CATALYST COMPOSITIONS AND PROCESSES FOR MAKING AND USING SAME - Patent application

Abstract

Catalyst compositions and processes for making and using same. The catalyst composition may comprise 0.001 wt% to 6 wt% of a Group 8-10 element disposed on a support, based on the weight of the support. The support may comprise Al and at least 0.5 wt% of a Group 2 element, based on the weight of the support. The catalyst composition may contain no Si or <0.5 wt% Si, based on the weight of the support.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 322,450, having a filing date of March 22, 2022, and U.S. Provisional Application No. 63 / 322,998, having a filing date of March 23, 2022, the disclosures of both of which are incorporated herein by reference in their entireties.

[0002] Field The present disclosure relates to catalyst compositions and processes for making and using same. [Background technology]

[0003] background Catalytic reforming or dehydrogenation, dehydroaromatization, and / or dehydrocyclization of alkanes and / or alkylaromatic hydrocarbons are endothermic, equilibrium-limited, industrially important chemical conversion processes. Alkanes, e.g., C1-C 12 The reforming or dehydrogenation, dehydroaromatization, and / or dehydrocyclization of alkanes and / or alkylaromatics, such as ethylbenzene, can be carried out over a variety of different catalyst compositions, such as Pt-based, Ni-based, Pd-based, Ru-based, Re-based, Cr-based, Ga-based, V-based, Zr-based, In-based, W-based, Mo-based, Zn-based, and Fe-based systems. Among the existing propane dehydrogenation processes, one process uses an alumina-supported chromia catalyst and provides one of the highest propylene yields of about 50% (55% propane conversion at 90% propylene selectivity), which is obtained at temperatures of about 560° C.-650° C. and low pressures of 20 kPa absolute to 50 kPa absolute. It would be desirable to increase the propylene yield and improve the efficiency of the dehydrogenation process without having to operate at such low pressures. Thus, there is a need for improved catalyst compositions and processes for making and using same. The present disclosure meets this and other needs. Summary of the Invention

[0004] summary Catalyst compositions and processes for making and using the same are provided. In some embodiments, the catalyst composition may include 0.001 wt% to 6 wt% of a Group 8-10 element disposed on a support, based on the weight of the support. The support may include Al and at least 0.5 wt% of a Group 2 element, based on the weight of the support. The catalyst composition may contain no Si or may contain <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.05 wt%, or <0.01 wt% Si, based on the weight of the support.

[0005] In some embodiments, a process for making the catalyst composition may include the steps of (I) preparing a slurry or gel that may include Al or a compound thereof, a Group 2 element or a compound thereof, and a liquid medium, (II) spray drying the slurry or gel to produce spray-dried particles that include Al or a compound thereof and a Group 2 element or a compound thereof, and (III) calcining the spray-dried particles under an oxidizing atmosphere to produce calcined support particles that may include Al or a compound thereof and a Group 2 element or a compound thereof. The process may include the following: (i) the Group 8-10 element may be present in the slurry or gel in the form of a Group 8-10 element-containing compound, and the catalyst composition may include catalyst particles that include calcined support particles having the Group 8-10 element disposed thereon; (ii) the Group 8-10 element may be deposited on the spray-dried particles by contacting the spray-dried particles with a Group 8-10 element-containing compound to produce Group 8-10 element-containing spray-dried particles, and the catalyst composition may include catalyst particles having the Group 8-10 element disposed thereon. and (iii) a Group 8-10 element can be deposited on the calcined support particles by contacting the calcined support particles with a Group 8-10 element-containing compound to produce the Group 8-10 element-containing calcined support particles, and the process may also include at least one of (IV) calcining the Group 8-10 element-containing calcined support particles to produce re-calcined support particles having the Group 8-10 element disposed thereon, and the catalyst composition comprises the re-calcined support particles. The catalyst particles may include a Group 8-10 element in an amount between 0.001 wt% and 6 wt%, at least 0.5 wt% of a Group 2 element, and the catalyst composition may contain no Si or <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.05 wt%, or <0.01 wt% Si, where all weight percentage values ​​are based on the weight of the calcined or recalcined support particles.

[0006] In some embodiments, a process for upgrading a hydrocarbon-containing feed may include the step of (I) contacting the hydrocarbon-containing feed with a catalyst composition that may include a Group 8-10 element disposed on a support to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the hydrocarbon-containing feed to produce a coked catalyst composition and an effluent that includes one or more upgraded hydrocarbons and molecular hydrogen. The hydrocarbon-containing feed may include one or more C2-C 16 Linear or branched alkanes, or one or more C4-C 16 Cyclic alkanes or one or more C8-C 16 The hydrocarbon-containing feed and the catalyst composition may include any C2-C4 alkyl aromatics, alkyl aromatics, or mixtures thereof. The hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature in the range of 300° C. to 900° C. for a time period of ≦3 hours under a hydrocarbon partial pressure of at least 20 kPa absolute. The hydrocarbon partial pressure is at least 20 kPa absolute, and may be ... 16 Alkanes and any C8-C 16 is the total partial pressure of alkyl aromatics. The support may include Al and at least 0.5 wt% of a Group 2 element based on the weight of the support. The catalyst composition may include a Group 8-10 element in an amount of 0.001 wt% to 6 wt% based on the weight of the support. The catalyst composition may contain no Si or may contain <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.05 wt%, or <0.01 wt% Si based on the weight of the support. The one or more upgraded hydrocarbons may include at least one of dehydrogenated hydrocarbons, dehydroaromatized hydrocarbons, and dehydrocyclized hydrocarbons. [Brief description of the drawings]

[0007] [Figure 1] 1 shows the C3H6 yield and selectivity of a catalyst composition containing Al in the support and no Si (catalyst 1) that maintained its performance over multiple cycles. [Diagram 2]1 shows the C3H6 yield and selectivity of a catalyst composition containing Al and Si in the support (catalyst 2), which deactivated rapidly with increasing number of cycles. [Diagram 3] 1 shows the C3H6 yield and selectivity of a catalyst composition containing Si in the support and lacking Al (Catalyst 3), which maintained its performance over multiple cycles. [Figure 4] Average CH yield plotted against cycle number for a catalyst composition containing Al and no Si in the support (catalyst 4) and a catalyst composition containing Al and 0.45 wt% Si (catalyst 5), with catalyst 5 deactivating with increasing cycle number while catalyst 4 did not. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Detailed Description Below, various specific embodiments, versions and examples of the present invention are described, including preferred embodiments and definitions adopted herein for the purpose of understanding the claimed invention. The detailed description below provides certain preferred embodiments, but those skilled in the art will recognize that these embodiments are merely exemplary and that the present invention can be practiced in other ways. For purposes of determining infringement, the scope of the present invention refers to any one or more of the appended claims, including their equivalents and elements or limitations that are equivalent to those recited. Any reference to the "invention" may refer to one or more, but not necessarily all, of the invention defined by the claims.

[0009] In this disclosure, a process is described as including at least one "step." Each step should be understood to be an act or operation that may be performed once or multiple times in the process in a continuous or discontinuous manner. Unless otherwise specified or the context clearly indicates otherwise, the steps of the process may be performed consecutively in the order as described, with or without overlap with one or more other steps, or, in some cases, in any other order. Furthermore, one or more or even all steps may be performed simultaneously on the same or different batches of material. For example, in a continuous process, a first step of the process may be performed on raw material just fed at the beginning of the process, while a second step may be performed simultaneously on intermediate material resulting from processing of raw material fed to the process at an earlier point in the first step. Preferably, the steps are performed in the order described.

[0010] Unless otherwise indicated, all numbers indicating quantities in this disclosure should be understood to be modified in all cases by the term "about". It should also be understood that the exact numerical values ​​used in the specification and claims constitute specific embodiments. Efforts have been made to ensure the accuracy of the data in the examples. However, it should be understood that any measured data inherently contains a certain level of error due to the limitations of the techniques and / or instruments utilized to make the measurements. Certain embodiments and features are described herein with a series of upper numerical limits and a series of lower numerical limits, and it should be understood that unless otherwise indicated, ranges including any combination of two values ​​are contemplated, for example, any combination of a lower limit with any upper limit, any combination of two lower limits, and / or any combination of two upper limits. As used herein, the indefinite articles "a" or "an" mean "at least one" unless there is a contrary stipulation or the context clearly indicates otherwise. Thus, embodiments using "a reactor" or "a conversion zone" include embodiments using one, two, or three or more reactors or conversion zones unless there is a contrary stipulation or the context clearly indicates that only one reactor or conversion zone is used.

[0011] The term "hydrocarbon" means (i) any compound consisting of hydrogen atoms and carbon atoms or (ii) any mixture of two or more such compounds of (i). The term "Cn hydrocarbon" (where n is a positive integer) means (i) any hydrocarbon compound containing a total of n carbon atoms in its molecule or (ii) any mixture of two or more such hydrocarbon compounds of (i). Thus, C2 hydrocarbons can be ethane, ethylene, acetylene, or any mixture of at least two of these compounds in any ratio. "Cm~Cn hydrocarbon" or "Cm-Cn hydrocarbon" (where m and n are positive integers and m < n) means any one of Cm, Cm+1, Cm+2,..., Cn-1, Cn hydrocarbons, or any mixture of two or more of these. Thus, "C2~C3 hydrocarbon" or "C2-C3 hydrocarbon" can be any one of ethane, ethylene, acetylene, propane, propene, propyne, propadiene, cyclopropane, and any mixture of two or more of these components in any ratio. "Saturated C2-C3 hydrocarbon" can be ethane, propane, cyclopropane, or any mixture of two or more of these in any ratio. "Cn+ hydrocarbon" means (i) any hydrocarbon compound containing at least n carbon atoms in total in its molecule or (ii) any mixture of two or more such hydrocarbon compounds of (i). "Cn- hydrocarbon" means (i) any hydrocarbon compound containing a maximum of n carbon atoms in total in its molecule or (ii) any mixture of two or more such hydrocarbon compounds of (i). "Cm hydrocarbon stream" means a hydrocarbon stream consisting essentially of Cm hydrocarbons. "Cm-Cn hydrocarbon stream" means a hydrocarbon stream consisting essentially of Cm-Cn hydrocarbons.

[0012] For purposes of this disclosure, the nomenclature of the elements is based on Hawley's Condensed Chemical Dictionary, 16 th The version of the Periodic Table of Elements (under the new notation) provided in Ed., John Wiley & Sons, Inc., (2016), Appendix V is based on the new notation. For example, Group 2 elements include Mg, Group 8 elements include Fe, Group 9 elements include Co, Group 10 elements include Ni, and Group 13 elements include Al. As used herein, the term "metalloid" refers to the following elements: B, Si, Ge, As, Sb, Te, and At. In this disclosure, when a given element is indicated as being present, it may be present in the elemental state or as any compound thereof, unless otherwise stated or the context clearly indicates otherwise.

[0013] The term "alkane" means a saturated hydrocarbon. The term "cyclic alkane" means a saturated hydrocarbon that contains a cyclic carbon ring in its molecular structure. Alkanes can be straight-chained, branched, or cyclic. The term "aromatic" is to be understood in accordance with its art-recognized scope and includes alkyl substituted and unsubstituted mononuclear and polynuclear compounds. When used in expressions such as "X-rich" or "rich in X" with respect to an exit stream obtained from an apparatus, e.g., a conversion zone, the term "rich" means that the material X is present at a higher concentration than in the feed material supplied to the same apparatus from which the stream is withdrawn. When used in expressions such as "X-lean" or "lean in X" with respect to an exit stream obtained from an apparatus, e.g., a conversion zone, the term "lean" means that the material X is present at a lower concentration than in the feed material supplied to the same apparatus from which the stream is withdrawn.

[0014] The term "mixed metal oxide" refers to a composition that contains oxygen atoms and at least two different metal atoms that are mixed on an atomic scale. For example, a "mixed Mg / Al metal oxide" has O, Mg, and Al atoms mixed on an atomic scale and is the same or identical to a composition obtained by calcining Mg / Al hydrotalcite having substantially the following general chemical formula: [ka] where A is the counter anion of the negative charge n, x is in the range >0 to <1, and m is ≧0. A material consisting of nm-sized MgO particles and nm-sized Al2O3 particles mixed together is not a mixed metal oxide because the Mg and Al atoms are not mixed on the atomic scale, but on the nm scale.

[0015] The term "selectivity" refers to the production rate (in terms of moles of carbon) of a particular compound in a catalytic reaction. For example, the phrase "alkane hydrocarbon conversion reaction has 100% selectivity to olefinic hydrocarbons" means that 100% (in terms of moles of carbon) of the alkane hydrocarbons converted in the reaction are converted to olefinic hydrocarbons. When used in relation to a particular reactant, the term "conversion" refers to the amount of reactant consumed in the reaction. For example, when the particular reactant is propane, a conversion of 100% means that 100% of the propane is consumed in the reaction. In another example, when the particular reactant is propane, if 1 mole of propane is converted to 1 mole of methane and 1 mole of ethylene, the selectivity to methane is 33.3% and the selectivity to ethylene is 66.7%. The yield (in terms of moles of carbon) is the conversion x selectivity. In this disclosure, "A, B, ... or combinations thereof" means "A, B, ... or any combination of any two or more of A, B, ...", and "A, B, ... or mixtures thereof" means "A, B, ... or any mixture of any two or more of A, B, ...".

[0016] catalyst composition The catalyst composition may be selected from the group consisting of 0.001 wt%, 0.002 wt%, 0.003 wt%, 0.004 wt%, 0.005 wt%, 0.006 wt%, 0.007 wt%, 0.008 wt%, 0.009 wt%, 0.01 wt%, 0.015 wt%, 0.02 wt%, 0.025 wt%, 0.03 wt%, 0.035 wt%, 0.04 wt%, 0.045 wt%, 0.05 wt%, 0.055 wt%, based on the weight of the support. , 0.06 wt%, 0.065 wt%, 0.07 wt%, 0.08 wt%, 0.085 wt%, 0.09 wt%, 0.095 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, or 1 wt% to 2 wt%, 3 wt%, 4 wt%, 5 wt%, or 6 wt% of a Group 8-10 element disposed on the support. In some embodiments, the catalyst composition has a mass of < 5.5 wt%, < 4.5 wt%, < 3.5 wt%, < 2.5 wt%, < 1.5 wt%, < 1 wt%, < 0.9 wt%, < 0.8 wt%, < 0.7 wt%, < 0.6 wt%, < 0.5 wt%, < 0.4 wt%, < 0.3 wt%, < 0.2 wt%, < 0.15 wt%, < 0.1 wt%, < 0.09 wt%, < 0.08 wt%, based on the mass of the support. %, ≦0.07wt%, ≦0.06wt%, ≦0.05wt%, ≦0.04wt%, ≦0.03wt%, ≦0.02wt%, ≦0.01wt%, ≦0.009wt%, ≦0.008wt%, ≦0.007wt%, ≦0.006wt%, ≦0.005wt%, ≦0.004wt%, ≦0.003wt%, or ≦0.002wt% of a Group 8-10 element disposed on the support.

[0017] In some embodiments, the Group 8-10 element can be or include, but is not limited to, Fe, Co, Ni, Ru, Pd, Os, Ir, Pt, combinations or mixtures thereof, and in at least one embodiment, the Group 8-10 element can be or include Pt. When two or more Group 8-10 elements are disposed on the support, the catalyst composition may be present in an amount of 0.001 wt%, 0.002 wt%, 0.003 wt%, 0.004 wt%, 0.005 wt%, 0.006 wt%, 0.007 wt%, 0.008 wt%, 0.009 wt%, 0.01 wt%, 0.015 wt%, 0.02 wt%, 0.025 wt%, 0.03 wt%, 0.035 wt%, 0.04 wt%, 0.045 wt%, 0.05 wt%, 0.06 wt%, 0.08 wt%, 0.09 wt%, 0.01 wt%, 0.015 wt%, 0.02 wt%, 0.025 wt%, 0.03 wt%, 0.035 wt%, 0.04 wt%, 0.045 wt%, 0.0 ...8 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt%, 0.08 wt %, 0.055 wt%, 0.06 wt%, 0.065 wt%, 0.07 wt%, 0.08 wt%, 0.085 wt%, 0.09 wt%, 0.095 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, or 1 wt% to 2 wt%, 3 wt%, 4 wt%, 5 wt%, or 6 wt% of two or more Group 8-10 elements disposed on a support. In some embodiments, the active component of the catalyst composition capable of effecting one or more of reforming or dehydrogenation, dehydroaromatization, and dehydrocyclization of a hydrocarbon-containing feed may be or include a Group 8-10 element(s) disposed on a support.

[0018] The support may be or include, but is not limited to, one or more group 2 elements and aluminum (Al). The group 2 elements may be or include Be, Mg, Ca, Sr, Ba, or combinations or mixtures thereof. In some embodiments, the group 2 elements and / or Al may be present in their elemental form. In other embodiments, the group 2 elements and / or Al may be present in the form of a compound. For example, the group 2 elements and / or Al may be present as an oxide, phosphate, halide, halate, sulfate, sulfide, borate, nitride, carbide, aluminate, carbonate, metaphosphate, selenide, tungstate, molybdate, chromate, chromate, or dichromate. In some embodiments, the mixture of any two or more compounds containing group 2 elements and / or Al may be present in different forms.

[0019] Surprisingly and unexpectedly, it has been discovered that when the support contains a Group 2 element and Al, the presence of silicon (Si) is detrimental to the life of the catalyst composition. More specifically, a catalyst composition containing a Group 2 element, Al, and ≧0.5 wt% Si based on the mass of the support will deactivate rapidly as the number of cycles increases. Each cycle includes at least the steps of contacting a hydrocarbon-containing feed with the catalyst composition to produce a coked catalyst composition and an effluent that may include one or more upgraded hydrocarbons and molecular hydrogen, and contacting the catalyst composition with an oxidant to cause combustion of at least a portion of the coke to produce a regenerated catalyst composition with less coke and combustion gas. A second cycle begins when an additional amount of the hydrocarbon-containing feed is contacted with the regenerated catalyst composition. In some embodiments, the catalyst composition may be free of any Si. In other embodiments, the catalyst composition comprises <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.09 wt%, <0.08 wt%, <0.07 wt%, <0.06 wt%, It may contain <0.05wt%, <0.04wt%, <0.03wt%, 0.02wt%, <0.01wt%, <0.007wt%, <0.005wt%, <0.003wt%, <0.001wt%, <0.0007wt%, <0.0005wt%, <0.0003wt%, or <0.0001wt% Si.

