Exxon Research and Engineering Company

James L Carter

Allan E Barnett

John H Sinfelt

Shun Chong Fung

Walter Weissman

Walter S Kmak

Gary Brice McVicker

Lawrence L Murrell

John Joseph Ziemiak

John C Roarty

Theodorus M Wortel

Ramdas Venkatram

A zeolite-based catalyst containing a metal oxide or oxide complex is dried by heating while in contact with the gas. Heat input to the catalyst and hence the rate of catalyst temperature increase are controlled so as to limit the rate of water evolution from the catalyst and the water vapor concentration in the gas, thereby to maintain the metal oxide or complex in dispersed form within the pores of the zeolite.

Catalyst drying and activation methods

A process for removing metal contaminants from a hydroconversion catalyst, said catalyst containing at least one metal from Groups VIB, VIIB or VIII supported on a refractory inorganic oxide. The process comprises contacting the contaminated catalyst with a buffered oxalic acid solution wherein contaminant is removed without dissolving the support.

Removal of metal comtaminants from catalysts using buffered oxalic acid

A process is disclosed for reactivating an agglomerated iridium and selenium containing catalyst and particularly platinum-iridium-selenium on alumina reforming catalysts. The process includes contacting a substantially decoked agglomerated catalyst with a reducing gas such as hydrogen to reduce agglomerated iridium oxides present to the free metal, a hydrogen halide pretreatment step to increase the halogen level of the catalyst to about 1.3 weight percent and above, and a redispersion step involving hydrogen halide and elemental oxygen. Use of hydrogen halide and elemental oxygen in the redispersion treatment eliminates the need for use of elemental chlorine gas. If no iridium oxides are initially present, the hydrogen reduction step is optional.

Reactivating iridium and selenium containing catalysts with hydrogen

A process is described for reactivating agglomerated iridium-containing catalysts such as Pt-Ir on Al.sub.2 O.sub.3 reforming catalyst. The agglomerated catalyst is decoked to remove carbon deposits; treated with hydrogen to reduce metal oxides to the free metals; pretreated with hydrogen halide to provide at least about a 1.3 weight percent halide content; and treated with a low mass flow rate of chlorine of about one gram chlorine per 100 grams catalyst per hour. Use of a low mass halogen flow rate significantly retards ferrous metal corrosion and significantly reduces the quantity of chlorine normally used in achieving high redispersion values.

Reactivation process for iridium-containing catalysts using low halogen

A process is disclosed for reactivating an agglomerated iridium-containing catalyst and particularly platinum-iridium on alumina reforming catalysts. The process includes contacting a substantially decoked agglomerated catalyst with a reducing gas such as hydrogen to reduce agglomerated iridium oxides present to the free metal, a hydrogen halide pretreatment step to increase the halogen level of the catalyst to about 1.3 weight percent and above, and a redispersion step involving hydrogen halide and elemental oxygen. Use of hydrogen halide and elemental oxygen in the redispersion treatment eliminates the need for use of elemental chlorine gas. If no iridium oxides are initially present, the hydrogen reduction step is optional.

Reactivating iridium-containing catalysts with hydrogen halide and oxygen

Supported coprecipitated cobalt-silica hydrogenation catalysts are disclosed. The catalysts are prepared by: preparing an aqueous reaction mixture containing cobalt cations, silicate anions and solid porous carrier particles under agitation to form a coprecipitate of the cobalt and silicate ions onto said solid porous support particles; heating the aqueous reaction mixture; and adding an alkaline precipitating agent to further precipitate the cobalt and silicate ions onto said solid porous carrier particles. The aqueous reaction mixture may additionally include copper cations.

