Silanized Reforming Catalyst for Acid Function and Metal Dispersion
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Solution Overview
Problem
Existing reforming catalysts face challenges in improving catalytic activity and acid function, leading to elevated acid cracking and loss of catalytic activity during the reforming process, which increases costs.
Innovation Solution
A process involving impregnation of a support with promoter metal and active metallic components, followed by contacting with non-metallic components and coating with a silanizing agent, then drying and calcination, to enhance the catalyst's acidic character and sinter resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing reforming catalysts are used to improve catalytic activity, then conversion efficiency increases, but acid cracking increases and catalytic activity is lost during the reforming process
Solution Approach 1:
The catalyst support is pre-modified with a silanizing agent before the reforming process to establish a protective silica layer in advance. This preliminary action prevents metal aggregation during high-temperature reactions, maintaining catalytic activity stability without requiring post-processing adjustments.
Solution Approach 2:
The invention creates a composite catalyst structure by combining the support material with promoter metals, active metallic components, and a silica coating layer. This multi-component composite approach enhances both catalytic activity and stability, preventing the trade-off between productivity and reliability.
2Productivity
If the acidic character of the catalyst is enhanced to improve conversion, then catalytic performance increases, but metal aggregation occurs during high-temperature reactions
Solution Approach 1:
A silica layer is introduced as an intermediary substance between the acidic support and the metallic components. This intermediate layer provides the necessary acidic character for catalysis while simultaneously preventing direct contact between metal particles and the acidic support, thus preventing aggregation and maintaining metal dispersion.
Solution Approach 2:
A thin silica film is deposited on the catalyst support to create a protective shell. This flexible thin film allows the catalyst to maintain high acidic character for improved performance while the film itself acts as a physical barrier preventing metal aggregation during high-temperature operations.
3Ease of manufacture
If conventional catalyst preparation methods are used, then manufacturing simplicity is maintained, but catalytic activity and acid function are insufficient
Solution Approach 1:
The silanizing agent is applied during the catalyst preparation stage rather than as a separate post-processing step. This preliminary action integrates the protective function into the manufacturing process itself, maintaining ease of manufacture while significantly improving catalytic activity and stability.
Solution Approach 2:
The invention modifies the chemical parameters of the catalyst support by introducing silanizing agents that alter the surface properties. This parameter change enhances catalytic activity and acid function while the process remains integrated into conventional manufacturing workflows, preserving ease of manufacture.
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 process improves the catalytic performance of the reforming catalyst by enhancing its acidic character and protecting the metals from aggregation during high-temperature reactions, thereby reducing costs and maintaining efficiency.
Implementation Method 1
coating the third catalytic precursor with at least one silanizing agent to obtain a coated third catalytic precursor
Implementation Method 2
a layer of silica oxide having a weight percentage in a range of 0.5-5.0% with respect to the reforming catalyst
Implementation Method 3
naphthas rich in paraffins and naphthenes are converted mainly to aromatic hydrocarbons by contacting with a catalyst at elevated temperatures and pressures
Implementation Method 4
impregnating at least one support with at least one promoter metal and at least one active metallic component to obtain a second catalytic precursor
Implementation Method 5
drying the coated third catalytic precursor to obtain a dried third catalytic precursor followed by calcination of the dried third catalytic precursor to obtain the reforming catalyst
Data Source
AI summary
The present disclosure provides a process for preparing a reforming catalyst, said process comprising: (a) impregnating at least one support with at least one promoter metal and at least one active metallic component to obtain a second catalytic precursor; (b) contacting the second catalytic precursor with at least one non-metallic component to obtain a third catalytic precursor; (c) coating the third catalytic precursor with at least one silanizing agent to obtain a coated third catalytic precursor; and (d) drying the coated third catalytic precursor to obtain a dried third catalytic precursor followed by calcination of the dried third catalytic precursor to obtain the reforming catalyst. The present disclosure also provides a reforming catalyst and the process for catalytically reforming a hydrocarbon feed stream by using the reforming catalyst.