrogenation catalyst displays at least two peaks of pore diameters, each peak having a maximum, wherein a first peak has a first maximum of pore diameters that is equal to or greater than about 200 nm and a second peak has a second maximum of pore diameters that is less than about 200 nm.
Also disclosed herein is a low angularity particle shape support formed from a high surface area alumina, wherein a pore size distribution for the low angularity particle shape support displays at least two peaks of pore diameters, each peak having a maximum; wherein a first peak has a first maximum of pore diameters of equal to or greater than about 200 nm and a second peak has a second maximum of pore diameters of less than about 200 nm; wherein greater than or equal to about 15% of a total pore volume of the low angularity particle shape support is contained within the first peak of pore diameters; and wherein the low angularity particle shape support is a sphere or a refined extrudate and has an attrition of from about 0.05% to about 5%.
Also disclosed herein is a method of preparing a hydrogenation catalyst comprising: selecting an inorganic material having a multimodal distribution of pore diameters, wherein at least one distribution of pore diameters comprises pores having a diameter of equal to or greater than about 200 nm; shaping a mixture comprising the inorganic material and water to form a shaped support wherein the shaped support has a low angularity particle shape and an attrition of from about 0.05% to about 5%; drying the shaped support to form a dried support; calcining the dried support to from a calcined support; and contacting the calcined support with a Group VIII metal and a Group 1B metal to form a hydrogenation catalyst.
Also disclosed herein is a method comprising preparing a plurality of low angularity particle shaped supports consisting essentially of α-alumina formed from a high surface area alumina, wherein the low angularity shaped supports have an attrition of from about 0.05% to about 5%; plotting the pore diameter as a function of a log of differential mercury intrusion for the low angularity particle shaped supports; and identifying the low angularity particle shaped supports having at least two peaks, each peak having a maximum, wherein a first peak comprises pores with a first pore diameter maximum equal to or greater than about 200 nm, and wherein the first peak of pore diameters represents greater than or equal to about 5% of a total pore volume of the low angularity particle shaped supports.
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