Catalyst compositions comprising homogenously distributed promoter and processes for making and using same

Abstract

Catalyst compositions and processes for making and using same. The catalyst composition includes a support, a Group 8-10 element such as platinum, and a promoter such as tin. The Group 8-10 element and promoter can be disposed through a volume of the support. The support can include a mixed Mg / AI metal oxide. The promoter is distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive X-ray spectroscopy analysis. In other embodiments, a process for making the catalyst composition can include forming a mixture that can include a Group 8-10 element-containing compound, a promoter-containing compound, a carboxylic acid, a liquid medium, and a support that can be or can include a mixed Mg / AI metal oxide. The promoter-containing compound can include Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. The process can also include heating the mixture to produce the catalyst composition.

Description

CATALYST COMPOSITIONS AND PROCESSES FOR MAKING AND USING SAME CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 553,748 having a filing date of February 15, 2024, the disclosure of which is incorporated herein by reference in its entirety. FIELD

[0002] This disclosure relates to catalyst compositions and processes for making and using same. BACKGROUND

[0003] Catalytic reforming or dehydrogenation, dehydroaromatization, and / or dehydrocyclization of alkane and / or alkyl aromatic hydrocarbons are industrially important chemical conversion processes that are endothermic and equilibrium-limited. The reforming or dehydrogenation, dehydroaromatization, and / or dehydrocyclization of alkanes, e.g., C1-C12 alkanes, and / or alkyl aromatics, e.g., ethylbenzene, can be done using a variety of different catalysts such as the 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.

[0004] Precious metals, e.g., Pt, used in synthesizing the catalyst can be expensive and can contribute significantly to the operating expenses of a chemical plant. As such, a promoter, e.g., Sn, Cu, Au, Ag, and / or Ga, is typically incorporated into the catalyst to improve the activity of the catalyst. During synthesis of the catalyst, it is believed that the distribution of the promoter about the support is an important aspect in formulating an active catalyst. The currently known synthesis processes that are used to produce the catalysts yield catalysts that exhibit less activity than desired because the promoter is not homogeneously distributed about the support.

[0005] There is a need, therefore, for improved catalyst compositions and processes for making and using same. This disclosure satisfies this and other needs. SUMMARY

[0006] Catalyst compositions and processes for making and using same are provided. In some embodiments, the catalyst can include a support, a Group 8-10 element, and a promoter. The Group 8-10 element and the promoter can be disposed through a volume of the support. The promoter can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combinationthereof, or a mixture thereof. The support can be or can include, but is not limited to, a mixed Mg / Al metal oxide. The promoter can be distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

[0007] In other embodiments, the process for making the catalyst can include forming a mixture that can include a Group 8-10 element-containing compound, a promoter-containing compound, a carboxylic acid, a liquid medium, and a support. The promoter can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. The support can be or can include, but is not limited to, a mixed Mg / Al metal oxide. The process can also include heating the mixture to produce a catalyst composition that can include the support, the Group 8-10 element, and the promoter, wherein the Group 8-10 element and the promoter can be disposed through the volume of the support.

[0008] In other embodiments, a process for upgrading a hydrocarbon can include contacting a hydrocarbon-containing feed with a catalyst composition that can include a support, a Group 8-10 element, and a promoter 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 can include one or more upgraded hydrocarbons and molecular hydrogen. The hydrocarbon-containing feed can include one or more of C2-C16 linear or branched alkanes, or one or more of C4-C16 cyclic alkanes, or one or more C8-C16alkyl aromatics, or a mixture thereof. The hydrocarbon-containing feed and catalyst composition can be contacted at a temperature in a range of from 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 the total partial pressure of any C2-C16 alkanes and any C8-C16alkyl aromatics in the hydrocarbon-containing feed. The support can be or can include a mixed Mg / Al metal oxide. The Group 8-10 element and the promoter can be disposed through a volume of the support. The promoter can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. The promoter can be distributed substantially homogeneously throughout the volume of the support, as determined by energy- dispersive x-ray spectroscopy analysis.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG.1 shows an energy-dispersive x-ray spectroscopy line scan of a cross-section of a 3 mm x 3 mm cylindrical extrudate of an inventive catalyst, i.e., Catalyst 1.

[0010] FIG.2 shows an energy-dispersive x-ray spectroscopy line scan of a cross-section of a 3 mm x 3 mm cylindrical extrudate of a comparative catalyst, i.e., Catalyst 2. DETAILED DESCRIPTION

[0011] Various specific embodiments, versions and examples of the invention will now be described, including preferred embodiments and definitions that are adopted herein for purposes of understanding the claimed invention. While the following detailed description gives specific preferred embodiments, those skilled in the art will appreciate that these embodiments are exemplary only, and that the invention may be practiced in other ways. For purposes of determining infringement, the scope of the invention will refer to any one or more of the appended claims, including their equivalents, and elements or limitations that are equivalent to those that are recited. Any reference to the “invention” may refer to one or more, but not necessarily all, of the inventions defined by the claims.

[0012] In this disclosure, a process is described as comprising at least one “step.” It should be understood that each step is an action or operation that may be carried out once or multiple times in the process, in a continuous or discontinuous fashion. Unless specified to the contrary or the context clearly indicates otherwise, multiple steps in a process may be conducted sequentially in the order as they are listed, with or without overlapping with one or more other steps, or in any other order, as the case may be. In addition, one or more or even all steps may be conducted simultaneously with regard to the same or different batch of material. For example, in a continuous process, while a first step in a process is being conducted with respect to a raw material just fed into the beginning of the process, a second step may be carried out simultaneously with respect to an intermediate material resulting from treating the raw materials fed into the process at an earlier time in the first step. Preferably, the steps are conducted in the order described.

[0013] Unless otherwise indicated, all numbers indicating quantities in this disclosure are to be understood as being modified by the term “about” in all instances. It should also be understood that the precise 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 limitation of the technique and / or equipment used for acquiring the measurement.

[0014] Certain embodiments and features are described herein using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and / or the combination of any two upper values are contemplated unless otherwise indicated.

[0015] The indefinite article “a” or “an”, as used herein, means “at least one” unless specified to the contrary or the context clearly indicates otherwise. Thus, embodiments using “a reactor” or “a conversion zone” include embodiments where one or two or more reactors or conversion zones are used, unless specified to the contrary or the context clearly indicates that only one reactor or conversion zone is used.

[0016] In this disclosure, “A, B, … or a combination thereof” means “A, B, … or any combination of any two or more of A, B, …” and “A, B, …, or a mixture thereof” means “A, B, …, or any mixture of any two or more of A, B, …”.

[0017] The term “hydrocarbon” means (i) any compound consisting of hydrogen and carbon atoms or (ii) any mixture of two or more such compounds in (i). The term “Cn hydrocarbon,” where n is a positive integer, means (i) any hydrocarbon compound comprising carbon atom(s) in its molecule at the total number of n, or (ii) any mixture of two or more such hydrocarbon compounds in (i). Thus, a C2 hydrocarbon can be ethane, ethylene, acetylene, or mixtures of at least two of these compounds at any proportion. A “Cm to Cn hydrocarbon” or “Cm-Cn hydrocarbon,” where m and n are positive integers and m < n, means any of Cm, Cm+1, Cm+2, …, Cn-1, Cn hydrocarbons, or any mixtures of two or more thereof. Thus, a “C2 to C3 hydrocarbon” or “C2-C3 hydrocarbon” can be any of ethane, ethylene, acetylene, propane, propene, propyne, propadiene, cyclopropane, and any mixtures of two or more thereof at any proportion between and among the components. A “saturated C2-C3 hydrocarbon” can be ethane, propane, cyclopropane, or any mixture thereof of two or more thereof at any proportion. A “Cn+ hydrocarbon” means (i) any hydrocarbon compound comprising carbon atom(s) in its molecule at the total number of at least n, or (ii) any mixture of two or more such hydrocarbon compounds in (i). A “Cn- hydrocarbon” means (i) any hydrocarbon compound comprising carbon atoms in its molecule at the total number of at most n, or (ii) any mixture of two or more such hydrocarbon compounds in (i). A “Cm hydrocarbon stream” means a hydrocarbon stream consisting essentially of Cm hydrocarbon(s). A “Cm-Cn hydrocarbon stream” means a hydrocarbon stream consisting essentially of Cm-Cn hydrocarbon(s).

[0018] For the purposes of this disclosure, the nomenclature of elements is pursuant to the version of the Periodic Table of Elements (under the new notation) as provided in Hawley'sCondensed Chemical Dictionary, 16thEd., John Wiley & Sons, Inc., (2016), Appendix V. For example, a Group 2 element includes Mg, a Group 8 element includes Fe, a Group 9 element includes Co, a Group 10 element includes Ni, and a Group 13 element includes Al. The term “metalloid”, as used herein, refers to the following elements: B, Si, Ge, As, Sb, Te, and At. In this disclosure, when a given element is indicated as present, it can be present in the elemental state or as any chemical compound thereof, unless it is specified otherwise or clearly indicated otherwise by the context.

[0019] The term “alkane” means a saturated hydrocarbon. The term “cyclic alkane” means a saturated hydrocarbon comprising a cyclic carbon ring in the molecular structure thereof. An alkane can be linear, branched, or cyclic.

[0020] The term “aromatic” is to be understood in accordance with its art-recognized scope, which includes alkyl substituted and unsubstituted mono- and polynuclear compounds.

[0021] The term “rich” when used in phrases such as “X-rich” or “rich in X” means, with respect to an outgoing stream obtained from a device, e.g., a conversion zone, that the stream comprises material X at a concentration higher than in the feed material fed to the same device from which the stream is derived. The term “lean” when used in phrases such as “X-lean” or “lean in X” means, with respect to an outgoing stream obtained from a device, e.g., a conversion zone, that the stream comprises material X at a concentration lower than in the feed material fed to the same device from which the stream is derived.

[0022] The term “mixed metal oxide” refers to a composition that includes oxygen atoms and at least two different metal atoms that are mixed on an atomic scale. For example, a “mixed Mg / Al metal oxide” comprises O, Mg, and Al atoms mixed on an atomic scale, which can have a composition obtained by calcining a Mg / Al hydrotalcite that has the general chemical formula ^^^^^^^ି௫^^^^^௫^^^^^^ଶ^^^^^^ି^ ∙ ^^^^ଶ^^, where A is a counter anion of a negative charge n (e.g.,^ < x <1, and m is a non-negative number. A material consisting ofsizes on the nanometer scale and discrete Al2O3particles having sizes on the nanometer scale physically mixed together is not a mixed metal oxide because the Mg and Al atoms are not mixed on an atomic scale but are instead mixed on a nanometer or larger scale.

[0023] The terms “calcination” and “calcining” refer to heating a material, e.g., a synthesized catalyst or a support, to a temperature of 350°C or more under any atmosphere, e.g., an oxidizing atmosphere, an inert atmosphere, or a reducing atmosphere. The term “calcined” refers to a material, e.g., a synthesized catalyst or a support, that has been subjected to calcination / calcining.