Support cobalt-silica coprecipitated hydrogenation catalyst

Process for hydrogenating organic compounds with a supported

Supported coprecipitated nickel-cobalt-silica and nickel-cobalt-copper-silica hydrogenation catalysts are disclosed. The catalysts are prepared by preparing an aqueous reaction mixture containing nickel and cobalt cations (and optionally copper cations), silicate anions and solid porous carrier particles under agitation to form a coprecipitate of the nickel, cobalt (and optionally copper) and silicate ions onto said solid porous support particles; heating the aqueous reaction mixture; and adding an alkaline precipitating agent to further precipitate the nickel, cobalt (and optionally copper) and silicate anions onto said solid porous carrier particles.

Hydrogenation process using supported nickel-cobalt-silica

Supported nickel-cobalt-silica coprecipitated hydrogenation catalyst

A copper promoted massive nickel catalyst is disclosed which is capable of having a reduced nickel surface area ranging from about 55 to about 100 m.sup.2 /g as determined by hydrogen chemisorption, after reduction at 400.degree. C., and a B.E.T. total surface area ranging from about 150 to about 300 m.sup.2 /g, wherein the amount of copper in the catalyst ranges from about 2 wt. % to about 10 wt. and the amount of nickel ranges from about 25 wt. % to about 50 wt. %, said wt. % of copper and nickle metal are based on the total weight of the catalyst. The copper promoted massive catalysts are prepared by the steps comprising comingling a solution containing copper and nickel cations with another solution containing silicate anions and coprecipitating the copper, nickel and silicate ions in an aqueous solution onto solid carrier particles. The catalysts are useful in hydrogenation processes.

Coprecipitated copper-nickel-silica catalysts, preparation and use

A copper promoted massive nickel catalyst is disclosed which is capable of having a reduced nickel surface area ranging from about 55 to about 100 m.sup.2 /g as determined by hydrogen chemisorption, after reduction at 400.degree. C., and a B.E.T. total surface area ranging from about 150 to about 300 m.sup.2 /g, wherein the amount of copper in the catalyst ranges from about 2 wt. % to about 10 wt. % and the amount of nickel ranges from about 25 wt. % to about 50 wt. %, said wt. % of copper and nickel metal are based on the total weight of the catalyst. The copper promoted massive catalysts are prepared by the steps comprising comingling a solution containing copper and nickel cations with another solution containing silicate anions and coprecipitating the copper, nickel and silicate ions in an aqueous solution onto solid carrier particles. The catalysts are useful in hydrogenation processes.

Process for hydrogenating organic compounds with coprecipitated

A startup method for a catalytic reforming process wherein the catalyst is maintained in a bed is provided in which a catalyst comprising an iridium component and at least one additional metal component such as a platinum group metal component is reduced, sulfided and contacted with hydrogen at specified conditions whereby the sulfur is distributed uniformly throughout the catalyst bed prior to contacting the catalyst with the hydrocarbon feed.

Startup method for a reforming process

This invention pertains to a method of stabilizing, with respect to atmospheric air, a bed containing pyrophoric reduced metal catalyst with high active metal surface area formed by reduction of a compound of said metal at an elevated temperature ranging from 200.degree. to 500.degree. C. which comprises:

Method for preparing reduced metal catalyst having metal surface area

The instant invention pertains to a process for activating a reducing catalyst comprising the steps: (a) reducing said catalyst by heating the catalyst in the presence of hydrogen at a temperature sufficient to partially active catalyst; (b) contacting said partially active catalyst in the presence of hydrogen with a reactant feed which undergoes an exothermic reaction in the presence of said partially activated catalyst at conditions whereby said reaction occurs, said conditions including a temperature at least greater than the temperature at which the catalyst is partially activated; and (c) continuing said contacting for a time sufficient to convert said partially activated catalyst to a high activity catalyst. The catalyst is preferably a massive nickel catalyst comprised of nickel and silica, and more preferably comprised of nickel, copper and silica, and capable of having a reduced nickel surface area ranging from 55 to 100 m.sup.2 /g and a B.E.T. total surface area ranging from 150 to 300 m.sup.2 /g.

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Westfield, NJ, United States of America

James L Carter