[0020] In some embodiments, the group 2 element and Al may be in the form of a mixed group 2 element / Al metal oxide with O, Mg, and Al atoms mixed on an atomic scale. In some embodiments, the support may be or include one or more oxides of group 2 element and Al in the form of oxides or group 2 element and Al2O3 that may be mixed on a nm scale. In some embodiments, the support may be or include oxides of group 2 elements mixed on a nm scale, such as MgO and Al2O3. In some embodiments, the support may be or include a first amount of Group 2 element and Al in the form of a mixed Group 2 element / Al metal oxide and a second amount of Group 2 element in the form of an oxide of the Group 2 element, in which the mixed Group 2 element / Al metal oxide and the oxide of the Group 2 element may be mixed on the nm scale, and the Group 2 element and Al in the mixed Group 2 element / Al metal oxide may be mixed on an atomic scale. In other embodiments, the support may be or include a first amount of Group 2 element and a first amount of Al in the form of a mixed Group 2 element / Al metal oxide, a second amount of Group 2 element in the form of an oxide of the Group 2 element, and a second amount of Al in the form of Al2O3, in which the mixed Group 2 element / Al metal oxide, the oxide of the Group 2 element, and Al2O3 may be mixed on the nm scale, and the Group 2 element and Al in the mixed Group 2 element / Al metal oxide may be mixed on an atomic scale.

[0021] In some embodiments, the carrier may be or include, but is not limited to, one or more of the following compounds: Mg w AlO 3+w (w is a positive number), Ca x AlO 3+x (x is a positive number), Sr y AlO 3+y (y is a positive number), Ba z AlO 3+z (z is a positive number), BeO, MgO, CaO, BaO, SrO, BeCO3, MgCO3, CaCO3, SrCO3, BaCO3, CaZrO3, Ca7ZrAl6O 18 , CaTiO3, Ca7Al6O 18 , Ca7HfAl6O 18 , BaCeO3, one or more magnesium chromates, one or more magnesium tungstates, one or more magnesium molybdates, combinations thereof, and / or mixtures thereof. In some embodiments, Mg w AlO 3+w(w is a positive number), when present as a support or as a component of a support, may have a molar ratio of Mg to Al ranging from 0.5, 1, 2, 3, 4, or 5 to 6, 7, 8, 9, or 10. In some embodiments, Mg w AlO 3+w may include MgAl2O4, Mg2Al2O5, or a mixture thereof. x AlO 3+x (x is a positive number), when present as a support or as a component of a support, may have a molar ratio of Ca to Al in the range of 1:12, 1:4, 1:2, 2:3, 5:6, 1:1, 12:14, or 1.5:1. x AlO 3+x may include tricalcium aluminate, dodecalcium heptaaluminate, monocalcium aluminate, monocalcium dialuminate, monocalcium hexaaluminate, dicalcium aluminate, pentacalcium trialuminate, tetracalcium trialuminate, or any mixture thereof. y AlO 3+y (y is a positive number), when present as a support or as a component of a support, may have a molar ratio of Sr to Al ranging from 0.05, 0.3, or 0.6 to 0.9, 1.5, or 3. z AlO 3+z (z is a positive number) may have a molar ratio of Ba to Al from 0.05, 0.3, or 0.6 to 0.9, 1.5, or 3 when present as a support or as a component of a support.

[0022] In some embodiments, the mass ratio of Group 2 element to Al in the support can range from 0.001, 0.005, 0.01, 0.05, 0.1, 0.15, 0.2, 0.3, 0.5, 0.7, or 1 to 3, 6, 12.5, 25, 50, 75, 100, 200, 300, 400, 500, 600, 700, 800, 900, or 1,000. In some embodiments, the support may be ≧0.5 wt%, ≧1 wt%, ≧2 wt%, ≧2.1 wt%, ≧2.5 wt%, ≧3 wt%, ≧3.5 wt%, ≧4 wt%, ≧4.5 wt%, ≧5 wt%, ≧5.5 wt%, ≧6 wt%, ≧6.5 wt%, ≧7 wt%, ≧8 wt%, ≧9 wt%, ≧10 wt%, ≧11 wt%, ≧12 wt%, ≧13 wt%, ≧14 wt%, ≧15 wt%, ≧16 wt%, ≧17 wt% based on the weight of the support. , ≧18wt%, ≧19wt%, ≧20wt%, ≧21wt%, ≧22wt%, ≧23wt%, ≧24wt%, ≧25wt%, ≧26wt%, ≧27wt%, ≧28wt%, ≧29wt%, ≧30wt%, ≧35wt%, ≧40wt%, ≧45wt%, ≧50wt%, ≧55wt%, ≧60wt%, ≧65wt%, ≧70wt%, ≧75wt%, ≧80wt%, ≧85wt%, or ≧90wt% of a Group 2 element. In some embodiments, the carrier may be 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.1 wt%, 2.3 wt%, 2.5 wt%, 2.7 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt%, 11 wt%, 13 wt%, 15 wt%, 1 ... The Group 2 element may range from 7 wt%, 19 wt%, 21 wt%, 23 wt%, or 25 wt% to 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, or 92.34 wt%. In some embodiments, the support may include Al in the range of 0.5 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.1 wt%, 2.3 wt%, 2.5 wt%, 2.7 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, 10 wt%, or 11 wt% to 15 wt%, 20 wt%, 25 wt%, 30 wt%, 40 wt%, 45 wt%, or 50 wt%, based on the weight of the support.

[0023] In some embodiments, the molar ratio of the Group 2 element to one or more Group 8-10 elements, such as Pt, disposed on the support is 0.24, 0.5, 1, 10, 50, 100, 300, 450, 600, 800, 1,000, 1,200, 1,500, 1,700, or 2,000 to 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, 8,000, 8,500, 9,000, 9,500, 10 The amount of a molecule may range from 10,000, 15,000, 20,000, 25,000, 30,000, 35,000, 40,000, 45,000, 50,000, 55,000, 60,000, 65,000, 70,000, 75,000, 80,000, 85,000, 90,000, 95,000, 100,000, 200,000, 300,000, 400,000, 500,000, 600,000, 700,000, 800,000, or 900,000.

[0024] In some embodiments, the catalyst composition may optionally include a promoter disposed on the support in an amount of up to 10 wt% based on the weight of the support. In some embodiments, the catalyst composition may include 0.01 wt%, 0.1 wt%, 0.2 wt%, 0.25 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, or 1 wt% to 2 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, or 10 wt% of a promoter disposed on the support based on the weight of the support. The promoter may be or include, but is not limited to, Sn, Cu, Au, Ag, Ga, Zn, Ge, In, Re, Ag, combinations thereof, or mixtures thereof. In some embodiments, the promoter may be associated with a Group 8-10 element. For example, a promoter and a Group 8-10 element, e.g., Pt, disposed on a support may form a Group 8-10 element-promoter cluster, which may be dispersed on the support. The promoter may improve the selectivity / activity / life of the catalyst composition for a given upgraded hydrocarbon. In some embodiments, the promoter may improve the propylene selectivity of the catalyst composition when the hydrocarbon-containing feed includes propane.

[0025] In some embodiments, the catalyst composition may optionally include one or more alkali metal elements disposed on the support in an amount of up to 5 wt% based on the weight of the support. In some embodiments, the catalyst composition may include 0.01 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, or 1 wt% to 2 wt%, 3 wt%, 4 wt%, or 5 wt% of the alkali metal elements disposed on the support based on the weight of the support. The alkali metal elements, if present, may be or include, but are not limited to, Li, Na, K, Rb, Cs, or combinations or mixtures thereof. In at least some embodiments, the alkali metal elements may be or include K and / or Cs. In some embodiments, the alkali metal elements, if present, may improve the selectivity of the catalyst composition for a given upgraded hydrocarbon.

[0026] In some embodiments, the support may also include, but is not limited to, at least one metal element and / or at least one metalloid element selected from a group other than Groups 2 and 8-10, and / or at least one compound thereof, where the at least one metal element and / or at least one metalloid element is not one of the alkali metal elements or one of the promoter elements. When the support also includes a compound including a metal element and / or at least one metalloid element selected from a group other than Groups 2 and 8-10 (where the at least one metal element and / or at least one metalloid element is not one of the alkali metal elements or one of the promoter elements), the compound may be present in the support as an oxide, phosphate, halide, halate, sulfate, sulfide, borate, nitride, carbide, aluminate, carbonate, metaphosphate, selenide, tungstate, molybdate, chromate, chromate, or dichromate. In some embodiments, the at least one metal element and / or at least one metalloid element selected from a group other than Groups 2 and 8-10 (wherein the at least one metal element and / or at least one metalloid element is not one of the alkali metal elements or one of the promoter elements) can be or include, without limitation, one or more rare earth elements, i.e., elements having an atomic number of 21, 39, or 57-71.

[0027] When the support comprises at least one metal element and / or at least one metalloid element selected from a group other than Groups 2 and 8-10 and / or at least one compound thereof (wherein the at least one metal element and / or at least one metalloid element is not one of the alkali metal elements or one of the promoter elements), the at least one metal element and / or at least one metalloid element may function as a binder in some embodiments and may be referred to as a "binder". For clarity and ease of explanation, the at least one metal element and / or at least one metalloid element selected from a group other than Groups 2 and 8-10 and / or at least one compound thereof (wherein the at least one metal element and / or at least one metalloid element is not one of the alkali metal elements or one of the promoter elements) will be described herein as a "binder". In some embodiments, the support may comprise from 0.01 wt%, 0.05 wt%, 0.1 wt%, 0.5 wt%, 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, or 40 wt% to 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% of a binder based on the weight of the support.

[0028] In some embodiments, suitable compounds that can be used as binders include, but are not limited to, the following: B2O3, AlBO3, Al2O3, ZrO2, TiO2, zinc aluminate, ZnO, VO, V2O3, VO2, V2O5, Ga s O t , In u O v, Mn2O3, Mn3O4, MnO, one or more molybdenum oxides, one or more tungsten oxides, one or more zeolites (s, t, u, and v are positive numbers), and mixtures and combinations thereof. When the Group 2 element is in the form of a mixed metal oxide, such as a mixed Mg / Al metal oxide, the additional metal(s) in the mixed metal oxide are not considered to be part of the binder. For example, the support may include a mixed Mg / Al metal oxide, such as that obtained by calcining Mg / Al hydrotalcite, and the Al would not be considered part of the binder, but the support may also include Al2O3 mixed at the nm scale with the mixed Mg / Al metal oxide, and the Al2O3 would be considered the binder.

[0029] In some embodiments, the catalyst composition may be in the form of catalyst particles or a monolithic structure. In some embodiments, when the catalyst composition is in the form of catalyst particles, the catalyst particles may have a median particle size ranging from 1 μm, 5 μm, 10 μm, 20 μm, 40 μm, or 60 μm to 80 μm, 100 μm, 115 μm, 130 μm, 150 μm, 200 μm, 300 μm, or 400, or 500 μm. In some embodiments, the catalyst particles have a median particle size of 0.3 g / cm, as measured according to ASTM D7481-18, modified using 10, 25, or 50 mL graduated cylinders instead of 100 or 250 mL graduated cylinders. 3 , 0.4g / cm 3 , 0.5g / cm 3 , 0.6g / cm 3 , 0.7g / cm 3 , 0.8g / cm 3 , 0.9g / cm 3 , or 1g / cm 3 from 1.1 g / cm 3 , 1.2g / cm 3 , 1.3g / cm 3 , 1.4g / cm 3 , 1.5g / cm 3 , 1.6g / cm 3 , 1.7g / cm 3 , 1.8g / cm 3 , 1.9g / cm 3, or 2 g / cm 3 In some embodiments, the catalyst particles may have an apparent loose bulk density ranging from ≦5 wt%, ≦4 wt%, ≦3 wt%, ≦2 wt%, ≦1 wt%, ≦0.7 wt%, ≦0.5 wt%, ≦0.4 wt%, ≦0.3 wt%, ≦0.2 wt%, ≦0.1 wt%, ≦0.07 wt%, or ≦0.05 wt% attrition loss after 1 hour, measured according to ASTM D5757-11(2017). The morphology of the particles may be predominantly spherical, making them suitable for moving around in a fluidized bed reactor. In some embodiments, the catalyst particles may have a size and density consistent with the Geldart A or Geldart B definition of a flowable solid.

[0030] In some embodiments, the catalyst particles are 0.1 m 2 / g, 1m 2 / g, 10m 2 / g, or 100m 2 / g to 500m 2 / g, 800m 2 / g, 1,000m 2 / g, or 1,500m 2 The catalyst particles may have surface areas ranging from 0.1 to 1.0 μm / g. The surface area of ​​the catalyst particles can be measured according to the Brunauer-Emmett-Teller (BET) method using nitrogen adsorption-desorption (temperature of liquid nitrogen, -196°C (77K)) on a Micromeritics 3flex instrument after degassing the powder at 350°C for 4 hours. More information on this method can be found, for example, in "Characterization of Porous Solids and Powders: Surface Area, Pore Size and Density," S. Lowell et al., Springer, 2004.

[0031] First manufacturing process of catalyst particles The process for preparing the catalyst composition may include preparing a slurry or gel, which may include milling, mixing, blending, mixing, or otherwise contacting Al and / or its compounds, Group 2 elements and / or its compounds, and a liquid medium. In some embodiments, preparing a slurry or gel may also include, but is not limited to, contacting Al or its compounds, Group 2 elements or its compounds, a liquid medium, and one or more additives. In other embodiments, preparing a slurry or gel may include, but is not limited to, contacting Al or its compounds, Group 2 elements or its compounds, a liquid medium, a binder or binder precursor, and, optionally, one or more additives.

[0032] In some embodiments, the Al-containing compound may be or include, but is not limited to, Al2O3, Al(OH)2, aluminum chlorohydrol (ACH), layered double hydroxides (including Al, Mg, or mixtures thereof). In some embodiments, the Group 2 element-containing compound may be in the form of an oxide, hydroxide, hydrated carbonate, salt, Group 2 element-containing clay, layered double hydroxide, phosphate, halide, halate, sulfate, sulfide, borate, nitride, carbide, aluminate, carbonate, metaphosphate, selenide, tungstate, molybdate, chromate, chromate, dichromate, or mixtures thereof. In some embodiments, the group 2 element may be or include Mg, and the group 2 element-containing compound may be in the form of magnesium oxide, magnesium hydroxide, hydromagnesite (hydrated magnesium carbonate mineral, Mg5(CO3)4(OH)2·4H2O), magnesium salts, magnesium-containing clays, hydrotalcite (a layered double hydroxide that also contains Al), organomagnesium compounds, or mixtures thereof. In some embodiments, the group 2 element and Al may be present as a mixed group 2 element / Al metal oxide. In some embodiments, the group 2 element and Al may be present as a mixed group 2 element / Al layered double hydroxide, such as hydrotalcite.

[0033] The liquid medium may be or include, but is not limited to, water, alcohol, acetone, chloroform, methylene chloride, dimethylformamide, dimethylsulfoxide, glycerin, ethyl acetate, or any mixture thereof. Illustrative alcohols may be or include, but are not limited to, methanol, ethanol, isopropanol, or any mixture thereof. The binder, if present, may be or include the binders described above. The binder precursor, if present, may be or include, but is not limited to, aluminum chlorohydrol, boehmite, pseudoboehmite, gibbsite, bayerite, aluminum nitrate, aluminum chloride, sodium aluminate, alumina sol, or any mixture thereof. In the literature, it is known that compounds referred to herein as "binders" may also be referred to as fillers, matrices, additives, etc. The one or more additives, if present, may be or include, but are not limited to, one or more acids, such as formic acid, lactic acid, citric acid, acetic acid, HNO3, HCl, oxalic acid, stearic acid, carbonic acid, etc.; one or more bases, such as ammonia solution, NaOH, KOH, etc.; inorganic salts, such as nitrates, carbonates, bicarbonates, chlorides, etc.; organic salts, such as acetates, oxalates, formates, citrates, etc.; polymers, such as polyvinyl alcohol, polysaccharides, etc., or any mixture thereof. The additives may help to improve the chemical / physical properties of the spray dried material and / or help to improve the rheological properties of the slurry / gel to facilitate spray drying.

[0034] The slurry or gel can be spray dried to produce spray-dried particles comprising the group 2 element and Al. Spray drying refers to a process of producing a dry particulate solid product from the slurry or gel. This process can include atomizing or atomizing the slurry or gel, for example, forming small droplets in a temperature-controlled gas stream to evaporate the liquid medium from the atomized droplets and produce the particulate solid product. For example, in a spray drying process, the slurry or gel can be atomized into small droplets and mixed with hot air or a hot inert gas, for example, nitrogen, to evaporate the liquid from the droplets. The temperature of the slurry or gel during the spray drying process can usually be close to or higher than the boiling temperature of the liquid. An outlet air temperature of about 60°C to about 120°C can be typical. The slurry or gel may be atomized with one or more pressure nozzles (e.g., fluid nozzle atomizers), one or more pulse atomizers, one or more high speed rotating disks (e.g., centrifugal or rotary atomizers), or any other known process. The median particle size, liquid (e.g., water) concentration, apparent loose bulk density, or any combination thereof, of the particulate solid product prepared by spray drying may be controlled, adjusted, or otherwise influenced by one or more operating conditions and / or parameters of the spray dryer. Illustrative operating conditions include, but are not limited to, the feed rate and temperature of the gas stream, the atomizer speed, the feed rate of the slurry or gel through the atomizer, the temperature of the slurry or gel, the droplet size and / or solids concentration, the dimensions of the spray dryer, or any combination thereof. It is well known in the art that the various operating conditions vary depending on the particular spray drying equipment used and can be readily determined by one of ordinary skill in the art.

[0035] The spray-dried particles can optionally be calcined under an oxidizing atmosphere, e.g., air, to produce calcined support particles comprising the Group 2 element and Al. In some embodiments, the spray-dried particles can be calcined at a temperature ranging from 450°C, 500°C, 525°C, 550°C, 575°C, 600°C, 625°C, 650°C, or 675°C to 700°C, 725°C, 750°C, 775°C, 800°C, 850°C, 900°C, or 950°C. In some embodiments, the spray-dried particles can be calcined at a temperature of ≦950°C, ≦900°C, ≦850°C, ≦800°C, ≦750°C, ≦700°C, ≦650°C, ≦600°C, or ≦550°C, ≦525°C, ≦500°C, ≦475°C, or ≦460°C. In some embodiments, the spray-dried particles may be calcined for a time period of ≦240 min, ≦180 min, ≦120 min, ≦90 min, ≦60 min, ≦45 min, ≦30 min, ≦25 min, ≦20 min, or ≦15 min. In some embodiments, the spray-dried particles may be calcined in the presence of oxygen, e.g., air. In some embodiments, the spray-dried particles may be calcined at a temperature in the range of 550° C. to 900° C. or 550° C. to 850° C. for a time period of ≦240 min, ≦180 min, ≦120 min, ≦90 min, ≦60 min, ≦45 min, ≦30 min, ≦25 min, ≦20 min, or ≦15 min. In some embodiments, the spray-dried particles may be calcined in the presence of oxygen, e.g., air. In some embodiments, the spray-dried particles may be calcined at temperatures ranging from 550° C. to 900° C. or 550° C. to 850° C. for times of ≦240 min, ≦180 min, ≦120 min, ≦90 min, ≦60 min, ≦45 min, ≦30 min, ≦25 min, ≦20 min, or ≦15 min. In other embodiments, the spray-dried particles may be calcined at temperatures ranging from ≦550° C., ≦540° C., ≦530° C., ≦520° C., ≦510° C., or ≦500° C. for times of ≦240 min, ≦180 min, ≦120 min, ≦90 min, ≦60 min, ≦45 min, ≦30 min, ≦25 min, ≦20 min, or ≦15 min.