[0024] The term “selectivity” refers to the production (on a carbon mole basis) of a specified compound in a catalytic reaction. As an example, the phrase “an alkane hydrocarbon conversion reaction has a 100% selectivity for an olefin hydrocarbon” means that 100% of the alkane hydrocarbon (carbon mole basis) that is converted in the reaction is converted to the olefin hydrocarbon. When used in connection with a specified reactant, the term “conversion” means the amount of the reactant consumed in the reaction. For example, when the specified reactant is propane, 100% conversion means 100% of the propane is consumed in the reaction. In another example, when the specified reactant is propane, if one mole of propane convers to one mole of methane and one mole of ethylene, the selectivity to methane is 33.3% and the selectivity to ethylene is 66.7%. Yield (carbon mole basis) is conversion times selectivity.

[0025] The term “sccm” means standard cubic centimeters per minute, which is a flow measurement used to indicate the cubic centimeters (cm3) of a gas at standard temperature and pressure passing a given point within one minute. Standard temperature and pressure (STP) refers to a temperature of 273.15 K (0°C, 32°F) and an absolute pressure of 105Pa (100 kPa, 1 bar).

[0026] The term “distributed substantially homogeneously throughout the volume of the support”, with regard to a promoter, e.g., Sn, means the counts per second indicative of the promoter deviate from an average counts per second across a cross-section of the support from a first side to an opposing side of no more than + / - 200%, no more than + / - 175%, no more than + / - 150%, no more than + / - 140%, no more than + / - 130%, no more than + / - 120%, no more than + / - 110%, no more than + / - 100%, no more than + / - 90%, no more than + / - 80%, no more than + / - 70%, no more than + / - 65%, no more than + / - 60%, no more than + / - 55%, no more than + / - 50%, no more than + / - 45%, or no more than + / - 40%, when the X-ray (keV) corresponds to the characteristic X-ray (Lα) of the promoter. For example, the characteristic X-ray (Lα) of Sn is 3.44 keV. Catalyst Composition

[0027] The catalyst composition can include a support, a Group 8-10 element, and a promoter. The Group 8-10 element and the promoter can be disposed through a volume of the support. The promoter can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. The support can be or can include, but is not limited to, a mixed Mg / Al metal oxide. The promoter can be distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

[0028] The catalyst composition can include 0.00001 wt%, 0.0001 wt%, 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%, 0.01wt%, 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%, 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 the Group 8-10 element disposed through the volume of the support, based on the weight of the support. In some embodiments, the catalyst composition can include ≤ 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%, ≤ 0.07 wt%, ≤ 0.06 wt%, ≤ 0.05 wt%, ≤ 0.04 wt%, ≤ 0.03 wt%, ≤ 0.025 wt%, ≤ 0.02 wt%, ≤ 0.015 wt%, ≤ 0.01 wt%, ≤ 0.009 wt%, ≤ 0.008 wt%, ≤ 0.007 wt%, ≤ 0.006 wt%, ≤ 0.005 wt%, ≤ 0.004 wt%, ≤ 0.003 wt%, or ≤ 0.002 wt% of the Group 8-10 element disposed through the volume of the support, based on the weight of the support.

[0029] In some embodiments, the Group 8-10 element can be or can include, but is not limited to, Fe, Co, Ni, Ru, Pd, Os, Ir, Pt, a combination thereof, or a mixture thereof. In some embodiments, the Group 8-10 element can be or can include Pt. If two or more Group 8-10 elements are disposed through the volume of the support, the catalyst composition can include 0.00001 wt%, 0.0001 wt%, 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%, 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 combined amount of the two or more Group 8-10 elements disposed through the volume of the support, based on the weight of the support. In some embodiments, an active component of the catalyst composition that can be capable of effecting one or more of reforming or dehydrogenation, dehydroaromatization, and dehydrocyclization of a hydrocarbon-containing feed can be or can include the Group 8-10 element(s) disposed through the volume of the support.

[0030] The catalyst composition can include the promoter in an amount of 0.0001wt%, 0.001wt%, 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% disposed through the volume of the support, based on the weight of the support. In some embodiments, the promoter can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. In some embodiments, the promoter canbe or can include Sn. In some embodiments, the Group 8-10 element can be or can include Pt and the promoter can be or can include Sn.

[0031] In some embodiments, the promoter can be associated with the Group 8-10 element. For example, the promoter and the Group 8-10 element disposed through the volume of the support can form Group 8-10 element-promoter clusters that can be dispersed through the volume of the support. The promoter can improve the selectivity, the activity, and / or the longevity of the catalyst composition for a given upgraded hydrocarbon produced by upgrading a hydrocarbon-containing feed. In some embodiments, the promoter can improve the propylene selectivity of the catalyst composition when the hydrocarbon-containing feed includes propane.

[0032] In some embodiments, the support can be or can include, but is not limited to, a mixed Mg / Al metal oxide. In some embodiments, the support can be or can include the Mg and the Al in the form of an oxide or one or more oxides of Mg and Al2O3that can be mixed on a nm scale. In some embodiments, the support can be or can include a mixed Mg / Al metal oxide obtained by calcining hydrotalcite.

[0033] In some embodiments, the support can be or can include a first quantity of the Mg and the Al in the form of a mixed Mg / Al metal oxide and a second quantity of the Mg in the form of an oxide of the Mg. In such embodiment, the mixed Mg / Al metal oxide and the oxide of the Mg can be mixed on the nm scale and the Mg and Al in the mixed Mg / Al metal oxide can be mixed on the atomic scale.

[0034] In other embodiments, the support can be or can include a first quantity of the Mg and a first quantity of the Al in the form of a mixed Mg / Al metal oxide, a second quantity of the Mg in the form of an oxide of the Mg, and a second quantity of the Al in the form of Al2O3. In such embodiment, the mixed Mg / Al metal oxide, the oxide of the Mg, and the Al2O3can be mixed on a nm scale and the Mg and Al in the mixed Mg / Al metal oxide can be mixed on the atomic scale. In some embodiments, the support can be MgwAl2O3+w, where w is a positive number.

[0035] In some embodiments, the support can include ≥ 0.5 wt%, ≥ 1 wt%, ≥ 2 wt%, ≥ 3 wt5, ≥ 4 wt%, ≥ 5 wt%, ≥ 10 wt%, or ≥ 20 wt%, ≥ 40 wt%, ≥ 80 wt%, or ≥ 90 wt% of Mg, based on the weight of the support. In some embodiments, the support can include Mg in a range of from 0.5 wt%, 3 wt%, 5 wt%, or 10 wt% to 30 wt%, 50 wt%, 70 wt%, or 90 wt%, based on the weight of the support. In some embodiments, a molar ratio of the Mg to the Group 8-10 element present in the catalyst composition can be in a range from 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, 10,000, 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, 800000, or 900,000.

[0036] In some embodiments, in addition to the mixed Mg / Al metal oxide, the support can further include, but is not limited to, one or more of the following compounds: CaxAl2O3+x, where x is a positive number; SryAl2O3+y, where y is a positive number; BazAl2O3+z, where z is a positive number. BeO; MgO; CaO; BaO; SrO; BeCO3; MgCO3; CaCO3; SrCO3, BaCO3; CaZrO3; Ca7ZrAl6O18; CaTiO3; Ca7Al6O18; Ca7HfAl6O18; BaCeO3; one or more magnesium chromates, one or more magnesium tungstates, one or more magnesium molybdates, combinations thereof, and mixtures thereof.

[0037] In some embodiments, the MgwAl2O3+w, where w is a positive number, if present in the support can have a molar ratio of Mg to Al in a range from 0.5, 1, 2, 3, 4, or 5 to 6, 7, 8, 9, or 10. In some embodiments, the MgwAl2O3+wcan include MgAl2O4, Mg2Al2O5, or a mixture thereof. In some embodiments, the CaxAl2O3+x, where x is a positive number, if present in the support can have a molar ratio of Ca to Al in a range from 1:12, 1:4, 1:2, 2:3, 5:6, 1:1, 12:14, or 1.5:1. In some embodiments, the CaxAl2O3+x can include tricalcium aluminate, dodecacalcium hepta-aluminate, monocalcium aluminate, monocalcium dialuminate, monocalcium hexa-aluminate, dicalcium aluminate, pentacalcium trialuminate, tetracalcium trialuminate, or any mixture thereof. In some embodiments, the SryAl2O3+y, where y is a positive number, if present in the support can have a molar ratio of Sr to Al in a range from 0.05, 0.3, or 0.6 to 0.9, 1.5, or 3. In some embodiments, the BazAl2O3+z, where z is a positive number, if present in the support can have a molar ratio of Ba to Al 0.05, 0.3, or 0.6 to 0.9, 1.5, or 3.

[0038] In some embodiments, the support can be or can include a mixed Mg / Al metal oxide having the same or similar structure as a compound produced or obtained by calcining hydrotalcite but made via an alternative process such that the support has a greater surface area than the compound produced or obtained by calcining hydrotalcite. For example, in some embodiments, the support can be or can include a mixed Mg / Al metal oxide produced by combining a first compound that includes Mg and a second compound that includes Al and additional ingredients to produce a slurry or a gel that can be processed to produce the mixed Mg / Al metal oxide. In some embodiments, the mixed Mg / Al metal oxide making up the support or at least a portion of the support can have a weight ratio of Mg to Al in a range of from 0.001, 0.005, 0.01, 0.05, 0.1, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or 5 to 6, 10, 12.5, 25, 50, 75, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1,000.

[0039] In some embodiments, the support can have a surface area in a range from ≥ 0.1 m2 / g, ≥ 1 m2 / g, ≥10 m2 / g, ≥ 50 m2 / g, ≥ 100 m2 / g, ≥ 125 m2 / g, ≥ 150 m2 / g, ≥ 175 m2 / g, ≥ 200 m2 / g, ≥ 225 m2 / g, ≥ 250 m2 / g, ≥ 275 m2 / g, ≥ 300 m2 / g, ≥ 303 m2 / g, ≥ 305 m2 / g, ≥ 310 m2 / g, ≥ 315 m2 / g, ≥ 320 m2 / g, ≥ 325 m2 / g, ≥ 330 m2 / g, ≥ 335 m2 / g, ≥ 340 m2 / g, ≥ 345 m2 / g, ≥ 350 m2 / g, ≥ 355 m2 / g, ≥ 360 m2 / g, ≥ 365 m2 / g, ≥ 370 m2 / g, ≥ 375 m2 / g, ≥ 380 m2 / g, ≥ 385 m2 / g, ≥ 390 m2 / g, ≥ 395 m2 / g, ≥ 400 m2 / g, ≥ 425 m2 / g, ≥ 450 m2 / g, ≥ 475 m2 / g, or ≥ 500 m2 / g. In some embodiments, the support can have a surface area in a range of from ≥ 100 m2 / g, ≥ 150 m2 / g, ≥ 200 m2 / g, ≥ 250 m2 / g, ≥ 275 m2 / g, ≥ 300 m2 / g, ≥ 325 m2 / g, ≥ 350 m2 / g, or ≥ 370 m2 / g to ≤ 400 m2 / g, ≤ 425 m2 / g, ≤ 450 m2 / g, or ≤ 475 m2 / g, ≤ 500 m2 / g, ≤ 525 m2 / g, ≤ 550 m2 / g, ≤ 575 m2 / g, ≤ 600 m2 / g, ≤ 625 m2 / g, ≤ 650 m2 / g. The surface area of the support can be measured according to the Brunauer-Emmett-Teller (BET) method using adsorption-desorption of nitrogen (temperature of liquid nitrogen, 77 K) with a Micromeritics 3flex instrument after degassing of the powders for 4 hrs at 350°C. More information regarding the 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.

