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Preview catalysts in Petroleum Refining and Petrochemical Industries 1995, Proceedings of the 2nd International Conference on Catalysts in Petroleum refining and Petrochemical Industries

FOREWORD The 2nd International Conference on Catalysts in Petroleum Refining and Petrochemical Industries was held in Kuwait during the period April 22-26, 1995, under the auspises of H.H. Sheikh Saad A1-Abdullah A1-Salem A1-Sabah, Kuwait's Crown Prince and Prime Minister. The 1st conference was also held in Kuwait in 1989. The present conference was scheduled to be held in 1993; however, it was postponed due to the events that encompassed Kuwait and the Gulf region in 1990-1991. The patronage of the conference, the organizing bodies, and the selective emphasis on the role of catalysts in the petroleum and petrochemical industries reflect the keen interest of the countries in the region in actively contributing to the development of these industries. Petroleum-related industries are the main economic activities of most countries in the region. The refining capacity in the Gulf Region exceeds 5 MM barrels/day and includes some of the most sophisticated petroleum refining schemes in the world. The basic petrochemical industry has been also growing steadily in the region since the early eighties. The conference was attended by around 300 specialists in the catalysis field from both academia and industry from over 30 countries. It provided a forum for the exchange of ideas between scientists and engineers from the region with their counterparts from the industrialized countries. A total of 62 scientific papers were presented. The papers were carefully selected to include a blend of fundamental and applied research, and industrial experience. Such a blend was thought to be essential for providing the participants from both industry and academia with a chance to become familiar with the challenges facing each group and the actions taken to meet them. A number of keynote speakers, carefully selected from high ranking officials, policy makers, and multinational company representatives, were also invited to address the conference. The keynote presentations, which are published as a separate volume by the Kuwait Institute for Scientific Research, provided the participants with an overview of the directions the petroleum and petrochemical industries will take over the next decade. The program of the conference included a field visit to one of Kuwait's most modem refineries. A trip was also organized to one of Kuwait's oil fields. The partipants had a chance to observe oil lakes and the extent of the damage incurred by the blowing up of Kuwait's oil wells. The success of the conference is perhaps difficult for the organizers to assess. However, the quality of the papers in this volume provides some indication. Another indication is the keen interest and encouragement expressed by numerous participants in attending the next meeting, which will be held in Kuwait in 1998. The Editors vi P R E F A C E Catalysis plays an increasingly critical role in modern petroleum refining and basic petrochemical industries. The market demands for and specifications of petroleum and petrochemical products are continuously changing. They have impacted the industry significantly over the past twenty years. Numerous new refining processes have been developed and significant improvements were made on existing technologies. Catalysts have been instrumental in enabling the industry to meet the continuous challenges posed by the market. As we enter the 21st century, new challenges for catalysis science and technology are anticipated in almost every field. Particularly, better utilization of petroleum resources and demands for cleaner transportation fuels are major items on the agenda. It is against this background that the 2nd International Conference on Catalysts in Petroleum Refining and Petrochemical Industries was organized. The papers from the conference were carefully selected from around 001 submissions. The papers were refereed in terms of scientific and technical content and format in accordance with internationally accepted standards. They were a mix of reviews providing an overview of selected areas, original fundamental research results, and industrial experiences. The papers in the proceedings were grouped in the following sections for quick reference: Plenary Papers - Hydroprocessing of Petroleum Residues dna Distillates - Fluid Catalytic Cracking - Oxidation Catalysis - Aromatization & Polymerization Catalysis - Catalyst Characterization dna Performance - The plenary papers were mostly reviews covering important topics related to the objectives of the conference. The remaining sections cover various topics of major impact on modern petroleum refining and petrochemical industries. A large number of papers dealt with hydroprocessing of petroleum distillates and residues which reflects the concern over meeting future sulfur-level specifications for diesel and fuel oils. The task of editing this volume was facilitated by the efforts of the International Advisory Committee and the Scientific Committee of the conference who reviewed all the papers. The editorial board gratefully acknowledge this effort; the cooperation, time and effort of all authors; and the management of the Kuwait Institute for Scientific Research for allocating the required resources to prepare the manuscript of this volume. The Editors xi ORGANIZING COMMITTEE Jasem IA Besharah Chairman KISR Khaled 1A Muhailan Rapporteur KFAS Mamun Absi Halabi Coordinator KISR Abbas ilA Khan Member KFAS Anwar Abdullah Member GCC Taher 1A Sahaf Member KU Mohammad ilA Abbas Member KPC Abdul-Karim Abbas Member KNPC Bader IA Safran Member PIC Faisal Mandani Member PAAET Hassan Qabazard Member KISR Mubarak IA Adwani Member KISR IA Tayeb Wenada Member OAPEC INTERNATIONAL ADVISORY COMMITTEE Mamun Absi Halabi Chairman Kuwait David L. Trimm Member Australia Bernard Delmon Member Belgium Burce .C Gates Member USA Walter Kaminsky Member Germany Yasuaki Okamoto Member Japan Mario L. Occelli Member USA Henrik Topsoe Member Denmark SCIENTIFIC COMMITTEE Taher 1A Sahaf Chairman KU Anthony Stanislaus Rapporteur KISR Abdullah .S 1A Nasser Member Mina Abdulla~NPC Jaleel Shishtary Member Mina 1A Ahmadi/KNPC Erdogan Alper Member KU Mustafa .A .A Gholoum Member Shuaiba/KNPC Faisal Mandani Member PAAET Ezra Kam Member KISR Xll .