[0036] The Group 8-10 element present in the catalyst particles can be introduced by one or more methods. In some embodiments, the process for making the catalyst composition can include (i) contacting Al and / or compounds thereof, Group 2 element and / or compounds thereof, and a liquid medium with a Group 8-10 element and / or compounds thereof, such that the Group 8-10 element can be present in a slurry or gel, and the catalyst composition can include catalyst particles including calcined support particles having the Group 8-10 element disposed thereon. In other embodiments, the process for making the catalyst composition can include (ii) depositing the Group 8-10 element and / or compounds thereof on the spray-dried particles by contacting the spray-dried particles with the Group 8-10 element and / or compounds thereof to produce Group 8-10 element-containing spray-dried particles, and the catalyst composition can include catalyst particles including calcined support particles having the Group 8-10 element disposed thereon. In other embodiments, the process for making the catalyst composition may include (iii) depositing the Group 8-10 element and / or compound thereof on the calcined support particles to produce calcined support particles containing the Group 8-10 element, if the spray-dried particles are optionally calcined by contacting the calcined support particles with a Group 8-10 element and / or compound thereof, and the process may optionally further include calcining the calcined support particles containing the Group 8-10 element to produce re-calcined support particles having the Group 8-10 element disposed thereon, in which case the catalyst composition may include the re-calcined support particles. In some embodiments, the catalyst composition may include the Group 8-10 element-containing calcined support particles without an optional additional calcination step. In other embodiments, the process for making the catalyst composition may include options (i), (ii), or (iii), (i) and (ii), (i) and (iii), (ii) and (iii), or (i), (ii), and (iii).In some embodiments, when the Group 8-10 element is in the form of a compound, suitable compounds containing a Group 8-10 element may be or include, but are not limited to, chloroplatinic acid hexahydrate, tetraammineplatinum(II) nitrate, platinum(II) acetylacetonate, platinum(II) bromide, platinum(II) iodide, platinum(II) chloride, platinum(IV) chloride, platinum(II) diammine dichloride, ammonium tetrachloroplatinate(II), tetraammineplatinum(II) chloride hydrate, tetraammineplatinum(II) hydroxide hydrate, nickel(II) chloride, palladium(II) acetate, palladium(II) nitrate, iron(II) chloride, iron(III) chloride, ruthenium(III) chloride hydrate, rhodium(III) nitrate, or any mixture thereof.

[0037] The optional promoter that may be present in the catalyst particles can be introduced by one or more methods. In some embodiments, the process for making the catalyst composition can include (iv) contacting at least Al and / or compounds thereof, Group 2 elements and / or compounds thereof, and a liquid medium with a compound containing a promoter element such that the promoter element is present in a slurry or gel, and the catalyst composition can include catalyst particles including spray-dried and / or calcined support particles having the promoter element disposed thereon. In other embodiments, the process for making the catalyst composition can include (v) depositing a compound containing a promoter element onto a spray-dried particle to produce a promoter-containing spray-dried particle, and the catalyst composition can include catalyst particles including a promoter-containing spray-dried and / or calcined support particle having the promoter element disposed thereon. In other embodiments, the process for making the catalyst composition can include (vi) depositing a compound containing a promoter element onto a calcined support particle to produce a promoter-containing calcined support particle, if the spray-dried particle is optionally calcined, and the process can further include optionally calcining the promoter-containing calcined support particle to produce a re-calcined support particle having the promoter element disposed thereon, in which case the catalyst composition includes a re-calcined support particle. In some embodiments, the catalyst composition may include the promoter-containing calcined support particles without an optional additional calcination step. In other embodiments, the process for making the catalyst composition may include options (iv), (v), (vi), (iv) and (v), (iv) and (vi), (v) and (vi), or (iv), (v), and (vi). In other embodiments, the process may include any one or more of options (i), (ii), and (iii) and any one or more of options (iv), (v), and (iv).The compound containing the promoter element may be or include, but is not limited to, tin(II) oxide, tin(IV) oxide, tin(IV) chloride pentahydrate, tin(II) chloride dihydrate, tin(II) bromide, ammonium hexachlorostannate(IV), tin(IV) bromide, tin(II) acetylacetonate, tin(II) acetate, tin(IV) acetate, tin(II) oxalate, silver(I) nitrate, gold(III) nitrate, copper(II) nitrate, gallium(III) nitrate, zinc(II) nitrate, germanium(IV) chloride, indium(III) nitrate, rhenium(VII) oxide, or any mixture thereof.

[0038] The alkali metal element, when present in the catalyst particles, can be introduced by one or more methods. In some embodiments, the process for producing the catalyst composition can include (vii) contacting Al and / or compounds thereof, Group 2 elements and / or compounds thereof, and a liquid medium with a compound containing an alkali metal element, such that the alkali metal element is present in a slurry or gel, and the catalyst composition can include catalyst particles including spray-dried and / or calcined support particles having the alkali metal element disposed thereon. In other embodiments, the process for producing the catalyst composition can include (viii) depositing a compound containing an alkali metal element on spray-dried particles to produce alkali metal element-containing spray-dried particles, and the catalyst composition can include catalyst particles including spray-dried and / or calcined support particles having the alkali metal element disposed thereon. In other embodiments, the process for making the catalyst composition may include (ix) depositing a compound containing an alkali metal element on the calcined support particles to produce an alkali metal element-containing calcined support particle when the spray-dried particles are optionally calcined, and the process may further include calcining the alkali metal element-containing calcined support particle to produce a re-calcined support particle having an alkali metal element disposed thereon, in which case the catalyst composition comprises a re-calcined support particle. In other embodiments, the process for making the catalyst composition may include options (vii), (viii), (ix), (vii) and (viii), (vi) and (ix), (viii) and (ix), or (vii), (viii), and (iv). In other embodiments, the process may include any one or more of options (i), (ii), and (iii), any one or more of options (iv), (v), and (iv), and any one or more of options (vii), (viii), and (ix). The compound containing an alkali metal element may be or include, but is not limited to, lithium nitrate, sodium nitrate, potassium nitrate, rubidium nitrate, cesium nitrate, or any mixture thereof.

[0039] In some embodiments, the process for making the catalyst composition may optionally include a step of hydrating the calcined support particles to produce hydrated support particles. For example, the calcined support particles may be contacted with water to produce hydrated support particles. In such embodiments, the process may also include a step of calcining the hydrated support particles to produce the catalyst composition comprising the recalcined support particles. The hydration step of the calcined support may be carried out at a temperature ranging from 20° C., 40° C., or 60° C. to 80° C., 120° C., 140° C., 160° C., 180° C., or 200° C. The calcined support may be contacted with water for a time ranging from 1 minute, 5 minutes, or 10 minutes to 20 minutes, 40 minutes, 80 minutes, 160 minutes, 6 hours, 12 hours, 24 hours, or 48 hours. In some embodiments, anions such as chloride, nitrate, carbonate, bicarbonate, acetate, oxalate, formate, and / or citrate ions may be present during hydration. In some embodiments, the process for making the catalyst composition may optionally include hydrating the spray-dried particles to produce hydrated spray-dried particles. For example, the spray-dried particles may be contacted with water to produce hydrated spray-dried particles. In such embodiments, the process may also include calcining the hydrated spray-dried particles to produce the catalyst composition comprising the calcined support particles. The hydration step of the spray-dried particles may be carried out at a temperature ranging from 20° C., 40° C., or 60° C. to 80° C., 120° C., 140° C., 160° C., 180° C., or 200° C. The spray-dried particles may be contacted with water for a time ranging from 1 minute, 5 minutes, or 10 minutes to 20 minutes, 40 minutes, 80 minutes, 160 minutes, 6 hours, 12 hours, 24 hours, or 48 hours. In some embodiments, anions such as chloride, nitrate, carbonate, bicarbonate, acetate, oxalate, formate, and / or citrate ions may be present during hydration.

[0040] In some embodiments, the process for making the catalyst composition may include optionally hydrating the spray-dried particles to produce hydrated spray-dried particles, calcining the hydrated spray-dried particles to produce calcined support particles, hydrating the calcined support particles to produce hydrated calcined support particles, and calcining the hydrated calcined support particles to produce re-calcined support particles. As a result, the catalyst composition may include spray-dried particles, calcined support particles, hydrated spray-dried particles, hydrated spray-dried particles that can be calcined, hydrated calcined support particles, hydrated calcined support particles that can be re-calcined, or any mixture thereof. In some embodiments, particles of catalyst produced by hydrating the calcined support particles or spray-dried particles and then calcining the hydrated calcined support particles or hydrated spray-dried particles can result in catalyst particles having an attrition loss after 1 hour, measured according to ASTM D5757-11(2017), that is less than the attrition loss after 1 hour of the calcined particles or spray-dried particles originally produced before the hydration step. In some embodiments, particles of catalyst produced by hydrating the calcined support particles or spray-dried particles and then calcining the hydrated support particles or hydrated support particles can result in catalyst particles having an attrition loss after 1 hour, measured according to ASTM D5757-11(2017), that is 10% less, 30% less, 50% less, 70% less, 90% less, or 100% less than the attrition loss after 1 hour of the calcined particles originally produced before the hydration step.

[0041] Second manufacturing process for catalyst particles In some embodiments, the catalyst composition may be or include catalyst particles, spray-dried particles, or combinations thereof, produced solely via a spray-drying step, where a slurry is prepared and the spray-dried particles are produced from the slurry having a Group 8-10 element and, optionally, a promoter and / or an alkali metal element added to the slurry. Thus, in some embodiments, the process for producing the catalyst composition may include preparing a slurry or gel that may include Al and / or compounds thereof, a Group 2 element and / or compounds thereof, a liquid medium, and, optionally, one or more of the additives described above, and spray-drying the slurry or gel to produce spray-dried support particles comprising at least Al and a Group 2 element. At least one of the following may be satisfied: (i) the Group 8-10 element may be present in the slurry or gel in the form of a Group 8-10 element-containing compound, and the catalyst composition may include catalyst particles including spray-dried support particles having a Group 8-10 element disposed thereon; and (ii) the Group 8-10 element may be deposited on the spray-dried support particles by contacting the spray-dried support particles with a Group 8-10 element-containing compound to produce a Group 8-10 element-containing spray-dried support particle, and the catalyst composition may include catalyst particles including spray-dried support particles having a Group 8-10 element disposed thereon. In some embodiments, at least one of the following may also be satisfied: (iii) the compound including the promoter element may be present in the slurry or gel, and the catalyst composition may include catalyst particles including spray-dried support particles having a promoter element disposed thereon; and (iv) the compound including the promoter element may be deposited on the spray-dried support particles to produce a promoter-containing spray-dried support particle, and the catalyst composition may include catalyst particles including spray-dried support particles having a promoter element disposed thereon. In some embodiments, an optional alkali metal element(s) and / or binder may be added during synthesis of the catalyst particles.

[0042] In some embodiments, the catalyst particles can be further processed or activated in situ by adding the catalyst particles to a hydrocarbon upgrading process that exposes the catalyst particles to more severe conditions to produce catalyst particles with a higher activation level than the spray-dried particles had just as they were prepared. In some embodiments, when the catalyst particles comprise catalyst particles, spray-dried support particles, or combinations thereof that have only been subjected to a spray drying step such that a slurry is prepared and the spray-dried support particles are produced from the slurry with Pt and promoter added to the slurry, the catalyst particles can be introduced into a reaction zone, a combustion zone, a reduction zone, or any other location within a fluid hydrocarbon upgrading process, some of which are described further below.

[0043] The preparation of the catalyst composition and the process for adding the Group 8-10 element, promoter(s), e.g., Sn, optional alkali metal element(s), and optional binder(s) to the catalyst composition are described above. In some embodiments, the preparation of the slurry or gel, the spray drying of the slurry, the calcination of the spray dried particles and / or the hydrated calcined particles, and / or the hydration of the Al and Group 2 element-containing calcined support particles or spray dried particles can be carried out as described in the literature, e.g., U.S. Pat. Nos. 4,866,019; 6,028,023; 6,589,902; 6,593,265; 6,800,578; 7,361,264; and 7,417,005; U.S. Patent Application Publication Nos. 2004 / 0029729; 2005 / 000396; and 2016 / 0082424; International Publication No. WO2008083563A1; and the publication Wang et al., Ind. Eng. Chem. Res. 2008, 47, This can also be done using one of the known methods reported in: Chubar et al., Chem. Eng. J. 2013, 234, 284-299; Valente et al., Energy Environ. Sci., 2011, 4, 4096-4107; and Julklang et al., Mater. Lett. 2017, 209, 429-432. Without wishing to be bound by theory, it is believed that the supports produced by any one of the above processes and / or other processes may contain (i) Mg and Al mixed together on the nm scale, (ii) Mg and Al in the form of a mixed Mg / Al metal oxide, or (iii) a combination of (i) and (ii).

[0044] The first upgrading process of hydrocarbons The first upgrading process of hydrocarbons may include contacting a hydrocarbon-containing feed (first hydrocarbon-containing feed) with a catalyst composition comprising a Group 8-10 element disposed on a support to cause one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first hydrocarbon-containing feed to produce a coked catalyst composition and an effluent that may include one or more upgraded hydrocarbons and molecular hydrogen. The catalyst composition and the first hydrocarbon-containing feed may be contacted with each other in any suitable environment, such as one or more reaction zones or conversion zones disposed in one or more reactors to produce an effluent and a coked catalyst composition. The reaction zones or conversion zones may be disposed or otherwise located in one or more fixed bed reactors, one or more fluidized or moving bed reactors, one or more counter-current reactors, or any combination thereof. The catalyst composition may include 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contains no Si or contains <0.5 wt% Si. All weight percentages herein are based on the weight of the support.

[0045] The first hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature ranging from 300° C., 350° C., 400° C., 450° C., 500° C., 550° C., 600° C., 620° C., 650° C., 660° C., 670° C., 680° C., 690° C., or 700° C. to 725° C., 750° C., 760° C., 780° C., 800° C., 825° C., 850° C., 875° C., or 900° C. In some embodiments, the first hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature of at least 620° C., at least 650° C., at least 660° C., at least 670° C., at least 680° C., at least 690° C., or at least 700° C. to 725° C., 750° C., 760° C., 780° C., 800° C., 825° C., 850° C., 875° C., or 900° C. The first hydrocarbon-containing feed may be introduced into the reaction or conversion zone and contacted with the catalyst composition therein for a time of ≦3 hours, ≦2.5 hours, ≦2 hours, ≦1.5 hours, ≦1 hour, ≦45 minutes, ≦30 minutes, ≦20 minutes, ≦10 minutes, ≦5 minutes, ≦1 minute, ≦30 seconds, ≦10 seconds, ≦5 seconds, or ≦1 second or ≦0.5 seconds. In some embodiments, the first hydrocarbon-containing feed may be contacted with the catalyst composition for a time ranging from 0.1 seconds, 0.5 seconds, 0.7 seconds, 1 second, 30 seconds, 1 minute, 5 minutes, or 10 minutes to 30 minutes, 50 minutes, 70 minutes, 1.5 hours, 2 hours, or 3 hours.

[0046] The first hydrocarbon-containing feed and the catalyst composition may be contacted under a hydrocarbon partial pressure of at least 20 kPa absolute, where the hydrocarbon partial pressure is at least 20 kPa absolute, and ... 16 Alkanes and any C8-C 16The total partial pressure of alkyl aromatics. In some embodiments, the hydrocarbon partial pressure during contact of the first hydrocarbon-containing feed with the catalyst composition may range from 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 150 kPa absolute, 200 kPa absolute, 300 kPa absolute, 500 kPa absolute, 750 kPa absolute, or 1,000 kPa absolute to 1,500 kPa absolute, 2,500 kPa absolute, 4,000 kPa absolute, 5,000 kPa absolute, 7,000 kPa absolute, 8,500 kPa absolute, or 10,000 kPa absolute. Here, the hydrocarbon partial pressure is the total partial pressure of any C2-C ... 16 Alkanes and any C8-C 16 The total partial pressure of alkyl aromatics. In other embodiments, the hydrocarbon partial pressure during contact of the hydrocarbon-containing feed with the catalyst composition can range from 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 150 kPa absolute, 200 kPa absolute, 250 kPa absolute, or 300 kPa absolute to 500 kPa absolute, 600 kPa absolute, 700 kPa absolute, 800 kPa absolute, 900 kPa absolute, or 1,000 kPa absolute. Here, the hydrocarbon partial pressure is the total partial pressure of any C2-C4 aromatic hydrocarbons in the first hydrocarbon-containing feed. 16 Alkanes and any C8-C 16 is the total alkyl aromatic partial pressure.

[0047] In some embodiments, the first hydrocarbon-containing feed comprises at least 60 vol.%, at least 65 vol.%, at least 70 vol.%, at least 75 vol.%, at least 80 vol.%, at least 85 vol.%, at least 90 vol.%, at least 95 vol.%, or at least 99 vol.% of a single C2-C 16 The first hydrocarbon-containing feed and the catalyst composition may comprise a single C2-C 16The alkane, for example, propane, may be contacted under a pressure of at least 20 kPa absolute, at least 50 kPa absolute, at least 70 kPa absolute, at least 80 kPa absolute, at least 90 kPa absolute, at least 95 kPa absolute, at least 100 kPa absolute, at least 150 kPa absolute, at least 250 kPa absolute, at least 300 kPa absolute, at least 400 kPa absolute, at least 500 kPa absolute, or at least 1,000 kPa absolute.

[0048] The first hydrocarbon-containing feed may be contacted with the catalyst composition in the reaction zone or conversion zone at any mass hourly space velocity (WHSV) effective to carry out the upgrading process. In some embodiments, the WHSV is 0.01 h -1 , 0.1 hours -1 , 1 hour -1 , 2 hours -1 , 5 hours -1 , 10 hours -1 , 20 hours -1 , 30 hours -1 or 50 hours -1 100 hours from -1 , 250 hours -1 , 500 hours -1 or 1,000 hours -1 In some embodiments, when the hydrocarbon upgrading process includes a fluidized or otherwise moving catalyst composition, the catalyst composition circulation mass flow rate and any C2-C 16 Alkanes and any C8-C 16 The ratio of the total amount of alkyl aromatic mass flow rates can range from 1, 3, 5, 10, 15, 20, 25, 30, or 40 to 50, 60, 70, 80, 90, 100, 110, 125, or 150 on a mass to mass basis. When the activity of the coked catalyst composition falls below a desired minimum amount, the coked catalyst composition, or at least a portion thereof, may undergo a regeneration process to produce a regenerated catalyst composition. More specifically, the coked catalyst composition may be contacted with one or more oxidants to cause combustion of at least a portion of the coke to produce a regenerated catalyst composition and combustion gases that are less coke. Depending on the particular reactor configuration, regeneration of the coked catalyst composition may occur within the reaction zone or conversion zone or in a separate combustion zone separate from the reaction zone or conversion zone to produce a regenerated catalyst composition. For example, regeneration of the coked catalyst composition may occur within the reaction zone or conversion zone when using a fixed bed or upflow reactor, or in a separate combustion zone separate from the reaction zone or conversion zone when using a fluidized bed reactor or other circulating or fluidized type reactor.