[0040] In some embodiments, the catalyst composition can be formed into any desired form with regular or irregular shapes, e.g., beads, granules, spheres, rings, toroidal shapes, powder, rods, cylinders, tubes, flakes, tablets, honeycombs, particulates, pellets, extrudates, and the like, or a mixture or combination thereof.

[0041] In some embodiments, the catalyst composition can be in the form of catalyst particles. If the catalyst composition is in the form of catalyst particles, the catalyst particles can have a median particle size in a range of 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. The catalyst particles can have an apparent loose bulk density in a range from 0.3 g / cm3, 0.4 g / cm3, 0.5 g / cm3, 0.6 g / cm3, 0.7 g / cm3, 0.8 g / cm3, 0.9 g / cm3, or 1 g / cm3to 1.1 g / cm3, 1.2 g / cm3, 1.3 g / cm3, 1.4 g / cm3, 1.5 g / cm3, 1.6 g / cm3, 1.7 g / cm3, 1.8 g / cm3, 1.9 g / cm3, or 2 g / cm3, as measured according to ASTM D7481-18 modified with a 10, 25, or 50 mL graduated cylinder instead of a 100 or 250 mL graduated cylinder. In some embodiments, the catalyst particles can have an attrition loss after one hour of ≤ 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%, as measured according to ASTM D5757-11(2017). In some embodiments, the morphology of the particles can be largely spherical so that they are suitable to run in a fluid bed reactor. In some embodiments, the catalyst particles can have a size and density that is consistent with a Geldart A or Geldart B definition of a fluidizable solid.

[0042] In some embodiments, the catalyst composition can optionally include one or more alkali metal elements in an amount of up to 5 wt% disposed on the support, based on the weight of the support. In some embodiments, the catalyst composition can include 0.0001 wt%, 0.001 wt%, 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 element disposed through the volume of the support, based on the weight of the support. The alkali metal element, if present, can be or can include, but is not limited to, Li, Na, K, Rb, Cs, or a combination thereof, or a mixture thereof. In at least some embodiments, the alkali metal element ca be or can include K and / or Cs. In some embodiments, the alkali metal element, if present, can improve the selectivity of the catalyst composition for a given upgraded hydrocarbon.

[0043] In some embodiments, the catalyst composition can also include a binder. In some embodiments, during formulation, one or more binders can be added to the catalyst and / or support to improve the chemical / physical properties of the catalyst. In some embodiments, when the catalyst composition includes the binder, the catalyst composition can include the binder in a range of 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%, based on the non-volatile weight of the catalyst composition.

[0044] In some embodiments, the binder can be or can include, but is not limited to, one or more of the following: B2O3, AlBO3, Al2O3, SiO2, ZrO2, TiO2, SiC, Si3N4, an aluminosilicate, zinc aluminate, ZnO, VO, V2O3, VO2, V2O5, GasOt, InuOv, Mn2O3, Mn3O4, MnO, one or more molybdenum oxides, one or more tungsten oxides, one or more zeolites, where s, t, u, and v are positive numbers and mixtures and combinations thereof. Processes for Making the Catalyst Composition

[0045] The process for making the catalyst composition can include forming a mixture that can include a Group 8-10 element-containing compound, a promoter-containing compound, a carboxylic acid, a liquid medium, and a support. In some embodiments, the mixture can optionally include the one or more binders. The promoter-containing compound can be or can include, but is not limited to, Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof. The support can be or can include, but is not limited to, a mixed Mg / Al metal oxide. The mixture can be heated to produce the catalyst composition that includes the Group 8-10 element and the promoter disposed through the support. The promoter disposed through the supportcan be distributed substantially homogeneously through the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

[0046] It has been surprisingly and unexpectedly discovered that the presence of the carboxylic acid in the mixture causes the promoter, e.g., Sn, in the promoter-containing compound to be substantially homogeneously distributed throughout the volume of the support as opposed to a relatively large portion of the promoter being distributed on the surface of the support with a relatively minor portion of the promoter being distributed within the volume of the support and / or a relatively large portion of the promoter being distributed throughout the volume of the support in the form of aggregates.

[0047] In some embodiments, the Group 8-10 element-containing compound, the promoter- containing compound, and the carboxylic acid can be combined with the liquid medium to produce a first mixture, e.g., an aqueous solution when the liquid medium comprises water. In such embodiments, the first mixture can be contacted with the support to form the mixture that can include the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support. In some embodiments, a weight ratio of the liquid medium to the support in the mixture that includes the Group 8-10 element- containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be in a range from 0.2:1, 0.3:1, 0.5:1, 0.7:1, or 1:1 to 1.3:1, 1.5:1, 1.7:1, 2:1, or greater, based on the weight of the support.

[0048] In other embodiments, a first mixture that includes the Group 8-10 element- containing compound and a first portion of the liquid medium, a second mixture that includes the promoter-containing compound and a second portion of the liquid medium, and a third mixture that includes the carboxylic acid and a third portion of the liquid medium can be formed. The first mixture, the second mixture, and the third mixture can be combined with one another simultaneously and / or in any order or sequence to produce a combined mixture that includes the Group 8-10 element-containing compound, the first portion of the liquid medium, the promoter-containing compound, the second portion of the liquid medium, the carboxylic acid, and the third portion of the liquid medium. The combined mixture can be contacted with the support to form the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support. In some embodiments, a weight ratio of the liquid medium to the support in the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be in a range from 0.2:1, 0.3:1, 0.5:1, 0.7:1, or 1:1 to 1.3:1, 1.5:1, 1.7:1, 2:1, or greater, based on the weight of the support.

[0049] In still other embodiments, a first mixture that includes the Group 8-10 element- containing compound, a first portion of the liquid medium, and the promoter-containing compound or the carboxylic acid can be formed and a second mixture that includes the promoter-containing compounds or the carboxylic acid and a second portion of the liquid medium can be formed. In such embodiments, the first mixture and the second mixture can be combined with one another to form a combined mixture. The combined mixture can be contacted with the support to form the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support. In some embodiments, a weight ratio of the liquid medium to the support in the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be in a range from 0.2:1, 0.3:1, 0.5:1, 0.7:1, or 1:1 to 1.3:1, 1.5:1, 1.7:1, 2:1, or greater, based on the weight of the support.

[0050] In some embodiments, the Group 8-10 element-containing compound can be or can include, but is 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, platinum (II) oxalate, or any mixture thereof.

[0051] In some embodiments, the promoter-containing compound comprises tin(IV) chloride pentahydrate, tin(II) chloride dihydrate, tin(II) bromide, tin(IV) bromide, tin(II) acetylacetonate, tin(II) acetate, tin(IV) acetate, tin(II) oxalate, tin(IV) oxalate, copper(II) nitrate, gold(III) nitrate, silver(I) nitrate, gallium(III) nitrate, or a mixture thereof. In some embodiments, the promoter- containing compound can be tin(IV) chloride pentahydrate, tin(II) chloride dihydrate, or a mixture thereof. In some embodiments, the alkali metal element-containing compound, present, can be or can include, but is not limited to, lithium nitrate, sodium nitrate, potassium nitrate, rubidium nitrate, cesium nitrate, or any mixture thereof.

[0052] In some embodiments, the carboxylic acid can include one, two, three, or more carboxylic acid functional groups (‒C(=O)‒OH). Said another way, the carboxylic acid can be a monocarboxylic acid, a dicarboxylic acid, a tricarboxylic acid, or a mixture thereof. In some embodiments, the carboxylic acid can be a saturated carboxylic acid, an unsaturated carboxylic acid, or a mixture of one or more saturated carboxylic acids and one or more unsaturated carboxylic acids. In some embodiments, the carboxylic acid can include linear carboxylic acids, e.g., formic acid, or branched carboxylic acids, e.g., citric acid. In some embodiments, the carboxylic acid can include cyclic carboxylic acids, e.g., cyclopentanecarboxylic acid, and / orone or more aromatic carboxylic acids, e.g., salicylic acid, phthalic acid, isophthalic acid, and / or terephthalic acid. In some embodiments, the carboxylic acid can include oxoacids (keto acids), e.g., glyoxylic acid and / or pyruvic acid. In some embodiments, the carboxylic acid can include alpha hydroxy acids, e.g., glycolic acid, beta hydroxy acids, e.g., 3-hydroxypropionic acid, gamma hydroxy acids, e.g., 4-hydroxybutanoic acid, omega hydroxy acids, e.g., 5- hydroxypentaonic acid. In some embodiments, the carboxylic acid can include sugar acids, e.g., aldonic acid, uronic acid, and / or aldaric acid. It should be understood that the term “carboxylic acid” can include not only the carboxylic acid itself, but also the various salts, esters, polyatomic anions found in solution, or any other form of the carboxylic acid, e.g., a hydrate.

[0053] In some embodiments, suitable monocarboxylic acids can include, but are not limited to, methanoic acid (formic acid), ethanoic acid (acetic acid), propanoic acid (propionic acid), butanoic acid (butyric acid), 2-methylpropanoic acid (isobutyric acid), trans-butenoic acid (crotonic acid), cis-butenoic acid (isocrotonic acid), pivalic acid, pentanoic acid (valeric acid), hexanoic acid (caproic acid), heptanoic acid (enanthic acid), 2-propenoic acid (acrylic acid), glycolic acid, glyoxylic acid, lactic acid, glyceric acid, aldonic acid, pyruvic acid, glycidic or a mixture thereof. In some embodiments, suitable dicarboxylic acids can include, but are not limited to, ethanedioic acid (oxalic acid), propanedioic acid (malonic acid), butanedioic acid (succinic acid), pentanedioic acid (glutaric acid), hexanedioic acid (adipic acid), heptanedioic acid (pimetic acid), aldaric acid, tartronic acid, mesoxalic acid, dihydroxypropanedioic acid (dihydroxymalonic acid) or a mixture thereof. In some embodiments, suitable tricarboxylic acids can include, but are not limited to, 2-hydroxypropane-1,2,3-tricarboxylic acid (citric acid), 1-hydroxypropane-1,2,3-tricarboxylic acid (isocitric acid), prop-1-ene-1,2,3-tricarboxylic acid (aconitic acid), propane-1,2,3-tricarboxylic acid (propane-1,2,3-tricarboxylic acid), 2- hydroxynonadecane-1,2,3-tricarboxylic acid (agaric acid), benzene-1,3,5-tricarboxylic acid (trimesic acid), or a mixture thereof.

[0054] In some embodiments, the carboxylic acid can be present in an amount sufficient to provide a molar ratio of carboxylic acid functional groups in the carboxylic acid to the promoter, e.g., Sn, in the promoter-containing compound of at least 1:1, at least 1.5:1, at least 2:1, at least 2.5:1, at least 2.7:1, at least 3:1, at least 3.3:1, at least 3.5:1, at least 3.7:1, at least 4:1, at least 4.3:1, at least 4.5:1, at least 4.7:1, or at least 5:1. In some embodiments, the carboxylic acid can be present in an amount sufficient to provide a molar ratio of carboxylic acid functional groups in the carboxylic acid to the promoter, e.g., Sn, in the promoter-containing compound in a range from 2:1, 2.5:1, or 3:1 to 3.5:1, 4:1, 5:1, 6:1, 7:1, 8:1, or greater.

