Lanthanide-Noble Metal Catalyst for Naphtha Reforming
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Solution Overview
Problem
Existing catalysts for hydrocarbon reforming lack flexibility in functionality, particularly in achieving high yields of C5+ hydrocarbons and aromatics while maintaining catalyst activity, often requiring excessive temperatures or additional catalyst quantities.
Innovation Solution
A catalyst comprising a noble metal, a lanthanide-series metal, and a support, with specific atomic ratios and distribution profiles, is used for catalytic reforming of naphtha, optimizing the yield of C5+ hydrocarbons and aromatics without significant activity debits, and maintaining activity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for hydrocarbon reforming, then catalyst activity can be maintained, but yield of C5+ hydrocarbons and aromatics is limited and excessive temperatures or catalyst quantities are required
Solution Approach 1:
The patent employs a composite catalyst system comprising a noble metal component (platinum, palladium, rhodium, ruthenium, osmium, or iridium) combined with a lanthanide-series metal component (elements with atomic numbers 57-71) supported on an appropriate carrier. This composite structure enables synergistic effects where the noble metal provides hydrogenation-dehydrogenation activity while the lanthanide component enhances cracking function and acidity, achieving high C5+ and aromatic yields at moderate temperatures without requiring excessive thermal input or catalyst quantities.
2Productivity
If catalyst functionality is increased to achieve high yields, then productivity improves, but catalyst complexity increases
Solution Approach 1:
The catalyst design integrates multiple functions within a single bimetallic system. The noble metal component performs hydrogenation-dehydrogenation reactions, while the lanthanide-series metal component contributes to cracking activity and acid-catalyzed reactions. This multi-functional composite catalyst simultaneously achieves dehydrogenation, hydrogenation, hydrocracking, hydrogenolysis, isomerization, desulfurization, cyclization, alkylation, polymerization, and cracking activities, thereby increasing productivity without requiring separate catalysts for each function.
Solution Approach 2:
The patent optimizes specific parameters including the atomic ratio of lanthanide-series metal to noble metal (maintained below 1.3:1), the bulk density of the catalyst (0.300-0.620 g/cm³), and the distribution concentration of lanthanide metal (surface layer concentration less than twice the central core concentration). These parameter optimizations enable high productivity while controlling catalyst complexity through defined compositional ranges and distribution profiles.
3Productivity
If catalyst activity is increased to process greater quantities of feed, then productivity improves, but selectivity to light ends increases due to excessive cracking
Solution Approach 1:
The patent modifies the acidity parameter of the catalyst by incorporating the lanthanide-series metal component, which adjusts the acid function to reduce excessive cracking activity. This parameter change allows the catalyst to maintain high productivity for processing greater feed quantities while suppressing unwanted cracking reactions that produce C3 and C4 light ends, thereby improving selectivity toward desired C5+ hydrocarbons and aromatics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst achieves high yields of C5+ hydrocarbons and aromatics with reduced cracking of alkanes to light ends, enhancing selectivity and catalyst activity, thereby increasing production of valuable products without the need for excessive temperatures or catalyst quantities.
Implementation Method 1
Some catalysts may have both a hydrogenation-dehydrogenation function and a cracking function and are useful for accelerating a wide spectrum of hydrocarbon-conversion reactions
Implementation Method 2
Different components, such as the carrier, may contribute to the cracking function while other portions, such as deposited metals, may contribute to the hydrogenation-dehydrogenation function
Data Source
AI summary
One exemplary embodiment can be a catalyst for catalytic reforming of naphtha. The catalyst can have a noble metal including one or more of platinum, palladium, rhodium, ruthenium, osmium, and iridium, a lanthanide-series metal including one or more elements of atomic numbers 57-71 of the periodic table, and a support. Generally, an average bulk density of the catalyst is about 0.300-about 0.620 gram per cubic centimeter, and an atomic ratio of the lanthanide-series metal:noble metal is less than about 1.3:1. Moreover, the lanthanide-series metal can be distributed at a concentration of the lanthanide-series metal in a 100 micron surface layer of the catalyst less than about two times a concentration of the lanthanide-series metal at a central core of the catalyst.