[0049] In some embodiments, the process may optionally include contacting at least a portion of the regenerated catalyst composition with a reducing gas to produce a regenerated and reduced catalyst composition. An additional amount of a hydrocarbon-containing feed may be contacted with at least a portion of the regenerated catalyst composition and / or at least a portion of any regenerated and reduced catalyst composition to produce a recoked catalyst composition and additional effluent. In some embodiments, the cycle time from contacting the hydrocarbon-containing feed with the catalyst composition to contacting an additional amount of the hydrocarbon-containing feed with the regenerated catalyst composition may be ≦5 hours, ≦4 hours, ≦3 hours, ≦2 hours, ≦1.5 hours, ≦1 hour, ≦50 minutes, ≦45 minutes, ≦40 minutes, ≦30 minutes, ≦25 minutes, ≦20 minutes, or ≦15 minutes. A first cycle begins when the catalyst composition contacts a first hydrocarbon-containing feed, and then contacts with at least an oxidizing gas to produce a regenerated catalyst composition or at least an oxidizing gas and an optional reducing gas to produce a regenerated and reduced catalyst composition, and the first cycle ends and a second cycle begins when the regenerated catalyst composition contacts an additional amount of the first hydrocarbon-containing feed. If one or more additional feeds (described in more detail below) are utilized between the flow of the first hydrocarbon-containing feed and the oxidizing gas, between the oxidizing gas and the reducing gas (if used), between the oxidizing gas and the additional amount of the first hydrocarbon-containing feed, and / or between the reducing gas and the additional amount of the first hydrocarbon-containing feed, the time during which such stripping gas is utilized will be included in the time included in the cycle time. Thus, the cycle time from the step of contacting the first hydrocarbon-containing feed with the catalyst composition to the step of contacting the additional amount of the hydrocarbon-containing feed with the regenerated catalyst composition may, in some embodiments, be ≦5 hours.

[0050] The oxidant may be or include, but is not limited to, O2, O3, CO2, H2O, or mixtures thereof. In some embodiments, an amount of oxidant greater than that required to combust 100% of the coke on the catalyst composition may be used to increase the rate of coke removal from the catalyst composition, which may result in less time required for coke removal and increased yields of upgraded products produced in a given time. Using pure O2 as the oxidant may facilitate capture and sequestration of the CO2 generated during combustion in one or more downstream CO2 capture systems. The coked catalyst composition and the oxidant may be contacted with each other at a temperature ranging from 500° C., 550° C., 600° C., 650° C., 700° C., 750° C., or 800° C. to 900° C., 950° C., 1,000° C., 1,050° C., or 1,100° C. to produce the regenerated catalyst composition. In some embodiments, the coked catalyst composition and the oxidant may be contacted with each other at a temperature ranging from 500° C. to 1,100° C., 600° C. to 1,000° C., 650° C. to 950° C., 700° C. to 900° C., or 750° C. to 850° C. to produce the regenerated catalyst composition. In some embodiments, the coked catalyst composition and the oxidant may be contacted with each other for a time period of ≦2 hours, ≦1 hour, ≦30 minutes, ≦10 minutes, ≦5 minutes, ≦1 minute, ≦30 seconds, ≦10 seconds, ≦5 seconds, or ≦1 second. For example, the coked catalyst composition and the oxidant may be contacted with each other for a time period ranging from 2 seconds to 2 hours. In some embodiments, the coked catalyst composition and the oxidant may be contacted with each other for a time period sufficient to remove ≧50 wt%, ≧75 wt%, or ≧90 wt%, or >99% of any coke disposed on the catalyst composition.

[0051] In some embodiments, the time that the coked catalyst composition and the oxidant are in contact with each other can be less than the time that the catalyst composition is in contact with the hydrocarbon-containing feed to produce an effluent and a coked catalyst composition. For example, the time that the coked catalyst composition and the oxidant are in contact with each other can be at least 90%, at least 60%, at least 30%, or at least 10% less than the time that the catalyst composition is in contact with the hydrocarbon-containing feed to produce an effluent. In other embodiments, the time that the coked catalyst composition and the oxidant are in contact with each other can be greater than the time that the catalyst composition is in contact with the hydrocarbon-containing feed to produce an effluent and a coked catalyst composition. For example, in some embodiments, the coking catalyst composition and the oxidant may be in contact with each other for a time that may be at least 50%, at least 100%, at least 300%, at least 500%, at least 1,000%, at least 10,000%, at least 30,000%, at least 50,000%, at least 75,000%, at least 100,000%, at least 250,000%, at least 500,000%, at least 750,000%, at least 1,000,000%, at least 1,250,000%, at least 1,500,000%, or at least 1,800,000% longer than the time the catalyst composition is in contact with the hydrocarbon-containing feed to produce an effluent. The coked catalyst composition and the oxidant may be contacted with each other under an oxidant partial pressure ranging from 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 300 kPa absolute, 500 kPa absolute, 750 kPa absolute, or 1,000 kPa absolute to 1,500 kPa absolute, 2,500 kPa absolute, 4,000 kPa absolute, 5,000 kPa absolute, 7,000 kPa absolute, 8,500 kPa absolute, or 10,000 kPa absolute. In other embodiments, the oxidant partial pressure during contact with the coked catalyst composition to produce the regenerated catalyst composition can range from 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 150 kPa absolute, 200 kPa absolute, 250 kPa absolute, or 300 kPa absolute to 500 kPa absolute, 600 kPa absolute, 700 kPa absolute, 800 kPa absolute, 900 kPa absolute, or 1,000 kPa absolute.

[0052] Without wishing to be bound by theory, it is believed that at least a portion of the Group 8-10 element, e.g., Pt, disposed on the coked catalyst composition may be agglomerated relative to the catalyst composition prior to contact with the first hydrocarbon-containing feed. It is believed that at least a portion of the Group 8-10 element may be redispersed around the support during combustion of at least a portion of the coke on the coked catalyst composition. Redispersing at least a portion of any agglomerated Group 8-10 element may improve the stability of the catalyst composition over multiple cycles. In some embodiments, at least a portion of the Group 8-10 elements, e.g., Pt, in the regenerated catalyst composition may be in a higher oxidation state than the Group 8-10 elements in the catalyst composition contacted with the first hydrocarbon-containing feed and than the Group 8-10 elements in the coked catalyst composition. As a result, as described above, in some embodiments, the process may optionally include contacting at least a portion of the regenerated catalyst composition with a reducing gas to produce a regenerated reduced catalyst composition. Suitable reducing gases (reducing agents) may be or include, but are not limited to, H2, CO, CH4, C2H6, C3H8, C2H4, C3H6, steam, or mixtures thereof. In some embodiments, the reducing agent may be mixed with an inert gas, e.g., Ar, Ne, He, N2, CO2, H2O, or mixtures thereof. In such embodiments, at least a portion of the Group 2 elements in the regenerated reduced catalyst composition may be reduced to a lower oxidation state, e.g., elemental state, than the Group 2 elements in the regenerated catalyst composition. In this embodiment, an additional amount of the hydrocarbon-containing feed may be contacted with at least a portion of the regenerated catalyst composition and / or at least a portion of the regenerated reduced catalyst composition.

[0053] In some embodiments, the regenerated catalyst composition and the reducing gas may be contacted at a temperature ranging from 400° C., 450° C., 500° C., 550° C., 600° C., 620° C., 650° C., or 670° C. to 720° C., 750° C., 800° C., or 900° C. The regenerated catalyst composition and the reducing gas may be contacted for a time ranging from 1 second, 5 seconds, 10 seconds, 20 seconds, 30 seconds, or 1 minute to 10 minutes, 30 minutes, or 60 minutes. The regenerated catalyst composition and reducing gas may be contacted at a reducing agent partial pressure of 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 300 kPa absolute, 500 kPa absolute, 750 kPa absolute, or 1,000 kPa absolute to 1,500 kPa absolute, 2,500 kPa absolute, 4,000 kPa absolute, 5,000 kPa absolute, 7,000 kPa absolute, 8,500 kPa absolute, or 10,000 kPa absolute. In other embodiments, the reducing agent partial pressure during contact with the regenerated catalyst composition to produce the regenerated catalyst composition may range from 20 kPa absolute, 50 kPa absolute, 70 kPa absolute, 80 kPa absolute, 90 kPa absolute, 95 kPa absolute, 100 kPa absolute, 150 kPa absolute, 200 kPa absolute, 250 kPa absolute, or 300 kPa absolute to 500 kPa absolute, 600 kPa absolute, 700 kPa absolute, 800 kPa absolute, 900 kPa absolute, or 1,000 kPa absolute. Within the reaction or conversion zone, at least a portion of the regenerated catalyst composition, the regenerated reduced catalyst composition, the fresh or unused catalyst composition, or a mixture thereof may be contacted with an additional amount of the first hydrocarbon-containing feed to produce additional effluent and additional coked catalyst composition. As noted above, in some embodiments, the cycle time from contacting the hydrocarbon-containing feed with the catalyst composition to contacting the additional amount of the hydrocarbon-containing feed with the regenerated catalyst composition, and / or the regenerated reduced catalyst composition, and optionally at least a portion of the fresh or unused catalyst composition, may be ≦5 hours.

[0054] In some embodiments, as described above, one or more additional feeds, e.g., one or more sweep fluids, may be utilized between the first hydrocarbon-containing feed and the oxidant flow, between the oxidant and the optional reducing gas, if used, between the oxidant and the additional first hydrocarbon-containing feed, and / or between the reducing gas and the additional first hydrocarbon-containing feed. The sweep fluid may, among other things, purge or otherwise remove undesirable materials, e.g., non-combustible particulates, including soot, from the reactor. In some embodiments, the additional feed may be inert under the dehydrogenation, dehydroaromatization, and dehydrocyclization, combustion, and / or reduction conditions. Suitable sweep fluids may be or include, but are not limited to, N2, He, Ar, CO2, H2O, CO2, CH4, or mixtures thereof. In some embodiments, if the process utilizes a sweep fluid, the duration for which the sweep fluid is utilized may range from 1 second, 5 seconds, 10 seconds, 20 seconds, 30 seconds, or 1 minute to 10 minutes, 30 minutes, or 60 minutes.

[0055] In some embodiments, the catalyst composition may remain sufficiently active and stable after multiple cycles, for example, at least 15, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 100 cycles, at least 125 cycles, at least 150 cycles, at least 175 cycles, or at least 200 cycles, with each cycle time lasting < 5 hours, < 4 hours, < 3 hours, < 2 hours, < 1 hour, < 50 minutes, < 45 minutes, < 30 minutes, < 15 minutes, < 10 minutes, < 5 minutes, < 1 minute, < 30 seconds, or < 10 seconds. In some embodiments, the cycle time may be from 5 seconds, 30 seconds, 1 minute, or 5 minutes to 10 minutes, 20 minutes, 30 minutes, 45 minutes, 50 minutes, 70 minutes, 2 hours, 3 hours, 4 hours, or 5 hours. In some embodiments, after stabilization of catalyst performance (the first few cycles may have relatively poor or relatively good performance, but performance may eventually stabilize), the process may provide a first upgraded hydrocarbon product yield, e.g., a propylene yield when the hydrocarbon-containing feed comprises propane, with an upgraded hydrocarbon selectivity, e.g., a propylene selectivity, of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95% upon initial contact with the first hydrocarbon-containing feed, and may have a second upgraded hydrocarbon yield, which may be at least 90%, at least 93%, at least 95%, at least 97%, at least 98%, at least 99%, at least 99.5%, or at least 100% of the first upgraded hydrocarbon product yield, with an upgraded hydrocarbon selectivity, e.g., a propylene selectivity, of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95% upon completion of the last cycle (at least 15 cycles in total).

[0056] In some embodiments, when the first hydrocarbon-containing feed comprises propane and the upgraded hydrocarbon comprises propylene, contacting the hydrocarbon-containing feed with the catalyst composition can result in a propylene yield of ≧52%, ≧53%, ≧55%, ≧57%, ≧60%, ≧62%, ≧63%, ≧64%, ≧65%, or ≧66% with a propylene selectivity of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95%. In some embodiments, when the first hydrocarbon-containing feed comprises propane and the upgraded hydrocarbon comprises propylene, contacting the hydrocarbon-containing feed with the catalyst composition can result in a propylene yield of ≧52%, ≧53%, ≧55%, ≧57%, ≧60%, ≧62%, ≧63%, ≧64%, ≧65%, or ≧66% with a propylene selectivity of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95% for at least 15, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 100 cycles, at least 125 cycles, at least 150 cycles, at least 175 cycles, or at least 200 cycles. In some embodiments, when the hydrocarbon-containing feed comprises at least 70 vol%, at least 75 vol%, at least 80 vol%, at least 85 vol%, at least 90 vol%, or at least 95 vol% propane based on the total volume of the first hydrocarbon-containing feed and is contacted under a propane partial pressure of at least 20 kPa absolute pressure, a propylene yield of ≧52%, ≧53%, ≧55%, ≧57%, ≧60%, ≧62%, ≧63%, ≧64%, ≧65%, or ≧66% can be obtained with a propylene selectivity of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95%.In other embodiments, when the hydrocarbon-containing feed comprises at least 70 vol%, at least 75 vol%, at least 80 vol%, at least 85 vol%, at least 90 vol%, or at least 95 vol% propane based on the total volume of the first hydrocarbon-containing feed and is contacted under a propane partial pressure of at least 20 kPa absolute pressure, a propylene yield of ≥ 52%, ≥ 53%, ≥ 55%, ≥ 57%, ≥ 60%, ≥ 62%, ≥ 63%, ≥ 64%, ≥ 65%, or ≥ 66% can be obtained with a propylene selectivity of ≥ 75%, ≥ 80%, ≥ 85%, ≥ 90%, ≥ 93%, or ≥ 95% for at least 15, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 100 cycles, at least 125 cycles, at least 150 cycles, at least 175 cycles, or at least 200 cycles. It is believed that by further optimizing the composition of the support and / or adjusting one or more process conditions, the propylene yield can be further increased to ≧67%, ≧68%, ≧70%, ≧72%, ≧75%, ≧77%, ≧80%, or ≧82% with a propylene selectivity of ≧75%, ≧80%, ≧85%, ≧90%, ≧93%, or ≧95% over ≧15 cycles, ≧20 cycles, ≧30 cycles, ≧40 cycles, ≧50 cycles, ≧60 cycles, ≧70 cycles, ≧100 cycles, ≧125 cycles, ≧150 cycles, ≧175 cycles, or ≧200 cycles. In some embodiments, this propylene yield may be obtained over ≧15 cycles, ≧20 cycles, ≧30 cycles, ≧40 cycles, ≧50 cycles, ≧60 cycles, ≧70 cycles, ≧100 cycles, ≧125 cycles, ≧150 cycles, ≧175 cycles, or ≧200 cycles when the catalyst composition is contacted with the catalyst composition at a temperature of ≧620°C, ≧630°C, ≧640°C, ≧650°C, ≧655°C, ≧660°C, ≧670°C, ≧680°C, ≧690°C, ≧700°C, or ≧750°C.

[0057] Systems suitable for carrying out the processes disclosed herein can include systems known in the art, such as fixed bed reactors as disclosed in International Publication No. WO2017078894; fluidized riser and / or downer reactors as disclosed in U.S. Pat. Nos. 3,888,762; 7,102,050; 7,195,741; 7,122,160; and 8,653,317; and U.S. Patent Application Publication Nos. 2004 / 0082824; 2008 / 0194891; and countercurrent reactors as disclosed in U.S. Pat. No. 8,754,276; U.S. Patent Application Publication No. 2015 / 0065767; and WO2013169461.

[0058] The first hydrocarbon-containing feed may include, but is not limited to, one or more alkane hydrocarbons, such as C2-C 16 Linear or branched alkanes and / or C4-C 16 Cyclic alkanes, and / or one or more alkyl aromatic hydrocarbons, e.g., C8-C 16 In some embodiments, the first hydrocarbon-containing feed may be or contain alkyl aromatics. In some embodiments, the first hydrocarbon-containing feed may be or contain any C2-C4 alkyl aromatics in the hydrocarbon-containing feed. 16 Alkanes and any C8-C 16 In another embodiment, the first hydrocarbon-containing feed may contain from 0.1 vol.% to 50 vol.% water vapor based on the total volume of alkyl aromatics. ... 16 Alkanes and any C8-C 16 It may contain <0.1 vol.% water vapor, based on the total volume of the alkyl aromatics, or may be free of water vapor.

[0059] C2-C 16The alkane may be or include, but is not limited to, ethane, propane, n-butane, isobutane, n-pentane, isopentane, n-hexane, 2-methylpentane, 3-methylpentane, 2,2-dimethylbutane, n-heptane, 2-methylhexane, 2,2,3-trimethylbutane, cyclopentane, cyclohexane, methylcyclopentane, ethylcyclopentane, n-propylcyclopentane, 1,3-dimethylcyclohexane, or mixtures thereof. For example, the first hydrocarbon-containing feed may include propane, which may be dehydrogenated to produce propylene, and / or isobutane, which may be dehydrogenated to produce isobutylene. In another example, the first hydrocarbon-containing feed may include liquefied petroleum gas (LP gas), which may be in the gas phase upon contact with the catalyst composition. In some embodiments, the first hydrocarbon in the hydrocarbon-containing feed may be substantially composed of a single alkane, such as propane. In some embodiments, the hydrocarbon-containing feed comprises ≥ 50 mol%, ≥ 75 mol%, ≥ 95 mol%, ≥ 98 mol%, or ≥ 99 mol% of a single C-C hydrocarbon, based on the total moles of all hydrocarbons in the first hydrocarbon-containing feed. 16 In some embodiments, the first hydrocarbon-containing feed is at least 50 vol%, at least 55 vol%, at least 60 vol%, at least 65 vol%, at least 70 vol%, at least 75 vol%, at least 80 vol%, at least 85 vol%, at least 90 vol%, at least 95 vol%, at least 97 vol%, or at least 99 vol% of a single C2-C3 hydrocarbon, based on the total volume of the first hydrocarbon-containing feed. 16 It may include alkanes such as propane.