[0055] In some embodiments, the liquid medium can be or can include, but is not limited to, water, one or more alcohols, acetone, chloroform, methylene chloride, dimethyl formamide, dimethyl sulfoxide, glycerin, ethyl acetate, or any mixture thereof. Illustrative alcohols can be or can include, but are not limited to methanol, ethanol, isopropanol, or a mixture thereof. In some embodiments, the water can be or can include, but is not limited to, tap water, distilled water, and / or deionized water.

[0056] In some embodiments, the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be heated to a temperature in a range from 350°C, 400°C, 450°C, 500°C, 525°C, or 550°C to 575°C, 600°C, 650°C, 675°C, 700°C, 725°C, 750°C, 775°C, 800°C, 825°C, 850°C, 875°C, or 900°C. In some embodiments, the mixture that includes the Group 8-10 element- containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be heated to the temperature for a time period in a range from 10 minutes, 15 minutes 20 minutes 30 minutes 45 minutes or 1 hour to 2 hours, 4 hours, 6 hours, 8 hours, 10 hours, 12 hours, 14 hours, 16 hours, 18 hours, 20 hours, 22 hours, 24 hours, or longer to produce the catalyst composition.

[0057] In some embodiments, the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be heated to the temperature in the presence of any desired gas or atmosphere, e.g., an oxidizing atmosphere, an inert atmosphere, or a reducing atmosphere. In some embodiments, suitable oxidizing gases can be or can include, but are not limited to, O2, O3, steam, or a mixture thereof. In some embodiments, the oxidizing atmosphere can be or can include, but is not limited to air, O2enriched air, O2depleted air, or any other suitable O2containing mixture. In some embodiments, suitable inert gases can be or can include, but are not limited to, He, Ne, Ar, N2, CO2, CH4, steam, or any mixture thereof. In some embodiments, suitable reducing gases can be or can include, but are not limited to, H2, CO, CH4, C2H6, C3H8, C2H4, C3H6, or any mixture thereof. In some embodiments, the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support can be heated to the temperature in the presence O2, e.g., air. Processes for Making the Support

[0058] The preparation of the support can be accomplished via any known process. For simplicity and ease of description, the preparation of a suitable support that includes a mixed oxide of magnesium and aluminum (Mg(Al)O or MgO / Al2O3) will be described in more detail.Catalyst synthesis techniques are well-known, and the following description is for illustrative purposes and not to be considered as limiting the synthesis of the support or the catalyst. In some embodiments, to make the mixed Mg / Al metal oxide that can make up at least a portion or all of the support, Mg and Al precursors can be mixed together, e.g., ball-milled, followed by calcination. In some embodiments, the Mg precursor can be or can include, but is not limited to, magnesium nitrate, a hydrated magnesium nitrate having a formula of Mg(NO3)2(H2O)x, where x = 6 or 2; a magnesium oxide; a magnesium hydroxide; hydromagnesite (a hydrated magnesium carbonate mineral, Mg5(CO3)4(OH)2•4H2O); a magnesium salt; a magnesium- containing clay; or a mixture thereof. In some embodiments, the Al precursor can be or can include, but is not limited to, aluminum nitrate, a hydrated aluminum nitrate having a formula of Al(NO3)3(H2O)9; aluminum oxide; (NaAlCO3(OH)2; (Al5(CO3)(OH)13•5(H2O)); (Al14(CO3)3(OH)36•nH2O); AlCl3; a mixture thereof.

[0059] In another embodiment, the two precursors can be dissolved in H2O, stirred until dry (with heat optionally applied), followed by calcination to produce the support. In another embodiment, the two precursors can be dissolved in H2O, followed by the addition of a base and a carbonate, e.g., NaOH / Na2CO3, to produce hydrotalcite, followed by calcination to produce the support. In still other embodiments, the support can be obtained by calcining a Mg / Al hydrotalcite. Without wishing to be bound by theory, it is believed that the support produced via any one of the above methods and / or other methods can include at least a portion of the Mg and at least a portion of the Al in the form of a mixed Mg / Al metal oxide.

[0060] In some embodiments, as noted above, the catalyst composition can optionally include one or more binders. In some embodiments, when the catalyst composition includes the binder, the binder can be added during the synthesis of the support. In such embodiments, the support includes the binder as a component thereof such that, in the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support, the binder can be present in the mixture as a component of the support. Processes for Making Fluidizable Catalyst Particles

[0061] In some embodiments, a process for making fluidizable catalyst particles can include spray drying the mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support to produce spray dried particles. Spray drying refers to the process of producing a dry particulate solid product from the mixture, which in some embodiments, can be in the form of a slurry or gel. The process can include spraying or atomizing the mixture, e.g., forming small droplets,into a temperature-controlled gas stream to evaporate the liquid components from the atomized droplets and produce the particulate solid product. For example, in the spray drying process, the mixture can be atomized to small droplets and mixed with hot air or a hot inert gas, e.g., nitrogen, to evaporate the liquid from the droplets. The temperature of the mixture during the spray drying process can usually be close to or greater than the boiling temperature of the liquid components. An outlet air temperature of about 60°C to about 120°C can be common.

[0062] The mixture can be atomized with one or more pressure nozzles (e.g., a fluid nozzle atomizer), one or more pulse atomizers, one or more high speed spinning discs (e.g., centrifugal or rotary atomizer), 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 via spray drying can be controlled, adjusted, or otherwise influenced by one or more operating conditions and / or parameters of the spray dryer. Illustrative operating conditions can include, but are not limited to, the feed rate and temperature of the gas stream, the atomizer velocity, the feed rate of the mixture via the atomizer, the temperature of the mixture, the size and / or solids concentration of the droplets, the spray dryer dimensions, or any combination thereof. It is well-known in the art that the various operating conditions will vary depending on the particular spray drying apparatus that is used and can be readily determined by persons having ordinary skill in the art.

[0063] In other embodiments, the process for making fluidizable catalyst particles can include preparing a slurry or gel that can include, milling, mixing, blending, combining, or otherwise contacting, but is not limited to, a compound containing Mg, a compound containing Al, and a liquid medium, e.g., water, to form a mixture. The mixture can be spray dried to produce spray dried support particles. The spray dried support particles can optionally be calcined to produce calcined spray dried support particles. A mixture that includes the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the spray dried support particles and / or the calcined spray dried support particles can be prepared and spray dried to produce the fluidizable catalyst particles.

[0064] In other embodiments, larger structure(s) of the catalyst composition can be milled, ground, or subjected to any other process capable of turning the larger structure(s) into a plurality of fluidizable catalyst particles.

[0065] Processes and equipment known in the art, such as forming through extruders, pelletizing using pelletizing machines, granulizing using a tumbler, or the like, may be used to make catalyst supports and final catalysts with various dimensions and geometry.A First Process for Upgrading a Hydrocarbon

[0066] The first process for upgrading a hydrocarbon can include contacting a first hydrocarbon-containing feed with the catalyst composition that can include the Group 8-10 element and promoter disposed about the 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 can include one or more upgraded hydrocarbons and molecular hydrogen. The catalyst composition and the first hydrocarbon-containing feed can be contacted with one another within any suitable environment such as one or more reaction or conversion zones disposed within one or more reactors to produce the effluent and the coked catalyst composition. The reaction or conversion zone can be disposed or otherwise located within one or more fixed bed reactors, one or more fluidized or moving bed reactors, one or more reverse flow reactors, or any combination thereof.

[0067] The first hydrocarbon-containing feed and the catalyst composition can be contacted at a temperature in a range 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 can 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 can be introduced into the reaction or conversion zone and contacted with the catalyst composition therein for a time period 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 second. In some embodiments, the first hydrocarbon-containing feed can be contacted with the catalyst composition for a time period in a range from 0.1 seconds, 0.5 seconds, 0.7 seconds, 1 second, 30 second, 1 minute, 5 minutes, or 10 minutes to 30 minutes, 50 minutes, 70 minutes, 1.5 hours, 2 hours, or 3 hours.

[0068] The first hydrocarbon-containing feed and the catalyst composition can be contacted under a hydrocarbon partial pressure of at least 20 kPa-absolute, where the hydrocarbon partial pressure is the total partial pressure of any C2-C16alkanes and any C8-C16alkyl aromatics in the first hydrocarbon-containing feed. In some embodiments, the hydrocarbon partial pressure during contact of the first hydrocarbon-containing feed and the catalyst composition can be in a range from 20 kPa-absolute, 50 kPa-absolute, 100 kPa-absolute, at least 150 kPa, at least 200 kPa 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, where the hydrocarbon partial pressure is the total partial pressure of any C2-C16alkanes and any C8-C16alkyl aromatics in the first hydrocarbon- containing feed. In other embodiments, the hydrocarbon partial pressure during contact of the first hydrocarbon-containing feed and the catalyst composition can be in a range from 20 kPa- absolute, 50 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, where the hydrocarbon partial pressure is the total partial pressure of any C2-C16alkanes and any C8-C16alkyl aromatics in the first hydrocarbon-containing feed.

[0069] In some embodiments, the first hydrocarbon-containing feed can include 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-C16alkane, e.g., propane, based on a total volume of the first hydrocarbon-containing feed. The first hydrocarbon- containing feed and the catalyst composition can be contacted under a single C2-C16 alkane, e.g., propane, pressure of at least 20 kPa-absolute, at least 50 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.

[0070] The first hydrocarbon-containing feed can be contacted with the catalyst composition within the reaction or conversion zone at any weight hourly space velocity (WHSV) effective for carrying out the upgrading process. In some embodiments, the WHSV can be 0.01 hr−1, 0.1 hr−1, 1 hr−1, 2 hr−1, 5 hr-1, 10 hr−1, 20 hr−1, 30 hr−1, or 50 hr−1to 100 hr−1, 250 hr−1, 500 hr−1, or 1,000 hr−1. In some embodiments, when the hydrocarbon upgrading process includes a fluidized or otherwise moving catalyst composition, a ratio of the catalyst composition circulation mass flow rate to a combined amount of any C2-C16 alkanes and any C8-C16 alkyl aromatics mass flow rate can be in a 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 weight to weight basis.

[0071] When the activity of the coked catalyst composition decreases below a desired amount, the coked catalyst composition or at least a portion thereof can be subjected to a regeneration process to produce a regenerated catalyst composition. More particularly, the coked catalyst composition can be contacted with one or more oxidants to effect combustion of at least a portion of the coke to produce a regenerated catalyst composition lean in coke and a combustion gas. Regeneration of the coked catalyst composition can occur within the reaction or conversion zone or within a combustion zone that is separate and apart from the reaction or conversion zone, depending on the particular reactor configuration, to produce theregenerated catalyst composition. For example, regeneration of the coked catalyst composition can occur within the reaction or conversion zone when a fixed bed or reverse flow reactor is used, or within a separate combustion zone that can be separate and apart from the reaction or conversion zone when a fluidized bed reactor or other circulating or fluidized type reactor is used.

[0072] In some embodiments the process can 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 quantity of the first hydrocarbon-containing feed can 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 re-coked catalyst composition and additional effluent. Reduction of the regenerated catalyst composition can occur within the reaction or conversion zone, within the regeneration zone, or within a reduction zone that is separate and apart from the reaction or conversion zone and the regeneration zone, depending on the particular reactor configuration, to produce the regenerated and reduced catalyst composition. For example, reduction of the regenerated catalyst composition can occur within the reaction or conversion zone when a fixed bed or reverse flow reactor is used, or within a separate reduction zone that can be separate and apart from the reaction or conversion zone and the regeneration zone when a fluidized bed reactor or other circulating or fluidized type reactor is used.

[0073] In some embodiments, a cycle time from contacting the first hydrocarbon-containing feed with the catalyst composition to contacting the additional quantity of the first hydrocarbon-containing feed with the regenerated catalyst composition can be ≤ 5 hours. The first cycle begins upon contact of the catalyst composition with the first hydrocarbon- containing feed, followed by contact with at least the oxidative gas to produce the regenerated catalyst composition or at least the oxidative gas and the optional reducing gas to produce the regenerated catalyst composition, and the first cycle ends upon contact of the regenerated catalyst composition with the additional quantity of the first hydrocarbon-containing feed. If one or more additional feeds (described in more detail below) are utilized between flows of the first hydrocarbon-containing feed and the oxidative gas, between the oxidative gas and the reducing gas (if used), between the oxidative gas and the additional quantity of the first hydrocarbon-containing feed, and / or between the reducing gas (if used) and the additional quantity of the first hydrocarbon-containing feed, the period of time such stripping gas(es) is / are utilized would be included in the period included in the cycle time. As such, the cycle time from contacting the first hydrocarbon-containing feed with the catalyst composition tothe contacting the additional quantity of the first hydrocarbon-containing feed with the regenerated catalyst composition, in some embodiments, can be ≤ 5 hours, ≤ 4 hours, ≤ 3 hours, ≤ 2 hours, ≤ 1 hour, ≤ 50 minutes, ≤ 45 minutes, ≤ 40 minutes, ≤ 35 minutes, ≤ 30 minutes, ≤ 25 minutes, ≤ 20 minutes, ≤ 15 minutes, ≤ 10 minutes, ≤ 5 minutes, ≤ 1 minute, ≤ 30 seconds, or ≤ 10 seconds.

[0074] The oxidant can be or can include, but is not limited to, O2, O3, CO2, H2O, or a mixture thereof. In some embodiments, an amount of oxidant in excess of that needed to combust 100% of the coke on the coked catalyst composition can be used to increase the rate of coke removal from the catalyst composition, so that the time needed for coke removal can be reduced and lead to an increased yield in the upgraded product produced within a given period of time. The use of pure O2 as an oxidant can facilitate the capturing and sequestration of CO2made during combustion in one or more downstream CO2recovery systems.

[0075] The coked catalyst composition and oxidant can be contacted with one another at a temperature in a range 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 oxidant can be contacted with one another at a temperature in a range 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.

[0076] The coked catalyst composition and oxidant can be contacted with one another for a time period of ≤ 2 hours, ≤ 1 hour, ≤ 30 minutes, ≤ 10 minutes, ≤ 5 minutes, ≤ 1 min, ≤ 30 seconds, ≤ 10 seconds, ≤ 5 seconds, or ≤ 1 second. For example, the coked catalyst composition and oxidant can be contacted with one another for a time period in a range from 2 seconds to 2 hours. In some embodiments, the coked catalyst composition and oxidant can be contacted for a time period sufficient to remove ≥ 50 wt%, ≥ 75 wt%, or ≥ 90 wt% or > 99 % of any coke disposed on the catalyst composition.

[0077] In some embodiments, the time period the coked catalyst composition and oxidant contact one another can be less than the time period the catalyst composition contacts the first hydrocarbon-containing feed to produce the effluent and the coked catalyst composition. For example, the time period the coked catalyst composition and oxidant contact one another can be at least 90%, at least 60%, at least 30%, or at least 10% less than the time period the catalyst composition contacts the first hydrocarbon-containing feed to produce the effluent. In other embodiments, the time period the coked catalyst composition and oxidant contact one another can be greater than the time period the catalyst composition contacts the first hydrocarbon- containing feed to produce the effluent and the coked catalyst composition. For example, insome embodiments, the coked catalyst composition and oxidant can contact one another for a time period that can 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% greater than the time period the catalyst composition contacts the first hydrocarbon-containing feed to produce the effluent.

[0078] The coked catalyst composition and oxidant can be contacted with one another under an oxidant partial pressure in a range from 20 kPa-absolute, 50 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 can be in a range from 20 kPa- absolute, 50 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 to produce the regenerated catalyst composition.

[0079] Without wishing to be bound by theory, it is believed that at least a portion of the Group 8-10 element present in / on the coked catalyst composition can be agglomerated as compared to the catalyst composition prior to contact with the first hydrocarbon-containing feed. It is believed that during combustion of at least a portion of the coke on the coked catalyst composition that at least a portion of the Group 8-10 element can be re-dispersed about the support of the catalyst composition. Re-dispersing at least a portion of any agglomerated Group 8-10 element can improve the stability of the catalyst composition over many cycles.

[0080] In some embodiments, at least a portion of the Group 8-10 element in the regenerated catalyst composition can be at a higher oxidized state as compared to the Group 8-10 element in the catalyst composition contacted with the first hydrocarbon-containing feed and as compared to the Group 8-10 element in the coked catalyst composition. As such, as noted above, in some embodiments the process can optionally include contacting at least a portion of the regenerated catalyst composition with a reducing gas to produce a regenerated and reduced catalyst composition. Suitable reducing gases (reducing agent) can be or can include, but are not limited to, H2, CO, CH4, C2H6, C3H8, C2H4, C3H6, steam, or a mixture thereof. In some embodiments, the reducing agent can be mixed with an inert gas such as Ar, Ne, He, N2, CO2, H2O or a mixture thereof. In such embodiments, at least a portion of the Group 8-10 element in the regenerated and reduced catalyst composition can be reduced to a loweroxidation state, e.g., the elemental state, as compared to the Group 8-10 element in the regenerated catalyst composition. In this embodiment, the additional quantity of the first hydrocarbon-containing feed can be contacted with at least a portion of the regenerated catalyst composition and / or at least a portion of the regenerated and reduced catalyst composition.

[0081] In some embodiments, the regenerated catalyst composition and the reducing gas can be contacted at a temperature in a range 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 can be contacted for a time period in a range 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 can be contacted at a reducing agent partial pressure of 20 kPa-absolute, 50 kPa-absolute, or 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 can be in a range from 20 kPa-absolute, 50 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 to produce the regenerated catalyst composition.

[0082] At least a portion of the regenerated catalyst composition, the regenerated and reduced catalyst composition, new or fresh catalyst composition, or a mixture thereof can be contacted with an additional quantity of the first hydrocarbon-containing feed within the reaction or conversion zone to produce additional effluent and additional coked catalyst composition. As noted above, in some embodiments, the cycle time from the contacting the first hydrocarbon-containing feed with the catalyst composition to the contacting the additional quantity of the first hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition, and / or the regenerated and reduced catalyst composition, and optionally with new or fresh catalyst composition can be ≤ 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.

[0083] In some embodiments, as noted above, one or more additional feeds, e.g., one or more sweep fluids, can be utilized between flows of the first hydrocarbon-containing feed and the oxidant, 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 can, among other things, purgeor otherwise urge undesired material from the reactors, such as non-combustible particulates including soot. In some embodiments, the additional feed(s) can be inert under the dehydrogenation, dehydroaromatization, and dehydrocyclization, combustion, and / or reducing conditions. Suitable sweep fluids can be or can include, but are not limited to, N2, He, Ar, CO2, H2O, CO2, CH4, or a mixture thereof. In some embodiments, if the process utilizes a sweep fluid the duration or time period the sweep fluid is used can be in a range from 1 second, 5 seconds, 10 seconds, 20 seconds, 30 seconds, or 1 minute to 10 minutes, 30 minutes, or 60 minutes.

[0084] In some embodiments, the catalyst composition can remain sufficiently active and stable after many cycles, e.g., 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 for ≤ 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 can 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 the catalyst performance stabilizes (sometimes the first few cycles can have a relatively poor or a relatively good performance, but the performance can eventually stabilize), the process can produce a first upgraded hydrocarbon product yield, e.g., propylene when the first hydrocarbon-containing feed includes propane, at an upgraded hydrocarbon selectivity, e.g., propylene, of ≥ 75%, ≥ 80%, ≥ 85%, ≥ 90%, ≥ 93%, or ≥ 95% when initially contacted with the first hydrocarbon-containing feed, and can have a second upgraded hydrocarbon product yield upon completion of the last cycle (at least 15 cycles total) that can 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 at an upgraded hydrocarbon selectivity, e.g., propylene, of ≥ 75%, ≥ 80%, ≥ 85%, or ≥ 90%, ≥ 93%, or ≥ 95%.

[0085] In some embodiments, when the first hydrocarbon-containing feed includes propane and the upgraded hydrocarbon includes propylene, contacting the first hydrocarbon-containing feed with the catalyst composition can produce a propylene yield of ≥ 52%, ≥ 53%, ≥ 55%, ≥ 57%, ≥ 60%, ≥ 62%, ≥ 63%, ≥ 64%, ≥ 65%, or ≥ 66% at 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 other embodiments, when the first hydrocarbon- containing feed includes at least 70 vol% of propane, based on a total volume of the firsthydrocarbon-containing feed, is contacted under a propane partial pressure of at least 20 kPa- absolute, a propylene yield of ≥ 52%, ≥ 53%, ≥ 55%, ≥ 57%, ≥ 60%, ≥ 62%, ≥ 63%, ≥ 64%, ≥ 65%, or ≥ 66% at a propylene selectivity of ≥ 75%, ≥ 80%, ≥ 85%, ≥ 90%, ≥ 93%, or ≥ 95% can be obtained 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 the propylene yield can be further increased to ≥ 67%, ≥ 68%, ≥ 70%, ≥ 72%, ≥ 75%, ≥ 77%, ≥ 80%, or ≥ 82% at a propylene selectivity of ≥ 75%, ≥ 80%, ≥ 85%, ≥ 90%, ≥ 93%, or ≥ 95% for ≥ 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 by further optimizing the composition of the support and / or adjusting one or more process conditions. In some embodiments, the propylene yield can be obtained when the catalyst composition is contacted with the first hydrocarbon-containing feed 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 for ≥ 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.

[0086] In some embodiments, when a fluidized bed reactor or other circulating or fluidized type reactor is used, the catalyst composition can be introduced into any location or combination of locations of the reactor system. In some embodiments, the catalyst composition can be introduced into the reaction or conversion zone, the regeneration zone, if present, the reduction zone, any location located between any two of the zones or any combination thereof. In some embodiments, when a fluidized bed reactor or other circulating or fluidized type reactor is used, the two or more portions or quantities of the catalyst composition can be introduced separately into the reactor system. In such embodiments, the two or more portions or quantities of the catalyst composition can be introduced into the same zone or into different zones or a first portion of the catalyst composition can be introduced into the reactor system at a first location and a second portion of the catalyst composition can be introduced into the reactor system at a second location.