[0060] C8-C 16 The alkyl aromatics may be or include, but are not limited to, ethylbenzene, propylbenzene, butylbenzene, one or more ethyltoluenes, or mixtures thereof. In some embodiments, the hydrocarbon-containing feed is ≧50 mol%, ≧75 mol%, ≧95 mol%, ≧98 mol%, or ≧99 mol% of a single C8-C8 aromatic hydrocarbon, based on the total mass of all hydrocarbons in the first hydrocarbon-containing feed.16 The first upgrading process of the hydrocarbons disclosed herein may include alkyl aromatics such as ethylbenzene. In some embodiments, the ethylbenzene may be dehydrogenated to produce styrene. As a result, in some embodiments, the first upgrading process of the hydrocarbons disclosed herein may include dehydrogenation of propane, dehydrogenation of butane, dehydrogenation of isobutane, dehydrogenation of pentane, dehydrocyclization of pentane to cyclopentadiene, naphtha reforming, dehydrogenation of ethylbenzene, dehydrogenation of ethyltoluene, and the like. In some embodiments, the first hydrocarbon-containing feed may be diluted, for example, with one or more diluents, such as one or more inert gases. Suitable inert gases may be or include, but are not limited to, Ar, Ne, He, N2, CO2, CH4, or mixtures thereof. When the hydrocarbon-containing feed includes a diluent, the hydrocarbon-containing feed may be diluted with any C2-C4 in the hydrocarbon-containing feed. 16 Alkanes and any C8-C 16 It may contain from 0.1 vol%, 0.5 vol%, 1 vol%, or 2 vol% to 3 vol%, 8 vol%, 16 vol%, or 32 vol% of the diluent, based on the total volume of the alkyl aromatics.

[0061] In some embodiments, the first hydrocarbon-containing feed may also contain H2. In some embodiments, when the first hydrocarbon-containing feed contains H2, H2 and any C2-C 16 Alkanes and any C8-C 16 The molar ratio to the total amount of alkyl aromatics can range from 0.1, 0.3, 0.5, 0.7, or 1 to 2, 3, 4, 5, 6, 7, 8, 9, or 10. In some embodiments, the first hydrocarbon-containing feed is substantially free of any water vapor, e.g., any C2-C4 in the hydrocarbon-containing feed. 16 Alkanes and any C8-C 16 There may be <0.1 vol.% water vapor, based on the total volume of alkyl aromatics. In other embodiments, the first hydrocarbon-containing feed may contain water vapor. For example, the first hydrocarbon-containing feed may contain any C2-C4 alkyl aromatics in the first hydrocarbon-containing feed.16 Alkanes and any C8-C 16 The alkyl aromatics may contain from 0.1 vol%, 0.3 vol%, 0.5 vol%, 0.7 vol%, 1 vol%, 3 vol%, or 5 vol% to 10 vol%, 15 vol%, 20 vol%, 25 vol%, 30 vol%, 35 vol%, 40 vol%, 45 vol%, or 50 vol% water vapor based on the total volume of the alkyl aromatics. In other embodiments, the first hydrocarbon-containing feed is a mixture of any C2-C 16 Alkanes and any C8-C 16 Based on the total volume of alkylaromatics, the first hydrocarbon-containing feed may contain ≦50 vol%, ≦45 vol%, ≦40 vol%, ≦35 vol%, ≦30 vol%, ≦25 vol%, ≦20 vol%, or ≦15 vol% water vapor. In other embodiments, the first hydrocarbon-containing feed may contain ≦50 vol%, ≦45 vol%, ≦40 vol%, ≦35 vol%, ≦30 vol%, ≦25 vol%, ≦20 vol%, or ≦15 vol% water vapor. 16 Alkanes and any C8-C 16 Based on the total volume of the alkyl aromatic, it may contain at least 1 vol.%, at least 3 vol.%, at least 5 vol.%, at least 10 vol.%, at least 15 vol.%, at least 20 vol.%, at least 25 vol.%, or at least 30 vol.% water vapor.

[0062] In some embodiments, the first hydrocarbon-containing feed may contain sulfur. For example, the first hydrocarbon-containing feed may contain sulfur in the range of 0.5 ppm, 1 ppm, 5 ppm, 10 ppm, 20 ppm, 30 ppm, 40 ppm, 50 ppm, 60 ppm, 70 ppm, or 80 ppm to 100 ppm, 150 ppm, 200 ppm, 300 ppm, 400 ppm, or 500 ppm. In other embodiments, the first hydrocarbon-containing feed may contain sulfur in the range of 1 ppm to 10 ppm, 10 ppm to 20 ppm, 20 ppm to 50 ppm, 50 ppm to 100 ppm, or 100 ppm to 500 ppm. When sulfur is present in the first hydrocarbon-containing feed, the sulfur may be or include, but is not limited to, H2S, dimethyl disulfide, one or more mercaptans, or mixtures thereof. In some embodiments, the first hydrocarbon-containing feed may be substantially free or completely free of molecular oxygen. In some embodiments, the first hydrocarbon-containing feed may contain ≦5 mol%, ≦3 mol%, or ≦1 mol% molecular oxygen (O2). Providing a first hydrocarbon-containing feed that is substantially free of molecular oxygen is believed to substantially prevent oxidation reactions that would otherwise consume at least a portion of the alkanes and / or alkylaromatics in the first hydrocarbon-containing feed.

[0063] The second upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the upgrading process disclosed in U.S. Patent Application Publication No. 2021 / 0276932. For example, the hydrocarbon upgrading process may include (I) contacting a first hydrocarbon-containing feed with a catalyst composition comprising a Group 8-10 element disposed on a support to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first hydrocarbon-containing feed to produce a coked catalyst composition and an effluent that may include one or more upgraded hydrocarbons and molecular hydrogen. The first hydrocarbon-containing feed may be one or more C2-C 16 Linear or branched alkanes, or one or more C4-C 16 Cyclic alkanes or one or more C8-C 16 The first hydrocarbon-containing feed and the catalyst composition may comprise an alkyl aromatic, an alkyl aromatic, or a mixture thereof. The first hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature in the range of 300° C. to 900° C. for a time period of ≦3 hours under a hydrocarbon partial pressure of at least 20 kPa absolute, where the hydrocarbon partial pressure is at least 20 kPa absolute of any C2-C4 aromatic hydrocarbons in the first hydrocarbon-containing feed. 16 Alkanes and any C8-C 16is the total partial pressure of alkylaromatics. The catalyst composition may comprise 0.001 wt% to 1 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contains no Si or <0.5 wt% Si, where all mass percentages are based on the mass of the support. The one or more upgraded hydrocarbons may comprise at least one of dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, and dehydrogenated cyclized hydrocarbons. The process may also include (II) contacting at least a portion of the coked catalyst composition with an oxidizing agent to cause combustion of at least a portion of the coke to produce a regenerated catalyst composition having less coke and a combustion gas. The process may also include (III) contacting an additional amount of the first hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition to produce a recoked catalyst composition and an additional effluent. The cycle time from contacting the first hydrocarbon-containing feed with the catalyst composition in step (I) to contacting an additional amount of the first hydrocarbon-containing feed with the regenerated catalyst composition in step (III) may be ≦5 hours. In some embodiments, at least a portion of the Group 8-10 elements in the regenerated catalyst may be in a higher oxidation state than the Group 8-10 elements in the catalyst contacted with the first hydrocarbon-containing feed, and the process may further include, after step (II) and before step (III), the following step (IIa): contacting at least a portion of the regenerated catalyst with a reducing gas to produce a regenerated reduced catalyst. In this case, at least a portion of the Group 8-10 elements in the regenerated reduced catalyst are reduced to a lower oxidation state than the Group 8-10 elements in the regenerated catalyst, and an additional amount of the hydrocarbon-containing feed may be contacted with at least a portion of the regenerated reduced catalyst.

[0064] The third upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the upgrading process disclosed in U.S. Patent Application Publication No. 2021 / 0276002. For example, the hydrocarbon upgrading process may include (I) contacting, in a conversion zone, a first hydrocarbon-containing feed with fluidized catalyst particles, which may include Group 8-10 elements disposed on a support, to cause one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first hydrocarbon-containing feed to produce a conversion effluent, which may include coked catalyst particles, one or more upgraded hydrocarbons, and molecular hydrogen. The first hydrocarbon-containing feed may be one or more C2-C 16 Linear or branched alkanes, at least one C4-C 16 Cyclic alkanes, one or more of C8-C 16 The first hydrocarbon-containing feed may comprise any C2-C4 alkyl aromatic hydrocarbons, or mixtures thereof. The first hydrocarbon-containing feed and the fluidized catalyst particles may be contacted at a temperature ranging from 300° C. to 900° C. for a time ranging from 0.1 seconds to 2 minutes under a hydrocarbon partial pressure of at least 20 kPa absolute, where the hydrocarbon partial pressure is at least 20 kPa absolute, and ... 16 Alkanes and any C8-C 16is the total partial pressure of alkyl aromatic hydrocarbons. The catalyst particles may comprise 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contain no Si or <0.5 wt% Si, where all mass percentages are based on the mass of the support. The one or more upgraded hydrocarbons may include dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, dehydrogenated cyclized hydrocarbons, or mixtures thereof. The process may also include (II) obtaining from the conversion effluent a first gas stream rich in the one or more upgraded hydrocarbons and molecular hydrogen, and a first particle stream rich in coked catalyst particles. The process may also include (III) contacting in a combustion zone at least a portion of the coked catalyst particles in the first particle stream with an oxidant to cause combustion of at least a portion of the coke to produce a combustion effluent that may include regenerated catalyst particles low in coke and combustion gases. The process may also include (IV) obtaining a second gas stream rich in combustion gases and a second particulate stream rich in regenerated catalyst particles from the combustion effluent. The process may also include (V) contacting an additional amount of the first hydrocarbon-containing feed with the fluidized regenerated catalyst particles to produce an additional converted effluent comprising recoked catalyst particles, additional one or more upgraded hydrocarbons, and additional molecular hydrogen. In some embodiments, the process may further include, after step (IV) and before step (V), contacting at least a portion of the regenerated catalyst particles with a reducing gas as described below in step (IVa) to produce regenerated and reduced catalyst particles, in which case an additional amount of a hydrocarbon-containing feed may be contacted with the fluidized regenerated and reduced catalyst particles in step (V).

[0065] The fourth upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the first multi-stage upgrading process disclosed in WO 2021 / 225747. For example, the upgrading process may include a multi-stage hydrocarbon upgrading process that may include (I) contacting in a first conversion zone a first hydrocarbon-containing feed with a first catalyst composition that may include a Group 8-10 element disposed on a support to cause one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of a portion of the first hydrocarbon-containing feed to produce a first conversion zone effluent that may include one or more upgraded hydrocarbons, molecular hydrogen, and the first unconverted hydrocarbon-containing feed. The process may also include (II) contacting in a second conversion zone a first conversion zone effluent with a second catalyst composition that may include a Group 8-10 element disposed on a support to cause one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first unconverted hydrocarbon-containing feed to produce a second conversion zone effluent that may include an additional amount of one or more upgraded hydrocarbons and molecular hydrogen. The first hydrocarbon-containing feed is one or more C-C 16 Linear or branched alkanes, at least one C4-C 16 Cyclic alkanes, one or more of C8-C 16 The first hydrocarbon-containing feed and the first catalyst composition may comprise an alkylaromatic hydrocarbon, an alkyl aromatic hydrocarbon, or a mixture thereof. The first hydrocarbon-containing feed and the first catalyst composition may be contacted under a hydrocarbon partial pressure of at least 20 kPa absolute for a time period ranging from 0.1 seconds to 3 hours, wherein the hydrocarbon partial pressure is at least 20 kPa absolute pressure, and ... 16 Alkanes and any C8-C 16 The first conversion zone effluent and the second catalyst composition may be contacted under a hydrocarbon partial pressure of at least 20 kPa absolute for a time period ranging from 0.1 seconds to 3 hours, where the hydrocarbon partial pressure is the total partial pressure of any C2-C alkylaromatic hydrocarbons in the first hydrocarbon-containing feed. 16 Alkanes and any C8-C 16is the total partial pressure of the alkylaromatic hydrocarbons. The first conversion zone effluent may have a temperature in the range of 300°C to 850°C. The second conversion zone effluent may have a temperature in the range of 350°C to 900°C. The temperature of the second conversion zone effluent may be higher than the temperature of the first conversion zone effluent. The first catalyst composition and the second catalyst composition may have the same composition or different compositions. The first catalyst composition and the second catalyst composition each comprise 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contain no Si or <0.5 wt% Si. All mass percentage values ​​herein are based on the mass of the support. The one or more upgraded hydrocarbons may include dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, dehydrogenated cyclized hydrocarbons, or mixtures thereof.

[0066] In some embodiments, at least one of the first catalyst composition and the second catalyst composition may be disposed in a fixed bed. In some embodiments, the first conversion zone and the second conversion zone may be disposed in a fixed bed reactor. In some embodiments, the first conversion zone and the second conversion zone may be disposed in a counter-flow reactor. In some embodiments, at least one of the first catalyst and the second catalyst may be in the form of fluidized catalyst particles. In some embodiments, the first catalyst and the second catalyst may be in the form of fluidized catalyst particles. In some embodiments, the first conversion zone and the second conversion zone may be substantially adiabatic. In some embodiments, the process may further include, after step (I) and before step (II), the following step: (Ia) contacting the first conversion zone effluent with one or more intermediate catalyst compositions, which may include a Group 8-10 element disposed on a support, in one or more intermediate conversion zones to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of a portion of the unconverted hydrocarbon-containing feed in the first conversion zone effluent to produce one or more coked intermediate catalysts and one or more intermediate conversion zone effluents having one or more intermediate temperatures and which may include the unconverted hydrocarbon-containing feed and an additional amount of one or more upgraded hydrocarbons and molecular hydrogen, the final intermediate conversion zone effluent being contacted with a second catalyst in step (II) in a second conversion zone. In some embodiments, when the process includes optional step (Ia), one or more intermediate temperatures of the one or more intermediate conversion zone effluents may be higher than the temperature of the first conversion zone effluent and the temperature of the second conversion zone effluent may be higher than the one or more intermediate temperatures of the one or more intermediate conversion zone effluents.

[0067] In some embodiments, contacting the hydrocarbon-containing feed with the first catalyst can result in a first coking catalyst, contacting the first conversion zone effluent with the second catalyst can result in a second coking catalyst, and the process can further include step (III) which can include contacting the first coking catalyst, the second coking catalyst, or the first coking catalyst and the second coking catalyst with an oxidant to cause combustion of at least a portion of the coke to produce combustion gases and the first regenerated catalyst, the second regenerated catalyst, or the first regenerated catalyst and the second regenerated catalyst. In some embodiments, in step (III), the first coking catalyst particles, the second coking catalyst particles, or the first coking catalyst particles and the second coking catalyst particles can be contacted with the oxidant at a temperature in the range of 580°C to 1,100°C, preferably 650°C to 1,000°C, more preferably 700°C to 900°C, and more preferably 750°C to 850°C. In some embodiments, the process may also include the step of (IV) contacting at least a portion of any of the first regenerated catalyst, at least a portion of any of the second regenerated catalyst, or at least a portion of any of the first regenerated catalyst and at least a portion of any of the second regenerated catalyst with a reduction gas to produce a first regenerated reduction catalyst, a second regenerated reduction catalyst, or a first regenerated reduction catalyst and a second regenerated reduction catalyst.

[0068] The fifth upgrading process of hydrocarbons In other embodiments, the hydrocarbon upgrading process may include the second multi-stage upgrading process disclosed in WO 2021 / 225747. For example, the multi-stage hydrocarbon upgrading process may include (I) contacting, in a first conversion zone, a first hydrocarbon-containing feed with a first plurality of fluidized catalyst particles, which may include a Group 8-10 element disposed on a support, to cause one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of a first portion of the first hydrocarbon-containing feed to produce a first conversion zone effluent, which may include first coked catalyst particles, one or more upgraded hydrocarbons, molecular hydrogen, and the first unconverted hydrocarbon-containing feed. The process may also include (II) contacting, in a second conversion zone, the first conversion zone effluent with a second plurality of fluidized catalyst particles, which may include Pt and a promoter disposed on a support, to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first unconverted hydrocarbon-containing feed to produce a second conversion zone effluent, which may include second coked catalyst particles, an additional amount of upgraded hydrocarbons, and an additional amount of molecular hydrogen. The first hydrocarbon-containing feed may be one or more C2-C 16 Linear or branched alkanes, at least one C4-C 16 Cyclic alkanes, one or more of C8-C 16 The first hydrocarbon-containing feed and the first plurality of fluidized catalyst particles may be contacted for a time period ranging from 0.1 seconds to 2 minutes under a hydrocarbon partial pressure of at least 20 kPa absolute, wherein the hydrocarbon partial pressure is at least 20 kPa absolute of any C2-C4 alkyl aromatic hydrocarbons in the first hydrocarbon-containing feed. 16 Alkanes and any C8-C 16 The first conversion zone effluent and the second plurality of fluidized catalyst particles may be contacted under a hydrocarbon partial pressure of at least 20 kPa absolute for a time period ranging from 0.1 seconds to 2 minutes, wherein the hydrocarbon partial pressure is the total partial pressure of any C2-C alkyl aromatic hydrocarbons in the first conversion zone effluent. 16 Alkanes and any C8-C 16is the total partial pressure of the alkylaromatic hydrocarbons. The first conversion zone effluent may have a temperature in the range of 300°C to 850°C. The second conversion zone effluent may have a temperature in the range of 350°C to 900°C. The temperature of the second conversion zone effluent may be higher than the temperature of the first conversion zone effluent. The first and second plurality of fluidized catalyst particles may each comprise 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and containing no or <0.5 wt% Si. All mass percentages herein are based on the mass of the support. The one or more upgraded hydrocarbons may include dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, dehydrogenated cyclized hydrocarbons, or mixtures thereof. The process may also include (III) obtaining from the second conversion zone effluent a first gas stream rich in upgraded hydrocarbons and molecular hydrogen and a first particulate stream rich in the first coked catalyst particles and the second coked catalyst particles. The process may also include (IV) splitting the first particulate stream into a second particulate stream and a third particulate stream. The process may also include (V) recycling the second particulate stream to the first conversion zone as a first plurality of fluidized particles. The process may also include (VI) contacting the third particulate stream with an oxidant in a combustion zone to cause combustion of at least a portion of the coke to produce a combustion effluent that may include regenerated catalyst particles that are low in coke and combustion gases. The process may also include (VII) obtaining from the combustion effluent a second gas stream rich in combustion gases and a fourth particulate stream rich in regenerated catalyst particles. The process may also include the step of (VIII) recycling the fourth particle stream to the second conversion zone as a second plurality of fluidized catalyst particles.

[0069] In some embodiments, the process may also include, after step (VII) and before step (VIII), a step (VIIa) below of contacting at least a portion of the fourth particle stream with a reducing gas to produce regenerated, reduced catalyst particles, which may be recycled to the second conversion zone as a second plurality of fluidized catalyst particles in step (VIII). In some embodiments, step (IV) may optionally include separating a fifth particle stream from the first particle stream, and the process may optionally include contacting the fourth particle stream with the fifth particle stream to produce a mixed particle stream. In some embodiments, the process may optionally include, after step (I) and prior to step (II), step (Ia) below of contacting the first conversion zone effluent with one or more plurality of intermediate fluid catalyst particles comprising a Group 8-10 element disposed on a support in one or more intermediate conversion zones to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of a portion of the unconverted hydrocarbon-containing feed in the first conversion zone to produce one or more plurality of coked intermediate fluid catalyst particles and one or more intermediate conversion zone effluents which may have one or more intermediate temperatures and may comprise the unconverted hydrocarbon-containing feed and additional amounts of one or more upgraded hydrocarbons and molecular hydrogen, the final intermediate conversion zone effluent may be contacted with a second catalyst in a second conversion zone in step (II).