[0087] Systems suitable for carrying out the processes disclosed herein can include systems that are well-known in the art such as the fixed bed reactors disclosed in WO Publication No. WO2017078894; the fluidized riser reactors and / or downer reactors disclosed in 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 the reverse flow reactors disclosed in U.S. Patent No. 8,754,276; U.S. Patent Application Publication No. 2015 / 0065767; and WO Publication No. WO2013169461.First hydrocarbon-containing Feed

[0088] The first hydrocarbon-containing feed can be or can include, but is not limited to, one or more alkane hydrocarbons, e.g., C2-C16 linear or branched alkanes and / or C4-C16 cyclic alkanes, and / or one or more alkyl aromatic hydrocarbons, e.g., C8-C16alkyl aromatics. In some embodiments, the first hydrocarbon-containing feed can optionally include 0.1 vol% to 50 vol% of steam, based on a total volume of any C2-C16alkanes and any C8-C16alkyl aromatics in the first hydrocarbon-containing feed. In other embodiments, the first hydrocarbon-containing feed can include < 0.1 vol% of steam or can be free of steam, based on the total volume of any C2-C16 alkanes and any C8-C16 alkyl aromatics in the first hydrocarbon-containing feed.

[0089] The C2-C16alkanes can be or can include, but are 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 a mixture thereof. For example, the first hydrocarbon-containing feed can include propane, which can be dehydrogenated to produce propylene, and / or isobutane, which can be dehydrogenated to produce isobutylene. In another example, the first hydrocarbon-containing feed can include liquid petroleum gas (LP gas), which can be in the gaseous phase when contacted with the catalyst composition. In some embodiments, the hydrocarbon in the first hydrocarbon-containing feed can be composed of substantially a single alkane such as propane. In some embodiments, the first hydrocarbon-containing feed can include ≥ 50 mol%, ≥ 75 mol%, ≥ 95 mol%, ≥ 98 mol%, or ≥ 99 mol% of a single C2-C16alkane, e.g., propane, based on total moles of all hydrocarbons in the first hydrocarbon- containing feed. In some embodiments, the first hydrocarbon-containing feed can include 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-C16 alkane, e.g., propane, based on a total volume of the first hydrocarbon-containing feed.

[0090] The C8-C16 alkyl aromatics can be or can include, but are not limited to, ethylbenzene, propylbenzene, butylbenzene, one or more ethyl toluenes, or a mixture thereof. In some embodiments, the first hydrocarbon-containing feed can include ≥ 50 mol%, ≥ 75 mol%, ≥ 95 mol%, ≥ 98 mol%, or ≥ 99 mol% of a single C8-C16alkyl aromatic, e.g., ethylbenzene, based on a total weight of all hydrocarbons in the first hydrocarbon-containing feed. In some embodiments, the ethylbenzene can be dehydrogenated to produce styrene. As such, in some embodiments, the first process for upgrading a hydrocarbon disclosed herein can includepropane dehydrogenation, butane dehydrogenation, isobutane dehydrogenation, pentane dehydrogenation, pentane dehydrocyclization to cyclopentadiene, naphtha reforming, ethylbenzene dehydrogenation, ethyl toluene dehydrogenation, and the like.

[0091] In some embodiments, the first hydrocarbon-containing feed can be diluted, e.g., with one or more diluents such as one or more inert gases. Suitable inert gases can be or can include, but are not limited to, Ar, Ne, He, N2, CO2, CH4, or a mixture thereof. If the hydrocarbon containing-feed includes a diluent, the first hydrocarbon-containing feed can include 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 a total volume of any C2-C16 alkanes and any C8-C16 alkyl aromatics in the first hydrocarbon- containing feed.

[0092] In some embodiments, the first hydrocarbon-containing feed can also include H2. In some embodiments, when the first hydrocarbon-containing feed includes H2, a molar ratio of the H2 to a combined amount of any C2-C16 alkane and any C8-C16 alkyl aromatic can be in a range from 0.1, 0.3, 0.5, 0.7, or 1 to 2, 3, 4, 5, 6, 7, 8, 9, or 10. In other embodiments, H2 can be introduced into the reactor system as a feed separate and apart from the first hydrocarbon- containing feed.

[0093] In some embodiments, first hydrocarbon-containing feed and the environment within the reactor system can be substantially free of any steam, e.g., < 0.1 vol% of steam, based on a total volume of any C2-C16alkanes and any C8-C16alkyl aromatics in the first hydrocarbon- containing feed. In other embodiments, the first hydrocarbon-containing feed can include steam and / or steam can be introduced into the reactor system as a feed separate and apart from the first hydrocarbon-containing feed. For example, the first hydrocarbon-containing feed or, if introduced separate from the first hydrocarbon-containing feed, the environment within the reactor system can include 0.1 vol%, 0.3 vol%, 0.5 vol%, 0.7 vol%, 1 vol%, 3 vol%, or 5 vol% to 10 vol%, 11 vol%, 12 vol%, 13 vol%, 14 vol%, 15 vol%, 16 vol%, 17 vol%, 18 vol%, 19 vol%, 20 vol%, 21 vol%, 22 vol%, 23 vol%, 24 vol%, 25 vol%, 26 vol%, 27 vol%, 28 vol%, 29 vol%, 30 vol%, 35 vol%, 40 vol%, 45 vol%, or 50 vol% of steam, based on a total volume of any C2-C16 alkanes and any C8-C16 alkyl aromatics in the first hydrocarbon-containing feed. In other embodiments, the first hydrocarbon-containing feed or, if introduced separate from the first hydrocarbon-containing feed, the environment within the reactor system can include ≤ 50 vol%, ≤ 45 vol%, ≤ 40 vol%, ≤ 35 vol%, ≤ 30 vol%, ≤ 25 vol%, ≤ 20 vol%, or ≤ 15 vol% of steam, based on a total volume of any C2-C16 alkanes and any C8-C16 alkyl aromatics in the first hydrocarbon-containing feed. In other embodiments, the first hydrocarbon-containing feed or, if introduced separate from the first hydrocarbon-containing feed, the environmentwithin the reactor system can include 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% of steam, based on a total volume of any C2-C16 alkanes and any C8-C16 alkyl aromatics in the first hydrocarbon-containing feed.

[0094] In some embodiments, the first hydrocarbon-containing feed can include sulfur or sulfur can be introduced as a feed separate and apart from the first hydrocarbon-containing feed. For example, the first hydrocarbon-containing feed can include sulfur in a range from 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 can include sulfur in a range from 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. The sulfur, if present in the first hydrocarbon-containing feed, can be or can include, but is not limited to, H2S, dimethyl disulfide, as one or more mercaptans, or any mixture thereof.

[0095] In some embodiments, the first hydrocarbon-containing feed and the environment within the reaction or conversion zone can be substantially free or free of molecular oxygen. In some embodiments, the first hydrocarbon-containing feed can include ≤ 5 mol%, ≤ 3 mol%, or ≤ 1 mol% of molecular oxygen (O2). It is believed that providing a first hydrocarbon- containing feed substantially-free of molecular oxygen substantially prevents oxidative reactions that would otherwise consume at least a portion of the alkane and / or the alkyl aromatic in first hydrocarbon-containing feed. Recovery and Use of the First Upgraded Hydrocarbon

[0096] In some embodiments, the first upgraded hydrocarbon in the effluent can include at least one upgraded hydrocarbon, e.g., an olefin, water, unreacted hydrocarbons, molecular hydrogen, etc. The upgraded hydrocarbon can be recovered or otherwise obtained via any convenient process, e.g., by one or more conventional processes. One such process can include cooling and / or compressing the effluent to condense at least a portion of any water and any heavy hydrocarbon that may be present, leaving the olefin and at least a portion of any unreacted alkane or alkyl aromatic primarily in the vapor phase. Olefin and unreacted alkane or alkyl aromatic hydrocarbons can then be removed from the reaction product in one or more separator drums. For example, one or more splitters or distillation columns can be used to separate the dehydrogenated product from the unreacted first hydrocarbon-containing feed.

[0097] In some embodiments, a recovered olefin, e.g., propylene, can be used for producing polymer, e.g., recovered propylene can be polymerized to produce polymer having segments or units derived from the recovered propylene such as polypropylene, ethylene-propylenecopolymer, etc. Recovered isobutene can be used, e.g., for producing one or more of: an oxygenate such as methyl tert-butyl ether, fuel additives such as diisobutene, synthetic elastomeric polymer such as butyl rubber, etc. A Second Process for Upgrading a Hydrocarbon

[0098] The second process for upgrading a hydrocarbon can include contacting a second hydrocarbon-containing feed with the catalyst composition that can include the Group 8-10 element and the promoter disposed about the support to effect reforming of at least a portion of the second hydrocarbon-containing feed to produce a coked catalyst composition and an effluent that can include carbon monoxide and molecular hydrogen. The catalyst composition and the second hydrocarbon-containing feed can be contacted with one another within any suitable environment such as one or more reaction or conversion zones disposed within one or more reactors to produce the effluent and the coked catalyst composition. The reaction or conversion zone can be disposed or otherwise located within one or more fixed bed reactors, one or more fluidized or moving bed reactors, one or more reverse flow reactors, or any combination thereof. For clarity and ease of description, the reforming reaction will be discussed in the context of a fluidized bed reactor, but it should be understood that fixed bed reactors, reverse flow or moving bed reactors, or any other reactor can be used to carry out the reforming of the second hydrocarbon-containing feed.

[0099] The reforming reaction can be used to produce reformed hydrocarbons via a continuous reaction process or a discontinuous reaction process. In some embodiments, the reaction process can include a reforming step, e.g., an endothermic reaction, and a regeneration step, e.g., an exothermic reaction, that operate continuously while the fluidized catalyst is transported in-between the reforming zone and regeneration zone of the reactor. The endothermic reaction can include hydrocarbon reforming in the presence of the catalyst composition. Fresh hydrocarbon and regenerated fluidized catalyst particles can enter the reforming zone. After spending some time in the reforming zone, the hydrocarbon can be at least partially converted to a reforming product that can exit the reforming zone together with the spent catalyst composition. The reforming product and unreacted feed can be separated from the spent catalyst composition by one or more separating devices. While the reforming product and unreacted feed from the separating devices go downstream for further purification, the spent catalyst composition 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 composition and a flue gas. After regeneration, the regenerated catalyst composition can be separated from the flue gas by oneor more separating devices and can be transported back to the reforming zone, joining more hydrocarbon feed to enter the reforming zone to initiate more reforming reaction. The reforming step can convert CO2 and / or H2O and hydrocarbons, e.g., CH4, to a synthesis gas that includes H2and CO. The regeneration step can combust reactants, e.g., coke disposed on the spent catalyst composition and / or the optional fuel and an oxidant, to generate heat that heats up the regenerated catalyst composition that can provide heat that can be used to drive the reforming reaction. In some embodiments, the catalyst composition can be heated to an average temperature in a range of from 600°C, 700°C, or 800°C to 1,000°C, 1,300°C, or 1,600°C during the regeneration step.

[0100] Illustrative fuels can be or can include, but are not limited to, hydrocarbons, e.g., methane, ethane, propane, butane, pentane, or hydrocarbon containing streams, e.g., natural gas, molecular hydrogen, fuel oil, heavy fuel oil, gasoline, diesel, kerosene, distillate, and / or other combustible compounds. The oxidant can be or can include O2. In some embodiments, the oxidant can be or can include air, O2 enriched air, O2 depleted air, or any other suitable O2 containing stream.

[0101] The regeneration of the catalyst composition can correspond to removal of coke from the particles in the catalyst composition. In some embodiments, during reforming, a portion of the feed introduced into the reforming zone can form coke. This coke can potentially block access to the catalytic sites (such as metal sites) of the catalyst composition. During regeneration at least a portion of the coke generated during reforming can be removed as CO or CO2. The regeneration of the catalyst composition can also correspond to re-dispersion of any agglomerated active phase of the catalyst such as the Group 8-10 element. Second Hydrocarbon-Containing Feed

[0102] The second hydrocarbon-containing feed can be or can include, but is not limited to, one or more reformable C1-C16hydrocarbons such as alkanes, alkenes, cycloalkanes, alkylaromatics, or any mixture thereof. In some embodiments, the second hydrocarbon- containing feed can be or can include methane, ethane, propane, butane, pentane, or a mixture thereof. In some embodiments, the second hydrocarbon-containing feed can be exposed to the catalyst composition under a pressure of less than 35 kPag. For example, the second hydrocarbon-containing feed can be exposed to the catalyst composition under a pressure in a range of from 0.7 kPag, 2 kPag, 3.5 kPag, 5 kPag, or 10 kPag to 15 kPag, 20 kPag, 25 kPag, or 30 kPag. In other embodiments, the second hydrocarbon-containing feed can be exposed to the catalyst composition under a pressure in a range of from 35 kPag to 15 MPag. In still other embodiments, the second hydrocarbon-containing feed can be exposed to the catalystcomposition under a pressure in a range of from 0.7 kPag, 2 kPag, 5 kPag, 20 kPag, 35 kPag, 50 kPag, or 100 kPag to 200 kPag, 1 MPag, 3 MPag, 5 MPag, 10 MPag, or 15 MPag. In still other embodiments, the second hydrocarbon-containing feed can be exposed to the catalyst composition under a pressure of less than 2.8 MPag, less than 2.5 MPag, less than 2.2 MPag, or less than 2 MPag.

[0103] The reforming reaction of the second hydrocarbon-containing feed, e.g., CH4, can occur in the presence of H2O (steam-reforming), in the presence of CO2 (dry-reforming), or in the presence of both H2O and CO2(bi-reforming). Examples of stoichiometry for steam, dry, and bi-reforming of CH4 are shown in equations (1) – (3). (1) Dry-Reforming: CH4+ CO2= 2CO + 2H2(2) Steam-Reforming: CH4 + H2O = CO + 3H2 (3) Bi-Reforming: 3CH4+ 2H2O + CO2= 4CO + 8H2

[0104] As shown in equations (1) – (3), dry reforming can produce lower ratios of H2 to CO than steam reforming. Reforming reactions performed with only steam can generally produce a synthesis gas having a H2:CO molar ratio of around 3, such as 2.5 to 3.5. In contrast, reforming reactions performed with only CO2 can generally produce a synthesis gas having a H2:CO molar ratio of roughly 1 or even lower. By using a combination of CO2and H2O during reforming, the reforming reaction can be controlled to generate a wide variety of H2 to CO ratios in a resulting synthesis gas.

[0105] It should be noted that the ratio of H2 to CO in a synthesis gas can also be dependent on the water gas shift equilibrium. Although the stoichiometry in Equations (1) – (3) shows ratios of roughly 1 or roughly 3 for dry reforming and steam reforming, respectively, the equilibrium amounts of H2and CO in a synthesis gas can be different from the reaction stoichiometry. The equilibrium amounts can be determined based on the water gas shift equilibrium, which relates the concentrations of H2, CO, CO2and H2O based on the reaction shown in equation (4). (4) H2O + CO ⇌ H2+ CO2

[0106] In some embodiments, the catalyst composition can also serve as water gas shift catalysts. Thus, if a reaction environment for producing H2 and CO also includes H2O and / or CO2, the initial stoichiometry from the reforming reaction may be altered based on the water gas shift equilibrium. However, this equilibrium is also temperature dependent, with higher temperatures favoring production of CO and H2O. As a result, the ratio of H2 to CO that is generated when forming synthesis gas is constrained by the water gas shift equilibrium at the temperature in the reaction zone when the synthesis gas is produced.

[0107] The ability to adjust the H2:CO molar ratio of the synthesis gas provides a flexible process that can be combined with a wide variety of synthesis gas upgrading processes. Illustrative synthesis gas upgrading processes can include, but are not limited to, Fischer- Tropsch processes, methanol and / or other alcohol synthesis, e.g., one or more C1-C4alcohols, fermentation processes, separation processes that can separate hydrogen to produce a H2-rich product, dimethyl ether, and combinations thereof. These synthesis gas upgrading processes are well-known to persons having ordinary skill in the art. In some embodiments, the upgraded product can include, but is not limited to, methanol, syncrude, diesel, lubricants, waxes, olefins, dimethyl ether, other chemicals, or any combination thereof.

[0108] Systems suitable for carrying out the reforming of the second hydrocarbon-containing feed can include systems that are well-known in the art such as the fixed bed reactors disclosed in WO Publication No. WO2017078894; the fluidized riser reactors and / or downer reactors disclosed in 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 the reverse flow reactors disclosed in U.S. Patent Nos.: 7,740,829; 8,551,444; 8,754,276; 9,687,803; and 10,160,708; and U.S. Patent Application Publication Nos.: 2015 / 0065767 and 2017 / 0137285; and WO Publication No. WO2013169461. Feeds and Energy

[0109] The first and second hydrocarbon-containing feeds described herein can be derived either from fossil fuel or non-fossil fuel resources. For example, propane can be a product or by-product of a process using biomass as the feed. The fuels described in this work can also be derived either from fossil fuel or non-fossil fuel resources. For example, methane or H2 can be a product or by-product of a process using biomass as the feed. The fuels described in this work can also be made from renewable energy such as renewable electricity. For example, renewable electricity can be used to produce H2through water electrolysis. The energy used in the processes described herein can also be provided by renewable electricity, instead of a fuel. Examples:

[0110] The foregoing discussion can be further described with reference to the following non-limiting examples.

[0111] Inventive catalysts (Catalyst 1 and Catalyst 3) and comparative catalysts (Catalyst 2 and Catalyst 4) were prepared according to the following procedures. The preparation of Catalyst 1 and Catalyst 2 utilized a hydrotalcite based support in the form of a cylindrical pellet prepared by extrusion. The hydrotalcite based supports had a diameter of about 3 mm and athickness of about 3 mm, a surface area in a range from about 100 m2 / g to about 200 m2 / g, and a Mg to Al2molar ratio in a range from about 6:4 to about 9:1. The preparation of Catalyst 3 and Catalyst 4 utilized a hydrotalcite based support in the form of spherical particles that were prepared by spray drying. The hydrotalcite based supports of Catalyst 3 and Catalyst 4 were in the form of spherical particles that had an average diameter of about 70 μm, a surface area in a range from about 100 m2 / g to about 200 m2 / g, and a Mg to Al2molar ratio in a range from about 6:4 to about 9:1.

[0112] Catalyst 1 and Catalyst 3 were prepared according to the following procedure. Aqueous solutions of hexachloroplatinic acid (8 wt%, 0.015 mL), citric acid (33 wt%, 1.8 mL), and tin(IV) chloride pentahydrate (24 wt%, 0.254 mL) were combined to form a mixture. The mixture was added by wet impregnation to the respective hydrotalcite-based support (2.3 g). The resulting material was calcined under air for 1 h at 550°C to produce the catalyst. Catalyst 1 and Catalyst 3 each contained about 0.025 wt% of Pt and about 1 wt% of Sn.

[0113] Catalyst 2 and Catalyst 4 were prepared according to the following procedure. Aqueous solutions of hexachloroplatinic acid (8 wt%, 0.015 mL), hydrochloric acid (37 wt%, 0.14 mL), and tin(IV) chloride pentahydrate (24 wt%, 0.254 mL) were combined to form a mixture. The mixture was added by wet impregnation to the respective hydrotalcite-based support (2.3 g). The resulting material was calcined under air for 1 h at 550°C to produce the catalyst. Catalyst 2 and Catalyst 4 each contained about 0.025 wt% of Pt and about 1 wt% of Sn.

[0114] FIG.1 shows an energy-dispersive x-ray spectroscopy line scan (Sn Lα, 3.44 keV) of a cross-section of a 3 mm x 3 mm cylindrical extrudate of the inventive catalyst, i.e., Catalyst 1. FIG. 2 shows an energy-dispersive x-ray spectroscopy line scan (Sn Lα, 3.44 keV) of a cross-section of a 3 mm x 3 mm cylindrical extrudate of the comparative catalyst, i.e., Catalyst 2. As shown in FIG.1, when Catalyst 1 was made with citric acid, the line scan indicates the Sn was distributed substantially homogeneously throughout the support. More particularly, the average counts per second (cps) was about 200 cps with a deviation of about 65% from the average cps. In contrast, as shown in FIG.2, when the catalyst was made with the hydrochloric acid instead of the citric acid, the line scan indicates the Sn was not distributed substantially homogeneously throughout the support. More particularly, the average cps was about 200 cps with a deviation of about 300% from the average cps. In fact, as shown in FIG.2, a substantialportion of the Sn was disposed on the outer surface of the support, which is clearly shown via peaks on the left and right sides of the extrudate. Examples that Used Catalyst 3 and Catalyst 4

[0115] Fixed bed experiments that used Catalyst 3 and Catalyst 4 were conducted at approximately 100 kPa-absolute. A gas chromatograph (GC) was used to measure the composition of the reactor effluents. The concentration of each component in the reactor effluents were then used to calculate the C3H6 yield and selectivity. The C3H6 yield and selectivity, as reported in these examples, were calculated on the carbon mole basis.

[0116] In each example, 0.3 g of the catalyst was mixed with an appropriate amount of SiC 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 largely isothermal during operation. The dead volume of the reactor was filled with quartz chips / rods.