[0070] The sixth upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the upgrading process disclosed in U.S. Patent Application No. 63 / 062,084. For example, the upgrading process may include: (I) one or more C2-C 16 Linear or branched alkanes, at least one C4-C 16 Cyclic alkanes, one or more of C8-C 16The process may include introducing a first hydrocarbon-containing feed, which may include alkyl aromatics, or a mixture thereof, into the reaction zone. The process may also include (II) contacting the first hydrocarbon-containing feed with a catalyst composition, which may include a Group 8-10 element disposed on a support, disposed within the reaction zone to cause at least one of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the first hydrocarbon-containing feed to produce a coked catalyst composition and a first effluent, which may include one or more upgraded hydrocarbons and molecular hydrogen. The first hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature in the range of 300° C. to 900° C. for a time period of 1 minute to 90 minutes under a hydrocarbon partial pressure of at least 20 kPa absolute, wherein the hydrocarbon partial pressure is less than or equal to any C2-C4 hydrocarbons in the hydrocarbon-containing feed. 16 Alkanes and any C8-C 16is the total partial pressure of alkyl aromatics. The catalyst composition may comprise 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contains no or <0.5 wt% Si, where all mass percentages are based on the mass of the support. The process may also include the steps of (III) stopping the introduction of the first hydrocarbon-containing feed into the reaction zone; (IV) introducing an oxidant into the reaction zone; (V) contacting the oxidant with a coked catalyst composition to cause combustion of at least a portion of the coke to produce a regenerated catalyst composition having less coke and a second effluent comprising combustion gas, wherein the oxidant and the coked catalyst composition are contacted for a time period of 1 minute to 90 minutes; and (VI) stopping the introduction of the oxidant into the reaction zone. The process may also include the steps of (VII) introducing a reducing gas into the reaction zone; (VIII) contacting the reducing gas with a regenerated catalyst composition to produce a regenerated reduced catalyst composition and a third effluent, the reducing gas and the regenerated catalyst composition being contacted for a time period of from 0.1 seconds to 90 minutes; and (IX) ceasing the introduction of the reducing gas into the reaction zone. The process may also include the steps of (X) introducing an additional amount of a first hydrocarbon-containing feed into the reaction zone and (XI) contacting the additional amount of the first hydrocarbon-containing feed with the regenerated reduced catalyst composition to produce a recoked catalyst composition and an additional first effluent. The additional amount of the first hydrocarbon-containing feed and the regenerated reduced catalyst composition may be contacted at a temperature in the range of from 300° C. to 900° C. for a time period of from 1 minute to 90 minutes under a hydrocarbon partial pressure of at least 20 kPa absolute, wherein the hydrocarbon partial pressure is less than or equal to the total hydrocarbon partial pressure of any C2-C ... 16 Alkanes and any C8-C 16 is the total alkyl aromatic partial pressure.

[0071] In some embodiments, the process optionally comprises, after step (III) and before step (IV), a1) introducing a stripping gas into the reaction zone to remove at least a portion of any residual hydrocarbon-containing feed, the first effluent, or both from the reaction zone; (III) a2 ) removing at least a portion of any residual hydrocarbon-containing feed, effluent, or both from the reaction zone by subjecting the reaction zone to a pressure less than atmospheric pressure; or step (III). a1 ) and Step (III a2 In some embodiments, the process may optionally include a combination of the following steps after step (VI) and before step (VII): a1 ) introducing a stripping gas into the reaction zone to remove at least a portion of any residual oxidant, the second effluent, or both from the reaction zone; (VI a2 ) removing at least a portion of any residual oxidant, the second effluent, or both from the reaction zone by subjecting the reaction zone to a pressure less than atmospheric pressure; or step (VI). a1 ) and Step(VI a2 ) combinations. In some embodiments, the process optionally comprises, after step (IX) and before step (X), a1 IX) introducing a stripping gas into the reaction zone to remove at least a portion of any residual reducing gas, the third effluent, or both from the reaction zone; a2 ) removing at least a portion of any residual reducing gas, the third effluent, or both from the reaction zone by subjecting the reaction zone to a pressure less than atmospheric pressure; or step (IX). a1 ) and Step (IX a2In some embodiments, step (IV) of the process may include introducing a fuel into the reaction zone, optionally with an oxidant; and combusting at least a portion of the fuel in the reaction zone to generate heat for heating the reaction zone to a temperature of ≧580° C., ≧620° C., ≧650° C., ≧680° C., ≧710° C., ≧740° C., ≧770° C., ≧800° C., ≧850° C., ≧900° C., or ≧1,000° C.

[0072] The seventh upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the upgrading process disclosed in U.S. Patent Application Serial No. 63 / 195,966. For example, the process may include the steps of: (I) contacting a first hydrocarbon-containing feed with a catalyst composition that may include a Group 8-10 element disposed on a support to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the hydrocarbon-containing feed to produce an at least partially deactivated catalyst composition that may include a Group 8-10 element and contaminants disposed on a support, and an effluent that may include one or more upgraded hydrocarbons and molecular hydrogen. The first hydrocarbon-containing feed may include one or more C2-C 16 Linear or branched alkanes, or one or more C4-C 16 Cyclic alkanes, one or more of C8-C 16The catalyst composition may comprise 0.001 wt% to 6 wt% of Group 8-10 elements disposed on a support comprising Al and at least 0.5 wt% of Group 2 elements, and contains no or <0.5 wt% Si, where all weight percentages are based on the weight of the support. The first hydrocarbon-containing feed and the catalyst composition may be contacted at a temperature ranging from 300° C. to 900° C. The one or more upgraded hydrocarbons may include at least one of dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, and dehydrogenated cyclized hydrocarbons. The process may also include (II) heating the at least partially deactivated catalyst composition with a heated gas mixture that may include H2O at a concentration greater than 5 mole % based on the total moles of the heated gas mixture to produce a precursor catalyst composition. The process may also include (III) providing an oxidizing gas that may include 5 mole % or less H2O based on the total moles of the heated gas mixture. The process may also include (IV) contacting the precursor catalyst composition with an oxidizing gas at an oxidation temperature in the range of 620° C. to 1,000° C. for a duration of at least 30 seconds to produce an oxidized precursor catalyst composition. The process may also include (V) obtaining a regenerated catalyst composition from the oxidized precursor catalyst composition. The process may also include (VI) contacting an additional amount of the first hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition to produce an additional at least partially deactivated catalyst composition and an additional effluent. In some embodiments, the heated gas mixture may be produced by combusting a fuel with an oxidizing gas. In some embodiments, the fuel may include at least one of H2, CO, and a hydrocarbon, and the oxidizing gas may include O2. In some embodiments, the oxidizing gas may be or include, but is not limited to, O2, O3, CO2, or a mixture thereof, and may include 5 mole % or less of H2O.

[0073] The eighth upgrading process of hydrocarbons In some embodiments, the hydrocarbon upgrading process may include the upgrading process disclosed in U.S. Patent Application No. 63 / 232,959. For example, the hydrocarbon upgrading process may include (I) contacting in a conversion zone a first hydrocarbon-containing feed with fluidized dehydrogenation catalyst particles that may include Group 8-10 elements disposed on a support to cause dehydrogenation of at least a portion of the hydrocarbon-containing feed to produce a conversion effluent that may include coked catalyst particles and one or more dehydrogenated hydrocarbons. The fluidized dehydrogenation catalyst particles may include 0.001 wt% to 6 wt% Group 8-10 elements disposed on a support that includes Al and at least 0.5 wt% Group 2 elements, and contains no Si or <0.5 wt% Si. All mass percentages are based on the mass of the support. The first hydrocarbon-containing feed may include one or more C2-C 16 Linear or branched alkanes, at least one C4-C 16 Cyclic alkanes, one or more of C8-C 16 The first hydrocarbon-containing feed may comprise any C2-C alkyl aromatic hydrocarbons, alkyl aromatic hydrocarbons, or mixtures thereof. 16 Alkanes and any C8-C 16 Based on the mass of aromatic hydrocarbons, 0.1 hours -1 ~1,000 hours -1 The fluidized dehydrogenation catalyst particles may be contacted with any of the C2-C 16 Alkanes and any C8-C 16The mass ratio of the first hydrocarbon-containing feed to the total amount of aromatic hydrocarbons may range from 3 to 100. The first hydrocarbon-containing feed and the catalyst particles may be contacted at a temperature ranging from 600° C. to 750° C. The process may also include (II) separating from the conversion effluent a first particulate stream rich in the coked catalyst particles and a first gas stream rich in the one or more dehydrogenated hydrocarbons. The process may also include (III) contacting in a combustion zone at least a portion of the coked catalyst particles in the first particulate stream with an oxidant and a fuel to cause combustion of at least a portion of the coke to produce a combustion effluent that may include the coke-reduced catalyst particles and combustion gases. The dehydrogenation activity of the coke-reduced catalyst particles may be lower than the dehydrogenation activity of the coked catalyst particles. The process may also include (IV) separating from the combustion effluent a second particulate stream rich in the coke-reduced catalyst particles and a second gas stream rich in combustion gases. The process may also include (V) contacting at least a portion of the low-coke catalyst particles in the second particle stream with an oxidizing gas in an oxygen soak zone at an oxidation temperature in the range of 620° C. to 1,000° C. for a duration of at least 30 seconds to produce conditioned catalyst particles having an activity that may be lower than the coked catalyst particles. The process may also include (VI) contacting at least a portion of the conditioned catalyst particles with a reducing gas in a reduction zone to produce regenerated catalyst particles having a dehydrogenation activity that may be higher than the coked catalyst particles. The process may also include (VII) contacting an additional amount of a hydrocarbon-containing feed with at least a portion of the regenerated catalyst particles in a conversion zone to produce an additional amount of a converted effluent that may include recoked catalyst particles and an additional amount of one or more dehydrogenated hydrocarbons. The process may also include (VIII) cooling the first gas stream to produce a cooled gas stream. The process may also include (IX) compressing at least a portion of the cooled gas stream to produce a compressed gas stream. The process may also include the step of (X) separating a plurality of products from the compressed gas stream.

[0074] In some embodiments, the first gas stream rich in one or more dehydrogenated hydrocarbons may further comprise entrained coking catalyst particles. In such embodiments, step (VIII) may include (VIIIa) contacting the first gas stream with a first quenching medium, or indirectly transferring heat from the first gas stream to a first heat transfer medium, or a combination thereof, to generate a cooling gas stream, and (VIIIb) contacting the cooling gas stream with a second quenching medium in a quenching tower, (VIIIc) recovering from the quenching tower a third gas stream that may comprise one or more dehydrogenated hydrocarbons and a slurry stream that may comprise at least a portion of the second quenching medium and entrained coking catalyst particles in the liquid phase, and step (IX) may include compressing at least a portion of the third gas stream to generate a compressed gas stream. In some embodiments, the conversion effluent may further comprise benzene, and the process may further include (XI) withdrawing a benzene product stream from the quenching tower.

[0075] The ninth upgrading process of hydrocarbons In some embodiments, the alkane and / or alkylaromatic hydrocarbon upgrading process may include the process disclosed in U.S. Patent Application Serial No. 63 / 231,939. For example, the hydrocarbon upgrading process may include (I) contacting in a conversion zone a first hydrocarbon-containing feed with fluidized dehydrogenation catalyst particles that may include 0.001 wt% to 6 wt% of a Group 8-10 element disposed on a support to cause dehydrogenation of at least a portion of the first hydrocarbon-containing feed to produce a conversion effluent that may include coked catalyst particles and one or more dehydrogenated hydrocarbons. The fluidized dehydrogenation catalyst particles may include contaminants and 0.001 wt% to 6 wt% of a Group 8-10 element disposed on a support that includes Al and at least 0.5 wt% of a Group 2 element, and contains no Si or <0.5 wt% Si. All mass percentages herein are based on the mass of the support. The process may also include (II) separating from the conversion effluent a first stream rich in coking catalyst particles and depleted in one or more dehydrogenated hydrocarbons and a second stream rich in one or more dehydrogenated hydrocarbons and containing entrained coking catalyst particles. The process may also include (III) contacting the second stream with a first quench medium to produce a second quenched stream. The process may also include (IV) contacting the second quenched stream with a second quench medium in a quench tower. The process may also include (V) recovering from the quench tower a gas stream that may contain one or more dehydrogenated hydrocarbons, the first concentrated quench medium stream, and a slurry stream that may contain at least a portion of the second quench medium and entrained coking catalyst particles in a liquid phase. The process may also include (VI) recycling at least a portion of the first concentrated quench medium to step (III). The process may also include (VII) separating at least a portion of the entrained coked catalyst particles from the slurry stream to provide a second recovered quench medium stream and a recovered entrained coked catalyst particle stream. The process may also include (VIII) recycling at least a portion of the second recovered quench medium stream to step (IV).

[0076] In some embodiments, the process may also include the steps of: (IX) contacting at least a portion of the coked catalyst particles in the first stream and at least a portion of the coked catalyst particles in the recovered entrained catalyst particle stream with an oxidant and optionally a fuel in a combustion zone to cause combustion of the coke and at least a portion of the fuel, if present, to produce a combustion effluent that may include regenerated catalyst particles having less coke and combustion gas; (X) separating the combustion gas stream and the regenerated catalyst particle stream; and (XI) contacting an additional amount of the first hydrocarbon-containing feed with the fluidized regenerated catalyst particles from the regenerated catalyst particle stream to produce an additional converted effluent that includes recoked catalyst particles and additional one or more dehydrogenated hydrocarbons. In some embodiments, the process may optionally further include (XII) transporting at least a portion of the recovered entrained catalyst particle stream to a metals reclamation facility; and (XIII) recovering at least a portion of the Group 8-10 elements from the coked catalyst particles in the recovered entrained coked catalyst particle stream. In some embodiments, the process may further include (XIV) cooling the slurry stream prior to step (VII) to produce a cooled slurry stream. In some embodiments, the conversion effluent may include benzene, and the process may further include (XV) removing a benzene product stream from the quench tower.

[0077] The 10th upgrading process of hydrocarbons In some embodiments, the alkane upgrading process may include the process disclosed in U.S. Patent Application No. 63 / 222,733. For example, the alkane dehydrogenation process may include introducing a first hydrocarbon-containing feed comprising one or more alkanes, e.g., propane, into a reactor that may include a catalyst composition that may include a Group 8-10 element disposed on a support disposed therein. The catalyst composition may include contaminants and 0.001 wt% to 6 wt% of a Group 8-10 element disposed on a support comprising Al and at least 0.5 wt% of a second element, and contains no Si or <0.5 wt% Si, where all percentages are based on the weight of the support. The process may also include contacting the first hydrocarbon-containing feed with the catalyst composition in the reactor to form a high temperature dehydrogenation product, the high temperature dehydrogenation product comprising at least a portion of the catalyst composition. The process may also include separating at least a portion of the catalyst composition from the hot dehydrogenation product in a primary separation unit and a secondary separation unit downstream of and in fluid communication with the primary separation unit. The process may also include combining the hot dehydrogenation product after it exits the secondary separation unit with a quench stream to cool the hot dehydrogenation product to form an intermediate temperature dehydrogenation product, the quench stream comprising hydrocarbons. The process may also include cooling the intermediate temperature dehydrogenation product to form a cooled dehydrogenation product.

[0078] In some embodiments, the quench stream comprises liquid hydrocarbons and the intermediate temperature product may be entirely in the gas phase. In some embodiments, mixing of the high temperature dehydrogenation product with the quench stream may occur in the plenum section of the reactor. In some embodiments, the process may further comprise further cooling the cooled dehydrogenation product downstream of the reactor in a heat exchanger or a secondary quench stream, which may comprise at least a portion of the cooled dehydrogenation product after being further cooled by the heat exchanger or the secondary quench stream. It should be understood that the second through tenth hydrocarbon upgrading processes may include the same or similar process conditions, such as operating temperatures, pressures, time intervals for particular steps, WHSV, etc., as described for the first hydrocarbon upgrading process, as would be apparent to one skilled in the art.

[0079] Recovery and use of first upgraded hydrocarbons In some embodiments, the first upgraded hydrocarbons produced via any one of the first to tenth hydrocarbon upgrading processes may include at least one upgraded hydrocarbon, such as olefins, water, unreacted hydrocarbons, molecular hydrogen, etc. The first upgraded hydrocarbons may be recovered or otherwise obtained via any conventional process, for example, by one or more conventional processes. One such process may include cooling and / or compressing the effluent to concentrate at least a portion of any water and any heavy hydrocarbons that may be present, leaving the olefins and any unreacted alkane or alkyl aromatic hydrocarbons primarily in the gas phase. The olefins and unreacted alkane or alkyl aromatic hydrocarbons may then be removed from the reaction product in one or more separator drums. For example, one or more splitters or distillation columns may be used to separate the dehydrogenation product from the unreacted first hydrocarbon-containing feed. In some embodiments, the recovered olefins, e.g., propylene, can be used to produce polymers, e.g., the recovered propylene can be polymerized to produce polymers having segments or units derived from the recovered propylene, e.g., polypropylene, ethylene-propylene copolymers, etc. The recovered isobutene can be used, for example, to produce one or more of the following: oxygenates, e.g., methyl tert-butyl ether, fuel additives, e.g., diisobutene, synthetic elastomeric polymers, e.g., butyl rubber, etc.

[0080] Catalyst Regeneration Process In some embodiments, the regeneration process of the catalyst composition may include the regeneration process disclosed in U.S. Patent Application No. 63 / 195,966. For example, a regeneration process usable to regenerate an at least partially deactivated catalyst composition that may include contaminants and a Group 8-10 element disposed on a support that includes Al and at least 0.5 wt% of a Group 2 element, and that contains no Si or <0.5 wt% Si, where all mass percentages are based on the mass of the support. In some embodiments, the contaminants may be or include coke. The process may include (I) heating the at least partially deactivated catalyst composition with a heated gas mixture that may include H2O at a concentration greater than 5 mole % based on the total moles of the heated gas mixture to produce a precursor catalyst composition. The process may also include (II) providing an oxidizing gas that may include 5 mole % or less H2O based on the total moles of the heated gas mixture. The process may also include (III) contacting the precursor catalyst composition with an oxidizing gas at an oxidation temperature in the range of 620° C. to 1,000° C. for a duration of at least 30 seconds, preferably at least 1 minute, preferably at least 5 minutes to produce an oxidized precursor catalyst composition. The process may also include (IV) obtaining a regenerated catalyst composition from the oxidized precursor catalyst composition. In some embodiments, the heated gas mixture may be produced by combusting a fuel with an oxidizing gas. In some embodiments, the fuel may include at least one of H2, CO, and a hydrocarbon, and the oxidizing gas may include O2. In some embodiments, the oxidizing gas may be or include, but is not limited to, O2, O3, CO2, or mixtures thereof, and may include 5 mole % or less of H2O.

[0081] 11th upgrading process of hydrocarbons The eleventh upgrading process of hydrocarbons may include contacting a hydrocarbon-containing feed (second hydrocarbon-containing feed) with a catalyst composition comprising a group 8-10 element disposed on a support to cause at least a portion of the second hydrocarbon-containing feed to be reformed to produce a coked catalyst composition and an effluent that may include carbon monoxide and molecular hydrogen. The catalyst composition may comprise 0.001 wt% to 6 wt% of a group 8-10 element disposed on a support comprising Al and at least 0.5 wt% of a group 2 element, and contains no Si or <0.5 wt% Si, where all mass percentages are based on the mass of the support. The catalyst composition and the second hydrocarbon-containing feed may be contacted with each other in any suitable environment, such as one or more reaction zones or conversion zones disposed in one or more reactors to produce an effluent and a coked catalyst composition. The reaction zone or conversion zone may be disposed or otherwise located in one or more fixed bed reactors, one or more fluidized or moving bed reactors, one or more countercurrent reactors, or any combination thereof. For clarity and ease of explanation, the reforming reaction will be discussed in the context of a fluidized bed reactor, however, it should be understood that a fixed bed reactor, an upflow or moving bed reactor, or any other reactor may be used to carry out the reforming of the second hydrocarbon-containing feed.

[0082] Reforming reactions can be used to produce reformed hydrocarbons by continuous or discontinuous reaction processes. In some embodiments, the reaction process can include a reforming step and a regeneration step, e.g., an exothermic reaction, which operate continuously while a fluid catalyst composition is transported between the reforming zone and the regeneration zone of the reactor. The endothermic reaction can include hydrocarbon reforming in the presence of the catalyst composition. Unused hydrocarbons and regenerated fluid catalyst particles can enter the reforming zone. After spending some time in the reforming zone, the hydrocarbons are at least partially converted to reformed products, which can exit the reforming zone together with the spent catalyst composition. The reformed products and unreacted feed can be separated from the spent catalyst by one or more separation devices. The reformed products and unreacted feed from the separation devices can proceed downstream for further purification, while the spent catalyst can be sent to the regeneration zone for regeneration. The exothermic regeneration reaction can be the reaction of an oxidant and optionally a fuel under combustion conditions to produce a regenerated catalyst and flue gas. After regeneration, the regenerated catalyst may be separated from the flue gas by one or more separators and transported back to the reforming zone to join with additional hydrocarbon feed and enter the reforming zone for further reforming reactions. The reforming step may convert CO2 and / or H2O and hydrocarbons, e.g., CH4, to synthesis gas containing H2 and CO. The regeneration step may burn reactants, e.g., coke and / or optional fuel and oxidant disposed on the spent catalyst, to generate heat to heat the regenerated catalyst, which may provide usable heat to drive the reforming reactions. In some embodiments, the catalyst may be heated to an average temperature ranging from 600°C, 700°C, or 800°C to 1,000°C, 1,300°C, or 1,600°C during the regeneration step.

[0083] Illustrative fuels may be or include, but are not limited to, hydrocarbons such as methane, ethane, propane, butane, pentane, or water vapor-containing hydrocarbons such as natural gas, molecular hydrogen, and / or other combustible compounds. The oxidant may be or include O2. In some embodiments, the oxidant may be or include air, O2-enriched air, O2-depleted air, or any other suitable O2-containing stream. Regeneration of the catalyst may correspond to the removal of coke from the catalyst particles. In some embodiments, a portion of the feed introduced into the reforming zone during reforming may form coke. This coke may block access to catalytic sites (e.g., metal sites) of the catalyst. During regeneration, at least a portion of the coke generated during reforming may be removed as CO or CO2. Regeneration of the catalyst may also correspond to the redispersion of any agglomerated active phases of the catalyst, such as Group 8-10 elements.

[0084] The second hydrocarbon-containing feed may include, but is not limited to, one or more reformable C1-C 16The second hydrocarbon-containing stream may be or include a hydrocarbon, such as an alkane, an alkene, a cycloalkane, an alkyl aromatic, or any mixture thereof. In some embodiments, the second hydrocarbon-containing stream may be or include methane, ethane, propane, butane, pentane, or a mixture thereof. In some embodiments, the second hydrocarbon-containing feed may be exposed to the catalyst composition under a pressure of less than 35 kPa-a. For example, the second hydrocarbon-containing feed may be exposed to the catalyst composition under a pressure ranging from 0.7 kPa-a, 2 kPa-a, 3.5 kPa-a, 5 kPa-a, or 10 kPa-a to 15 kPa-a, 20 kPa-a, 25 kPa-a, or 30 kPa-a. In other embodiments, the second hydrocarbon-containing feed may be exposed to the catalyst composition under a pressure ranging from 35 kPa-a to 15 MPa-a. In yet other embodiments, the second hydrocarbon-containing feed may be exposed to the catalyst composition under pressures ranging from 0.7 kPa-a, 2 kPa-a, 5 kPa-a, 20 kPa-a, 35 kPa-a, 50 kPa-a, or 100 kPa-a to 200 kPa-a, 1 MPa-a, 3 MPa-a, 5 MPa-a, 10 MPa-a, or 15 MPa-a. In yet other embodiments, the second hydrocarbon-containing feed may be exposed to the catalyst composition under pressures less than 2.8 MPa-a, less than 2.5 MPa-a, less than 2.2 MPa-a, or less than 2 MPa-a.

[0085] The reforming reaction of a second hydrocarbon-containing feed, e.g., CH4, can occur in the presence of HO (steam reforming), in the presence of CO2 (dry reforming), or in the presence of both HO and CO2 (dual reforming). Example stoichiometries for steam reforming, dry reforming, and dual reforming of CH4 are shown in Equations (1)-(3). (1) Dry reforming: CH4 + CO2 = 2CO + 2H2 (2) Steam reforming: CH4 + H2O = CO + 3H2 (3) Double reforming: 3CH4+2H2O+CO2=4CO+8H2 As shown in equations (1)-(3), dry reforming can result in a lower H2 to CO ratio than steam reforming. A reforming reaction carried out only with steam can produce a syngas having a H2:CO molar ratio of typically about 3, e.g., 2.5-3.5. In contrast, a reforming reaction carried out only with CO2 can produce a syngas having a H2:CO molar ratio of typically about 1 or even less than 1. By using a combination of CO2 and H2O during reforming, the reforming reaction can be controlled to produce a wide variety of H2 to CO ratios in the resulting syngas.

[0086] The reforming reaction of the second hydrocarbon-containing feed may be carried out in the presence of O2 or may be carried out partially in the presence of O2, which is often referred to as a partial oxidation reaction. Examples of partial and complete oxidation stoichiometries are shown in equations (4) and (5). (4) Partial oxidation: CH4+0.5O2=CO+2H2 (5) Complete oxidation: CH4 + 2O2 = CO2 + 2H2O During the partial oxidation of methane, some degree of complete oxidation of methane may be unavoidable, in which the CO2 and H2O produced during the complete oxidation of methane may further reform methane via one or more of reactions (1) to (3). It should be noted that the ratio of H2 to CO in the syngas may also depend on the water-gas shift equilibrium. Although the stoichiometries of equations (1)-(4) indicate a ratio of approximately 1-3, the equilibrium amounts of H2 and CO in the syngas may differ from the reaction stoichiometry. The equilibrium amounts can be determined based on the water-gas shift equilibrium, which relates the concentrations of H2, CO, CO2, and HO based on the reaction shown in equation (6). [ka]

[0087] In some embodiments, the catalyst composition may also serve as a water-gas shift catalyst. Thus, if the reaction environment for producing H2 and CO also includes HO and / or CO2, the initial stoichiometry from the reforming reaction may change based on the water-gas shift equilibrium. However, this equilibrium is also temperature dependent at higher temperatures that favor the production of CO and HO. As a result, the ratio of H2 to CO resulting in the formation of syngas is constrained by the water-gas shift equilibrium at the temperature in the reaction zone during syngas production. The ability to adjust the H2:CO molar ratio of the syngas provides a flexible process that can be used with a wide variety of syngas upgrading processes. Illustrative syngas upgrading processes can include, but are not limited to, Fischer-Tropsch processes, synthesis of methanol and / or other alcohols, e.g., one or more C1-C4 alcohols, fermentation processes, separation processes in which hydrogen can be separated to produce H2-rich products, dimethyl ether, and combinations thereof. These syngas upgrading processes are well known to those skilled in the art. In some embodiments, the upgraded products can include, but are not limited to, methanol, synthetic crude, diesel, lubricants, wax, olefins, dimethyl ether, other chemicals, or any combination thereof.

[0088] Suitable systems for carrying out the reforming of the second hydrocarbon-containing feed include systems known in the art, such as fixed bed reactors as disclosed in International Publication No. WO2017078894; U.S. Patent Nos. 3,888,762; 7,102,050; 7,195,741; 7,122,160; and 8,653,317; and U.S. Patent Application Publication Nos. 2004 / 0082824; 2008 / 0194891. and 10,160,708; and U.S. Patent Application Publication Nos. 2015 / 0065767 and 2017 / 0137285; and International Publication No. WO2013169461.

[0089] Feed and Energy The hydrocarbon-containing feeds described herein may be derived from either fossil fuels or non-fossil fuel sources. For example, propane may be a product or by-product of a process that uses biomass as a feed. The fuels described herein may also be derived from either fossil fuels or non-fossil fuel sources. For example, methane or H2 may be a product or by-product of a process that uses biomass as a feed. The fuels described herein may also be made from renewable energy, such as renewable electricity. For example, renewable electricity may be used to produce H2 by water electrolysis. The energy used in the processes described herein may also be provided directly by renewable electricity instead of fuel through an electric furnace. EXAMPLES

[0090] Working Example: The foregoing discussion can be further illustrated with reference to the following non-limiting examples: Catalyst compositions 1-5 were prepared according to the following procedures. Catalyst Composition 1-Al(OH)3 (SPACERITE® S-11) and calcined Mg-Al hydrotalcite (PURALOX® MG70 / 170) were mixed in deionized water to form a slurry. The slurry was milled and spray dried in a BUCHI® B-290 Mini Spray Dryer to produce spray-dried particles. The spray-dried particles were calcined in air at 550°C for 4 hours to produce calcined support particles containing nominally 50 wt% PURALOX® MG70 / 170 and 50 wt% Al2O3 derived from SPACERITE® S-11. An aqueous solution containing tin(IV) chloride pentahydrate, chloroplatinic acid hexahydrate, and deionized water was impregnated into the calcined support particles by incipient wetness impregnation. The impregnated material was equilibrated at room temperature in a closed vessel for 120 hours, then dried in air at 110° C. for 6 hours and calcined in air at 800° C. for 12 hours. The final product contained nominally 0.3 wt % Pt and 1.5 wt % Sn based on the weight of the support particles.

[0091] Catalyst Composition 2 - Colloidal SiO2 (LUDOX® AS-40) (50 g) and calcined Mg-Al hydrotalcite (PURALOX® MG70 / 170) (22 g) were mixed in deionized water (236 ml) to form a slurry. The slurry was milled and spray dried in a BUCHI® B-290 Mini Spray Dryer to produce spray-dried particles. The spray-dried particles were calcined in air at 550°C for 4 hours to produce calcined support particles containing nominally 50 wt% PURALOX® MG70 / 170 and 50 wt% SiO2 derived from LUDOX® AS-40. An aqueous solution containing tin(IV) chloride pentahydrate, chloroplatinic acid hexahydrate, and deionized water was impregnated into the calcined support particles by incipient wetness impregnation. The impregnated material was equilibrated at room temperature in a closed vessel for 120 hours, then dried in air at 110° C. for 6 hours and calcined in air at 800° C. for 12 hours. The final product contained nominally 0.3 wt % Pt and 1.5 wt % Sn based on the weight of the support particles.

[0092] Catalyst composition 3 - A 2 / 1 (wt / wt) Mg / Si mixed metal oxide was prepared in an agate ball mill cup by adding MgO (8.04 g) (Acros), SiO2 (4.03 g) (Sigma-Aldrich), deionized water (10 g) and three agate balls. The material was ball milled at 500 rpm for 70 hours. The lid was closed during ball milling to reduce water evaporation. After ball milling, a thick paste was obtained. The paste was calcined at 200 °C for 4 hours and then at 800 °C for 4 hours, all in air, to obtain the support. In a glass vial, chloroplatinic acid hexahydrate (0.0296 g) (Sigma Aldrich) and tin(IV) chloride pentahydrate (0.0365 g) (Sigma Aldrich) were dissolved in deionized water (1.4319 g) to obtain a clear dark orange solution (Pt / Sn solution). To a 50 mL plastic bottle was added 2 / 1 Mg / Si mixed metal oxide support (2.8178 g), followed by dropwise addition of Pt / Sn solution (1.2704 g). The material was mixed using a small lab shaker until a homogenous light orange powder was obtained. The metal-impregnated catalyst was dried in air at 120° C. for 4 hours and then calcined at 800° C. for 12 hours. The final product contained nominally 0.33 wt % Pt and 0.33 wt % Sn based on the weight of the support. Without wishing to be bound by theory, it is believed that some of the Mg and Si were mixed on the atomic scale, i.e., some of the Mg and Si were in the form of mixed Mg / Si metal oxides, and some of the Mg and some of the Si were mixed on the nm scale.

[0093] Catalyst composition 4 - A slurry was prepared containing 40 wt% aluminum chlorohydrol solution (ACH) (42 g), calcined Mg-Al hydrotalcite (PURALOX® MG70 / 170) (97 g), tin(II) chloride dehydrate (3 g), and 3.1 wt% tetraammineplatinum(II) nitrate solution (10 g) in deionized water (592 ml). The slurry was milled and spray dried in a BUCHI® B-290 Mini Spray Dryer to produce spray-dried particles. The spray-dried particles were calcined at 800°C in air for 12 hours to produce a catalyst composition containing nominally 0.3 wt% Pt and 1.5 wt% Sn on 90:10 MG70 / 170:Al2O3.

[0094] Catalyst Composition 5 - Catalyst Composition 4 was impregnated with an aqueous solution of tetramethylammonium silicate. The impregnated material was equilibrated in a closed vessel at room temperature for 24 hours, then dried in air at 110°C for 6 hours and calcined in air at 800°C for 12 hours. The final product contained nominally 0.3 wt% Pt, 0.45 wt% Si, and 1.5 wt% Sn.

[0095] Examples using the above catalyst compositions 1 to 5 Fixed bed catalytic experiments were carried out with catalyst compositions 1-5 at approximately 100 kPa absolute pressure. The reactor effluent composition was measured using a gas chromatograph (GC). The concentrations of each component in the reactor effluent were then used to calculate the C3H6 yield and selectivity. The C3H6 yields and selectivities reported in these examples were calculated on a moles of carbon basis. In each example, 0.3 g of catalyst was mixed with an appropriate amount of quartz diluent and loaded into a quartz reactor. The amount of diluent was determined so that the catalyst bed (catalyst + diluent) overlapped with the isothermal zone of the quartz reactor and the catalyst bed was mostly isothermal during operation. Quartz chips / rods filled the dead volume of the reactor.

[0096] The process steps using catalyst compositions 1 and 2 were as follows: 1. The system was flushed with inert gas. 2. Dry air was passed through the bypass of the reaction zone at a flow rate of 83.9 sccm while passing the inert gas through the reaction zone. The reaction zone was heated to a regeneration temperature of 800°C. 3. Dry air was then passed through the reaction zone at a flow rate of 83.9 sccm for 10 minutes to regenerate the catalyst. 4. The system was flushed with inert gas. 5. While passing the inert gas through the reaction zone, H2-containing gas having 10 vol% H2 and 90 vol% Ar was passed through the bypass of the reaction zone at a flow rate of 46.6 sccm for a specific time. After this, the H2-containing gas was passed through the reaction zone at 800°C for 3 seconds. 6. The system was flushed with inert gas. During this process, the temperature of the reaction zone was changed from 800°C to the reaction temperature of 670°C. 7. While passing inert gas through the reaction zone, a hydrocarbon-containing (HC gas) feed containing 81 vol% C3H8, 9 vol% inert gas (Ar or Kr) and 10 vol% water vapor was passed through the bypass of the reaction zone at a flow rate of 17.6 sccm for a specified time. The hydrocarbon-containing feed was then passed through the reaction zone at 670°C for 10 minutes. GC sampling of the reaction effluent was started as soon as the feed was switched from the reaction zone bypass to the reaction zone. The above process steps were repeated periodically.

[0097] Figures 1-3 of the present application show the C3H6 yield and C3H6 selectivity as a function of time for various catalyst compositions. Thus, in Figures 1, 2, and 3, the horizontal axis is time in hours, and the vertical axis is C3H6 yield (lower set of data shown as filled squares) and C3H6 selectivity (upper set of data shown as filled circles) in mole % carbon. 1 and 2 show the C3H6 yield and C3H6 selectivity, respectively, of catalyst compositions 1 and 2. Catalyst composition 2, which contained 50 wt% SiO2, deactivated rapidly with increasing cycle number, while catalyst composition 1, which did not contain any SiO2, did not deactivate.

[0098] The process steps using catalyst composition 3 were as follows: 1. The system was flushed with inert gas. 2. Dry air was passed through the bypass of the reaction zone at a flow rate of 83.9 sccm while passing the inert gas through the reaction zone. The reaction zone was heated to a regeneration temperature of 800°C. 3. Dry air was then passed through the reaction zone at a flow rate of 83.9 sccm for 15 minutes to regenerate the catalyst. 4. The system was flushed with inert gas while cooling to 620°C. 5. An H2-containing gas having 10 vol% H2 and 90 vol% Ar was passed through the bypass of the reaction zone at a flow rate of 46.6 sccm for a specified time while passing the inert gas through the reaction zone. After this, the H2-containing gas was passed through the reaction zone at 620°C for 60 seconds. 6. The system was flushed with inert gas. 7. While passing inert gas through the reaction zone, a hydrocarbon-containing (HC gas) feed containing 81 vol% C3H8, 9 vol% inert gas (Ar or Kr) and 10 vol% water vapor was passed through the bypass of the reaction zone at a flow rate of 17.6 sccm for a specified time. The hydrocarbon-containing feed was then passed through the reaction zone at 620°C for 10 minutes. GC sampling of the reaction effluent was started as soon as the feed was switched from the reaction zone bypass to the reaction zone. The above process steps were repeated periodically.

[0099] Figure 3 shows the C3H6 yield and selectivity of catalyst composition 3 (x-axis, time in hours; y-axis, mole % carbon; the top set of data points is C3H6 selectivity; the bottom set of data points is C3H6 yield). Figures 1-3 show that Si causes catalyst deactivation only when Al is present.