[0117] The process steps that used Catalyst 3 and Catalyst 4 were as follows: 1. The system was flushed with an inert gas. 2. Dry air at a flow rate of 83.9 sccm was passed through a by- pass of the reaction zone, while an inert gas was passed through the reaction zone. The reaction zone was heated to a regeneration temperature of 800°C. 3. Dry air at a flow rate of 83.9 sccm was then passed through the reaction zone for 10 min to regenerate the catalyst. 4. The system was flushed with an inert gas. 5. A H2containing gas with 10 vol% H2and 90 vol % Ar at a flow rate of 46.6 sccm was passed through the by-pass of the reaction zone for a certain period of time, while an inert gas was passed through the reaction zone. This was then followed by flowing the H2 containing gas through the reaction zone at 800°C for 3 seconds. 6. The system was flushed with an inert gas. During this process, the temperature of the reaction zone was decreased from 800°C to a reaction temperature of 670°C. 7. A hydrocarbon-containing (HCgas) feed that included 81 vol% of C3H8, 9 vol% of inert gas (Ar) and 10 vol% of steam at a flow rate of 17.6 sccm was passed through the by-pass of the reaction zone for a certain period of time, while an inert gas was passed through the reaction zone. The hydrocarbon-containing feed was then passed through the reaction zone at 670°C for 10 min. GC sampling of the reaction effluent was started as soon as the feed was switched from the by-pass of the reaction zone to the reaction zone. The above process steps were repeated in cycles.

[0118] The Table below shows the C3H6yield and C3H6selectivity of Catalyst 3 and Catalyst 4 during the 25th cycle, when the performances of the catalysts had stabilized. Catalyst 3 that was made with the citric acid as an additive showed significant increases in the C3H6yield both at 0 minute and 10 minutes of passing the hydrocarbon-containing feed throughthe reaction zone. It is believed that the more even distribution of the promoter Sn throughout the volume of the support of Catalyst 3 as compared to the distribution of the promoter Sn throughout the volume of the support of Catalyst 4 resulted in more active catalytic sites, resulting in appreciable performance improvement. Table C3H6 Yield C3H6 Yield C3H6 Selectivity C3H6 Selectivity ) Listi

[0119] This disclosure may further include the following non-limiting embodiments.

[0120] A1. A process for upgrading a hydrocarbon, comprising: (I) contacting a hydrocarbon-containing feed with a catalyst composition to effect reforming of at least a portion of the hydrocarbon-containing feed to produce a coked catalyst composition and a synthesis gas comprising H2and CO, wherein: the hydrocarbon-containing feed comprises one or more C1-C16 hydrocarbons and H2O, CO2, or a mixture of H2O and CO2, the hydrocarbon- containing feed and catalyst composition are contacted at a temperature of 400°C or more, the catalyst composition comprises a support, a Group 8-10 element, and a promoter, wherein the Group 8-10 element and the promoter are disposed through a volume of the support, the promoter comprises Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof, the support comprises a mixed Mg / Al metal oxide, and wherein the promoter is distributed substantially homogeneously throughout the volume of the support, as determined by energy- dispersive x-ray spectroscopy analysis.

[0121] A2. The process of A1, further comprising (II) contacting at least a portion of the coked catalyst composition with an oxidant to effect combustion of at least a portion of the coke to produce a regenerated catalyst composition lean in coke and a combustion gas.

[0122] A3. The process of A2, further comprising (III) contacting a fuel with the oxidant and the coked catalyst composition to effect combustion of at least a portion of the fuel.

[0123] A4. The process of A2 or A3, further comprising (IV) contacting an additional quantity of the hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition to produce a re-coked catalyst composition and additional effluent.

[0124] A5. The process of any one of A1 to A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a fluidized bed reactor.

[0125] A6. The process of any one of A1 to A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a fixed bed reactor.

[0126] A7. The process of any one of A1 to A4, wherein the hydrocarbon-containing feed is contacted with the catalyst composition in a reverse flow reactor.

[0127] A8. The process of any one of A1 to A7, wherein the catalyst composition comprises 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 the Group 8-10 element based on the weight of the support.

[0128] A9. The process of any one of A1 to A8, wherein the Group 8-10 element comprises Pt.

[0129] A10. The process of any one of A1 to A9, wherein the catalyst composition further comprises an alkali metal element comprising Li, Na, K, Rb, Cs, a combination thereof, or a mixture thereof disposed on the support in an amount of up to 5 wt% based on the weight of the support.

[0130] A11. The process of any one of A1 to A10, wherein the catalyst composition is in the form of particles having a size and particle density that is consistent with a Geldart A or Geldart B definition of a fluidizable solid.

[0131] A12. The process of any one of A1 to A11, wherein a weight ratio of the Mg to the Al in the support is in a range from 0.001, 0.01, 0.1, or 1 to 6, 12.5, 100, or 1,000.

[0132] A13. The process of any one of A1 to A12, wherein: a portion of the Mg is in the form of an oxide of the Mg, a portion of the Al is in the form Al2O3, and the oxide of the Mg and the Al2O3 are mixed on a nm scale.

[0133] A14. The process of any one of A1 to A13, wherein: a portion of the Mg is in the form of MgO, a portion of the Al is in the form Al2O3, and the oxide of the MgO and the Al2O3 are mixed on a nm scale.

[0134] A15. The process of any one of A1 to A14, further comprising at least one of: reacting at least a portion of the synthesis gas under effective Fischer-Tropsch conditions in the presence of a Fischer-Tropsch catalyst to produce an upgraded product, wherein the Fischer-Tropsch catalyst comprises a shifting Fischer-Tropsch catalyst or a non-shifting Fischer-Tropsch catalyst; subjecting at least a portion of the synthesis gas to a fermentation process to produce an alcohol, an organic acid, or a mixture thereof; contacting at least a portion of the synthesis gas with a catalyst to produce at least one C1-C4 alcohol; and separating H2 from the synthesis gas to produce a H2-rich product.

[0135] Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.

[0136] While the foregoing 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, and the scope thereof is determined by the claims that follow.

Claims

CLAIMS: What is claimed is:

1. A catalyst composition, comprising a support, a Group 8-10 element, and a promoter, wherein: the Group 8-10 element and the promoter are disposed through a volume of the support; the promoter comprises Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof; the support comprises a mixed Mg / Al metal oxide; and the promoter is distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

2. The catalyst composition of claim 1, wherein the Group 8-10 element comprises Pt.

3. The catalyst composition of claim 1 or claim 2, wherein the promoter comprises Sn.

4. The catalyst composition of any one of claims 1 to 3, wherein a weight ratio of the Mg to the Al in the mixed Mg / Al metal oxide is in a range from 0.001to 1,000.

5. The catalyst composition of any one of claims 1 to 4, wherein the catalyst composition comprises up to 6 wt% of the Group 8-10 element and up to 10 wt% of the promoter, based on the weight of the support.

6. The catalyst composition of any one of claims 1 to 5, wherein the catalyst composition is in the form of particles having a size and a particle density that is consistent with a Geldart A or Geldart B definition of a fluidizable solid.

7. A process for making a catalyst composition, comprising: forming a mixture comprising a Group 8-10 element-containing compound, a promoter-containing compound, a carboxylic acid, a liquid medium, and a supportcomprising a mixed Mg / Al metal oxide, wherein the promoter comprises Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof; and heating the mixture to produce the catalyst composition comprising the Group 8- 10 element and the promoter disposed through a volume of the support.

8. The process of claim 7, wherein: the liquid medium comprises water, the Group 8-10 element-containing compound, the promoter-containing compound, and the carboxylic acid are combined with the water to produce an aqueous solution, and the aqueous solution is contacted with the support to form the mixture.

9. The process of claim 7, wherein the liquid medium comprises water, the process further comprising: forming a first aqueous mixture comprising the Group 8-10 element-containing compound and a first portion of the water; forming a second aqueous mixture comprising the promoter-containing compound and a second portion of the water; forming a third aqueous mixture comprising the carboxylic acid and a third portion of the water; combining the first, second, and third aqueous mixtures with one another to produce a combined aqueous mixture, and contacting the support with the combined aqueous mixture to form the mixture comprising the Group 8-10 element-containing compound, the promoter-containing compound, the carboxylic acid, the liquid medium, and the support.

10. The process of any one of claims 7 to 9, wherein the Group 8-10 element- containing compound comprises Pt.

11. The process of any one of claims 7 to 10, wherein the Group 8-10 element- containing compound comprises 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) chloridehydrate, tetraammineplatinum(II) hydroxide hydrate, platinum (II) oxalate, or any mixture thereof.

12. The process of any one of claims 7 to 11, wherein the promoter-containing compound comprises Sn.

13. The process of any one of claims 7 to 12, wherein the promoter-containing compound comprises tin(IV) chloride pentahydrate, tin(II) chloride dihydrate, tin(II) bromide, tin(IV) bromide, tin(II) acetylacetonate, tin(II) acetate, tin(IV) acetate, tin(II) oxalate, tin(IV) oxalate, copper(II) nitrate, gold(III) nitrate, silver(I) nitrate, gallium(III) nitrate, or a mixture thereof.

14. The process of any one of claims 7 to 13, wherein the carboxylic acid comprises one, two, or three carboxylic acid functional groups.

15. The process of any one of claims 7 to 14, wherein the carboxylic acid is present in an amount sufficient to provide a molar ratio of carboxylic acid functional groups in the carboxylic acid to the Sn in the Sn-containing compound of at least 3:

1.

16. The process of any one of claims 7 to 15, wherein the carboxylic acid comprises citric acid.

17. The process of any one of claims 7 to 16, wherein the mixture is heated to a temperature of 350°C to 900°C in the presence of oxygen to produce the catalyst composition.

18. The process of any one of claims 7 to 17, wherein the mixture is heated for a time period in a range from 30 minutes to 24 hours to produce the catalyst composition.

19. The process of any one of claims 7 to 18, wherein a weight ratio of the Mg to the Al in the mixed Mg / Al metal oxide is in a range from 0.001 to 1,000.

20. The process of any one of claims 7 to 19, wherein the catalyst composition comprises up to 6 wt% of the Group 8-10 element and up to 10 wt% of the Sn, based on the weight of the support.

21. The process of any one of claims 7 to 20, wherein a weight ratio of the liquid medium to the support is in a range from 0.2:1 to 2:

1.

22. The process of any one of claims 7 to 21, wherein the promoter is distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

23. The process of any one of claims 7 to 22, wherein the support is in the form of a plurality of particles.

24. A process for upgrading a hydrocarbon, comprising: contacting a hydrocarbon-containing feed with a catalyst composition comprising a support, a Group 8-10 element, and a promoter 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 comprises one or more of C2-C16linear or branched alkanes, or one or more of C4-C16 cyclic alkanes, or one or more C8- C16alkyl aromatics, or a mixture thereof, the hydrocarbon-containing feed and catalyst composition are contacted at a temperature in a range of from 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 the total partial pressure of any C2-C16alkanes and any C8-C16 alkyl aromatics in the hydrocarbon-containing feed, the support comprises a mixed Mg / Al metal oxide, the Group 8-10 element and the promoter are disposed through a volume of the support, the promoter comprises Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof, andthe promoter is distributed substantially homogeneously throughout the volume of the support, as determined by energy-dispersive x-ray spectroscopy analysis.

25. The process of claim 24, further comprising: contacting at least a portion of the coked catalyst composition with an oxidant to effect combustion of at least a portion of the coke to produce a regenerated catalyst composition lean in coke and a combustion gas; and contacting an additional quantity of the hydrocarbon-containing feed with at least a portion of the regenerated catalyst composition to produce a re-coked catalyst composition and additional effluent, wherein a cycle time from contacting the hydrocarbon-containing feed with the catalyst composition to contacting the additional quantity of the hydrocarbon-containing feed with the regenerated catalyst composition is ≤ 5 hours.

Images