[0100] The process steps using catalyst compositions 4 and 5 were as follows: 1. The system was flushed with inert gas. 2. A 90% air, 10% H2O mixture was passed through the bypass of the reaction zone at a flow rate of 93.2 sccm while passing the inert gas through the reaction zone. The reaction zone was heated to a regeneration temperature of 800°C. 3. A 90% air, 10% H2O mixture was then passed through the reaction zone at a flow rate of 93.2 sccm for 1 minute, followed by dry air at a flow rate of 83.9 sccm through the reaction zone for an additional 10 minutes to regenerate the catalyst. 4. The system was flushed with inert gas. 5. While passing the inert gas through the reaction zone, a H2-containing gas having 10 vol% H2 and 90 vol% Ar was passed through the bypass of the reaction zone at a flow rate of 46.6 sccm for a specified time. This was followed by passing the H2-containing gas through the reaction zone at 800°C for 3 seconds. 6. The system was flushed with inert gas. During this process, the temperature of the reaction zone was changed from 800°C to the reaction temperature of 655°C. 7. While passing the inert gas through the reaction zone, a hydrocarbon-containing (HC gas) feed containing 81 vol% C3H8, 9 vol% inert gas (Ar or Kr) and 10 vol% water vapor was passed through the bypass of the reaction zone at a flow rate of 17.6 sccm for a specific time. The hydrocarbon-containing feed was then passed through the reaction zone at 655°C for 10 minutes. GC sampling of the reaction effluent was started as soon as the feed was switched from the reaction zone bypass to the reaction zone. The above process steps were repeated periodically.

[0101] 4 shows the average CH yield for each cycle plotted against cycle number for catalyst compositions 4 and 5, respectively (filled circle data points are average CH yield for catalyst composition 4; filled square data points are average CH yield for catalyst composition 5). Catalyst composition 5, which contained 0.45 wt % Si, deactivated with increasing cycle number, while catalyst composition 4, which did not contain any Si, did not deactivate.

[0102] LIST OF EMBODIMENTS The present disclosure may further include the following non-limiting embodiments. A1. A process for upgrading a hydrocarbon, comprising: (I) contacting a hydrocarbon-containing feed with a catalyst composition comprising a Group 8-10 element disposed on a support to effect reforming of at least a portion of the hydrocarbon-containing feed to produce a coked catalyst composition and a synthesis gas comprising H2 and CO; wherein the hydrocarbon-containing feed is a mixture of one or more C1-C10 elements; 16 1. A process for the preparation of a catalytic composition comprising a hydrocarbon and H2O, CO2, or a mixture of H2O and CO2, wherein the hydrocarbon-containing feed and the catalyst composition are contacted at a temperature of 400°C or greater, the support comprises Al and at least 0.5 wt% of a Group 2 element, the catalyst composition comprises 0.001 wt% to 6 wt% of a Group 8-10 element, and the catalyst composition contains no Si or <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.05 wt%, or <0.01 wt% Si, and all mass percentages are based on the weight of the support. A2. The process of A1, further comprising the step of (II) contacting at least a portion of the coked catalyst composition with an oxidant to cause combustion of at least a portion of the coke to produce a regenerated catalyst composition having less coke and combustion gases. A3. The process of A2, further comprising the step of (III) contacting the fuel with an oxidizer and a catalyst composition to cause combustion of at least a portion of the fuel. A4. The process of A2 or A3, further comprising (IV) contacting an additional amount of a hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition to produce a recokized catalyst composition and an additional effluent.

[0103] A5. The process of any of A1-A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a fluidized bed reactor. A6. The process of any of A1-A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a fixed bed reactor. A7. The process of any of A1-A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a countercurrent reactor. A8. The process of any of A1-A7, wherein the catalyst composition comprises from 0.001 wt%, 0.001 wt%, 0.01 wt%, 0.1 wt%, 0.15 wt%, or 0.2 wt% to 0.4 wt%, 0.6 wt%, 0.8 wt%, 1 wt%, 2 wt%, 3 wt%, 4 wt%, 5 wt%, or 6 wt% of a Group 8-10 element based on the weight of the support. A9. The process according to any one of A1 to A8, wherein the Group 8 to 10 element comprises Pt. A10. The process of any of A1-A9, wherein the catalyst composition further comprises a promoter disposed on the support in an amount of up to 10 wt% based on the weight of the support, the promoter comprising Sn, Cu, Au, Ag, Ga, Zn, Ge, In, Re, Ag, combinations thereof, or mixtures thereof. A11. The process of any of A1-A10, wherein the catalyst composition further comprises an alkali metal element comprising Li, Na, K, Rb, Cs, combinations thereof, or mixtures thereof disposed on the support in an amount up to 5 wt% based on the weight of the support. A12. The process of any of A1-A11, wherein the catalyst composition is in the form of particles having a size and particle density consistent with the Geldart A or Geldart B definition of a flowable solid.

[0104] A13. The process according to any one of A1 to A12, wherein the mass ratio of Group 2 element to Al in the support is in the range of 0.001, 0.01, 0.1, or 1 to 6, 12.5, 100, or 1,000. A14. The process according to any one of A1 to A13, wherein the Group 2 element comprises Mg, and at least a portion of the Mg is in the form of MgO or a mixed metal oxide comprising Mg. A15. The process according to any of A1-A14, wherein the Group 2 element comprises Mg, and at least a portion of the Mg and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide. A16. The process according to any of A1-A15, wherein the Group 2 element comprises Mg, and at least a portion of the Mg and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide, and the mass ratio of Al to Mg in the mixed Mg / Al metal oxide is in the range of 0.001, 0.01, 0.1, or 1 to 6, 12.5, 100, or 1,000. A17. The process according to any of A1 to A16, wherein at least a portion of the group 2 element is in the form of an oxide of the group 2 element, at least a portion of the Al is in the form Al2O3, and the oxide of the group 2 element and Al2O3 are mixed on the nm scale. A18. The process according to any of A1-A17, wherein the group 2 element comprises Mg, at least a portion of the Mg is in the form of MgO, at least a portion of the Al is in the form Al2O3, and the MgO oxide and Al2O3 are mixed on the nm scale.

[0105] A19. The process of any of A1-A18, further comprising at least one of the steps of reacting at least a portion of the syngas in the presence of a Fischer-Tropsch catalyst under effective Fischer-Tropsch conditions to produce an upgraded product, wherein the Fischer-Tropsch catalyst composition comprises a shifted Fischer-Tropsch catalyst or a non-shifted Fischer-Tropsch catalyst, exposing at least a portion of the syngas to a fermentation process to produce alcohols, organic acids, or mixtures thereof, contacting at least a portion of the syngas with a catalyst to produce at least one C1-C4 alcohol, and separating H2 from the syngas to produce an H2-rich product.

[0106] B1. A process for producing a catalyst composition, comprising the steps of: (I) preparing a slurry or gel comprising Al and / or compounds thereof, a Group 2 element and / or compounds thereof, and a liquid medium; and (II) spray drying the slurry or gel to produce spray-dried support particles comprising at least Al and a Group 2 element, wherein: (i) the Group 8-10 element is present in the slurry or gel in the form of a Group 8-10 element-containing compound, and the catalyst composition comprises catalyst particles comprising spray-dried support particles having a Group 8-10 element disposed thereon; and (ii) contacting the spray-dried particles with the Group 8-10 element-containing compound, thereby depositing the Group 8-10 element on the spray-dried support particles to form a Group 8-10 element-containing catalyst particle. % Group 8-10 element disposed on a support, and the catalyst composition comprises catalyst particles comprising spray-dried support particles having a Group 8-10 element disposed thereon; wherein the catalyst particles comprise 0.001 wt% to 6 wt% Group 8-10 element disposed on a support, based on the weight of the spray-dried support particles, and the support comprises Al and at least 0.5 wt% Group 2 element, and contains no Si or <0.5 wt%, <0.45 wt%, <0.4 wt%, <0.35 wt%, <0.3 wt%, <0.25 wt%, <0.2 wt%, <0.15 wt%, <0.1 wt%, <0.05 wt%, or <0.01 wt% Si.

[0107] B2. The process of B1, further comprising at least one of the following: (iii) the compound comprising the promoter element is present in a slurry or gel, and the catalyst composition comprises catalyst particles comprising spray-dried support particles having a promoter element disposed thereon; and (iv) the compound comprising the promoter element is deposited on a spray-dried support particle to produce a promoter-containing spray-dried support particle, and the catalyst composition comprises catalyst particles comprising spray-dried support particles having a promoter element disposed thereon; wherein the promoter element comprises Sn, Cu, Au, Ag, Ga, Zn, Ge, In, Re, Ag, combinations thereof, or mixtures thereof. B3. The process of B2, wherein the spray-dried support particles comprise up to 10 wt. % of a promoter element, based on the weight of the spray-dried support particles. B4. The process of any of B1-B3, wherein the Group 8-10 element-containing compound is present in a slurry or gel. B5. The process of any of B1-B4, wherein the Group 8-10 element-containing compound is deposited on a spray-dried support particle. B6. The process according to any one of B2 to B5, wherein the compound containing the promoter element is present in a slurry or gel. B7. The process according to any of B2-B6, wherein the compound containing the promoter element is deposited on a spray-dried support particle. B8. The process of any of B1-B7, wherein the Group 2 element comprises Mg, and at least a portion of the Group 2 element and at least a portion of the Al in the spray-dried support particles is in the form of a mixed Mg / Al metal oxide. B9. The process of any of B1-B8, further comprising (III) calcining the spray dried support particles under an oxidizing atmosphere to produce calcined support particles, wherein the catalyst composition comprises catalyst particles comprising Al and a Group 2 element, and comprising the calcined support particles having disposed thereon a Group 8-10 element, and optionally a promoter element. B10. The process of B9, further comprising (IV) hydrating the calcined support particles after step (III) to form hydrated support particles; and (V) calcining the hydrated support particles to form a catalyst composition comprising recalcined support particles, wherein the catalyst particles produced via steps (IV) and (V) have an attrition loss after one hour, as measured according to ASTM D5757-11(2017), that is less than the attrition loss after one hour of the calcined particles produced in step (III).

[0108] Various terms have been defined above. Unless a term used in the claims is defined above, it should be given the broadest definition that one skilled in the art would give that term as reflected in at least one publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are incorporated by reference in their entirety to the extent that their disclosures are not inconsistent with this application, and for all authorities to which such incorporation is permitted. While the forgoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, the scope of which is determined by the claims that follow.

Claims

1. 1. A catalyst composition comprising 0.001 wt % to 6 wt % of a Group 8-10 element disposed on a support, The support comprises Al and at least 0.5 wt % of a Group 2 element; The catalyst composition contains no Si or contains <0.5 wt.% Si, and All weight percent values ​​are based on the weight of the support. The catalyst composition.

2. 2. The catalyst composition according to claim 1, wherein the mass ratio of the Group 2 element to Al in the support is in the range of 0.001 to 1,000.

3. The Group 2 element includes Mg, and At least a portion of the Mg is in the form of MgO or a mixed metal oxide containing Mg; 3. The catalyst composition according to claim 1 or claim 2.

4. The Group 2 element includes Mg, and at least a portion of the Mg and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide; 3. The catalyst composition according to claim 1 or claim 2.

5. the Group 2 element comprises Mg, at least a portion of the Mg and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide; and The mass ratio of Mg to Al in the mixed Mg / Al metal oxide is within the range of 0.001 to 1,000.

2. The catalyst composition of claim 1.

6. At least a portion of the Group 2 element is in the form of an oxide of the Group 2 element; At least a portion of the Al is in the form Al 2 O 3 is in and The oxide of the Group 2 element and the Al 2 O 3 are mixed on the nm scale, 3. The catalyst composition according to claim 1 or claim 2.

7. the Group 2 element comprises Mg, At least a portion of the Mg is in the form of MgO; At least a portion of the Al is in the form Al 2 O 3 is in and The oxide MgO and the Al 2 O 3 are mixed on the nm scale, 3. The catalyst composition according to claim 1 or claim 2.

8. 8. The catalyst composition of claim 1, wherein the catalyst comprises 0.01 wt % to 0.15 wt % of the Group 8-10 element or compound thereof disposed on the support, based on the weight of the support.

9. 9. The catalyst composition according to claim 1, wherein the Group 8-10 element comprises Pt.

10. 10. The catalyst composition of any one of claims 1 to 9, further comprising a promoter disposed on the support in an amount up to 10 wt% based on the weight of the support, the promoter comprising Sn, Cu, Au, Ag, Ga, combinations thereof, or mixtures thereof.

11. 11. The catalyst composition of any one of claims 1 to 10, further comprising an alkali metal element comprising Li, Na, K, Rb, Cs, or a combination or mixture thereof disposed on the support in an amount up to 5 wt % based on the weight of the support.

12. 12. The catalyst composition of any one of claims 1 to 11, wherein the catalyst composition is in the form of particles having a size and particle density consistent with the Geldart A or Geldart B definition of a flowable solid.

13. 1. A process for producing a catalyst composition comprising: (I) preparing a slurry or gel comprising Al or a compound thereof, a Group 2 element or a compound thereof, and a liquid medium; (II) spray drying the slurry or gel to produce spray-dried particles comprising the Al or a compound thereof and the Group 2 element or a compound thereof; (III) calcining the spray-dried particles under an oxidizing atmosphere to produce calcined support particles comprising the Al or a compound thereof and the Group 2 element or a compound thereof; Where: (i) a Group 8-10 element is present in the slurry or gel in the form of a Group 8-10 element-containing compound, and the catalyst composition comprises catalyst particles comprising the calcined support particles having the Group 8-10 element disposed thereon; (ii) a Group 8-10 element is deposited on the spray-dried particles by contacting the spray-dried particles with a Group 8-10 element-containing compound to produce a Group 8-10 element-containing spray-dried particle, and a catalyst composition comprises catalyst particles comprising the calcined support particles having the Group 8-10 element disposed thereon; and (iii) contacting the calcined support particles with a Group 8-10 element-containing compound to deposit a Group 8-10 element on the calcined support particles to produce Group 8-10 element-containing calcined support particles, and the process further comprises (IV) calcining the Group 8-10 element-containing calcined support particles to produce recalcined support particles having the Group 8-10 element disposed thereon, and the catalyst composition comprises the recalcined support particles; is satisfied, where: the catalyst particles contain the Group 8-10 element in an amount of 0.001 wt % to 6 wt %; the catalyst particles contain at least 0.5 wt. % of the Group 2 element; The catalyst composition contains no Si or contains <0.5 wt.% Si, and All weight percentages are based on the weight of the calcined or recalcined support particles. The above process.

14. the below described: (iv) a compound comprising a promoter element is present in the slurry or gel, and the catalyst composition comprises catalyst particles comprising the calcined support particles having the promoter element disposed thereon; (v) a compound comprising a promoter element is deposited on said spray-dried particles to produce a promoter-containing spray-dried particle, and said catalyst composition comprises catalyst particles comprising said calcined support particles having said promoter element disposed thereon; (vi) a compound comprising a promoter element is deposited on the calcined support particle to produce a promoter-containing calcined support particle, and the process further comprises (V) calcining the promoter-containing calcined support particle to produce a recalcined support particle having the promoter element disposed thereon, and the catalyst composition comprises the recalcined support particle; is satisfied, where: The promoter elements include Sn, Cu, Au, Ag, Ga, combinations thereof, or mixtures thereof; and the catalyst particles comprising the promoter element in an amount of up to 10 wt. %, based on the weight of the calcined or recalcined support particle; 14. The process of claim 13.

15. 15. The process of claim 13 or claim 14, wherein the spray-dried particles are calcined at a temperature in the range of 550°C to 900°C for a time period of ≦45 minutes.

16. 15. The process of claim 13 or claim 14, wherein the spray-dried particles are calcined at a temperature of <550°C for a time of ≦45 minutes.

17. 17. The process of any one of claims 13 to 16, wherein the Group 8-10 element-containing compound is present in the slurry or gel.

18. 18. The process of any one of claims 13 to 17, wherein the Group 8-10 element-containing compound is deposited on the spray-dried particles.

19. The process of any one of claims 14 to 18, wherein the compound containing the promoter element is present in the slurry or gel.

20. The process according to any one of claims 14 to 19, wherein the compound comprising the promoter is deposited on the spray-dried particles.

21. moreover, (IV) hydrating the calcined support particles after step (III) to form hydrated support particles; (V) calcining the hydrated support particles to form a catalyst comprising recalcined support particles.

21. The process of any one of claims 13 to 20, wherein the catalyst particles produced via steps (VI) and (VII) have an attrition loss after 1 hour, measured according to ASTM D5757-11(2017), that is less than the attrition loss after 1 hour of the calcined particles produced in step (III).

22. The Group 2 element includes Mg, and The process of any one of claims 13 to 21, wherein at least a portion of the group 2 element and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide.

23. 1. A hydrocarbon upgrading process comprising: (I) contacting a hydrocarbon-containing feed with a catalyst composition comprising a Group 8-10 element disposed on a support to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the hydrocarbon-containing feed to produce a coked catalyst composition and an effluent comprising one or more upgraded hydrocarbons and molecular hydrogen, wherein: The hydrocarbon-containing feed may comprise one or more C 2 -C 16 Linear or branched alkanes, or one or more C 4 -C 16 Cyclic alkanes or one or more C 8 -C 16 alkyl aromatics, or mixtures thereof; The hydrocarbon-containing feed and the catalyst composition are contacted at a temperature in the range of 300° C. to 900° C. for a time period of ≦3 hours under a hydrocarbon partial pressure of at least 20 kPa absolute, wherein the hydrocarbon partial pressure is less than or equal to 100 kPa absolute of any C in the hydrocarbon-containing feed. 2 -C 16 Alkanes and any C 8 -C 16 is the total alkyl aromatics partial pressure, The support comprises Al and at least 0.5 wt % of a Group 2 element; the catalyst composition comprises the Group 8-10 element in an amount of 0.001 wt % to 6 wt %; The catalyst composition contains no Si or contains <0.5 wt.% Si, All weight percent values ​​are based on the weight of the support; and The one or more upgraded hydrocarbons include at least one of dehydrogenated hydrocarbons, dehydrogenated aromatized hydrocarbons, and dehydrogenated cyclized hydrocarbons; The above process.

24. moreover, (II) contacting at least a portion of the coked catalyst with an oxidant to cause combustion of at least a portion of the coke to produce a regenerated catalyst having less coke and combustion gases; (III) contacting an additional amount of the hydrocarbon-containing feed with at least a portion of the regenerated catalyst to produce a recokized catalyst and an additional effluent.

24. The process of claim 23, wherein the cycle time from contacting the hydrocarbon-containing feed with the catalyst particles in step (I) to contacting the additional amount of hydrocarbon-containing feed with the regenerated catalyst in step (III) is ≦5 hours.

25. The Group 2 element includes Mg, and 25. The process of claim 23 or claim 24, wherein at least a portion of the Group 2 element and at least a portion of the Al are in the form of a mixed Mg / Al metal oxide.

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