~ ACKNOWLEDGEMENTS The Organizing Committee was deeply honored by the patronage of//. H. The Crown Prince and Prime Minister Sheikh Saad A1-Abdullah A1-Salem AI-Sabah, which reflects his keen interest in science and technology. The Committee is also grateful for the financial support of the Kuwait Institute for Scientific Research, the Kuwait Foundation for the Advancement of Science, the Kuwait National Petroleum Company, the Kuwait Petroleum Corporation, Kuwait University, the Gulf Cooperation Council, Public Authority for Applied Education and Training, the Petrochemical Industries Company and the Organization of Arab Petroleum Exporting Countries. The Committee would like also to express gratitude for the efforts of the Japan Petroleum Institute in coordinating and supporting the participation of prominent Japanese scientists in this event. The Committee would like also to extend its deep appreciation for the effort and time put forth by the distiguished keynote speakers, namely H.E. Mr. Hisham Al-Nazer, H.E. Mr. Erwin Valera, H.E. Mr. Lulwanu Lukman, Mr. Abdullatif AI-Hamad, Mr. Charles DiBona, Mr. John Yimoyines, Mr. .J Kent Murray, Mr. Mahmoud Yusef, Mr. Moayad Al-Qurtas, Mr. Khalaf A1-Oteibeh, Mr. Khaled Buhamra, and Mr. Nader Sultan. The Organizing Committee are also appreciative of the efforts of the members of the International Advisory Committee and the Scientific Committee for their thorough work in selecting and refereeing the submitted papers. The Committee also acknowledges the help and guidance provided by Elsevier Science Publishing Company and the advisory editors of this series ni preparing this proceedings. We would like to thank our colleagues at the Kuwait Institute for Scientific Research, the Kuwait Ministry of Oil, and the chairmen and cochairmen of the sessions, who provided unlimited assistance at times when it was badly needed. Finally, we feel deeply indebted to the participants who enriched the meeting with their serious discussions till the end. DR. JASEM BESHARA CHAIRMAN, ORGANIZING COMMITTEE Catalysts in Petroleum Refining and Petrochemical Industries 1995 M. Absi-Halabi et .la (Editors) (cid:14)9 1996 Elsevier Science B.V. llA rights reserved. CONTROL OF CATALYST PERFORMANCE IN SELECTIVE OXIDATION OF LIGHT HYDROCARBONS: CATALYST DESIGN AND OPERATIONAL CONDITIONS B. Delmon, P. Ruiz, S.R.G. Carraz~in, S. Korili, M.A. Vicente Rodriguez, Z. Sobalik Catalyse et Chimie des Mat6riaux Divis6s, Universit6 Catholique de Louvain, Place Croix du Sud 2/17 - 1348 Louvain-la-Neuve, Belgium This paper is an attempt to summarize the situation with respect to the selective catalytic oxidation of light alkanes using heterogeneous catalysts. Methane oxidation reactions and the oxidation of butane to maleic anhydride will only be alluded to occasionally, because they have been reviewed in detail in a large number of papers. We shall first show that it is still far from clear which are the families of catalysts to be used for the various reactions: mainly oxidative dehydrogenation or oxidation to oxygen-containing molecules of ethane, propane or isobutane. Much research is still necessary for understanding the mechanisms leading to high selectivity. In this context, we shall suggest that many concepts inherited from the development in selective oxidation and ammoxidation of olefins are probably of little use. Conversely, much emphasis has to be laid on new data which opens promising perspectives, namely (i) the occurrence of cooperation effects between two (or several) separate phases and especially the role of spillover oxygen and the so-called "remote control" and (ii) the occurrence of homogeneous non-catalysed reactions which occur at temperatures only slightly higher than the catalytic ones and correspond to similar selectivities. This suggests that research on selective catalytic oxidation, to be effective, should be comprehensive: it should continue to involve a search for new active phases and efforts to improve the already known catalysts. But research should also include investigations on the role of spillover oxygen, the nature of this oxygen (more or less electrophilic), the donors that can generate it, and the way this spillover oxygen reacts with the catalytic surface. Research should also contemplate the problem of how homogeneous and heterogeneous reactions proceed simultaneously or consecutively. In parallel with these research lines, chemical engineering must develop new concepts and new reactors. Recent spectacular results in methane coupling or oxidative dehydrogenations show that considerable progress can be made if the problem of light alkane selective oxidation benefits from a multifacetted approach. 1. INTRODUCTION Making valuable products from light hydrocarbons is presently one of the major challenges for the petroleum and petrochemical industries. Among the various processes able to transform light hydrocarbons to useful products, catalysis has a major role to play. Conceptually, the cheapest and easiest route is through catalytic oxidation. The reason is that oxygen (pure or in air) is cheap and possesses the high reactivity necessary to activate saturated hydrocarbons. For that type of activation, heterogeneous and homogeneous catalysis are competing. Nevertheless, the preference in principle goes to heterogeneous catalysis, especially if very large quantities have to be transformed, as in the case of methane. On the whole, a continuous progress towards a more selective oxidation of light saturated hydrocarbons is observed, and recent announcements demonstrate that dramatic progress can be made even in the very difficult case of methane activation, using either heterogeneous or homogeneous catalysts. The activation of light saturated hydrocarbons becomes increasingly more difficult as the molecules become smaller, with methane reactions being the most difficult to control. On the other hand, the occurrence of non-catalysed gas phase oxidation makes selectivity control very complicted. This is a problem common to almost all oxidations, unless one of the products is extremely stable (cid:12)9 examples are unsaturated nitriles (e.g. acrylonitrile in the ammoxidation of propane) or maleic anhydride (in the oxidation of butane). There is a parallel trend in the changes of reactivity with molecular weight in catalytic and non catalytic (gas phase) oxidation. The challenge to catalysis to achieve selective reactions at lower temperature is thus equally important for all light hydrocarbons. The activation of very light hydrocarbons (propane, ethane and methane) in the presence of oxygen has been achieved only at temperatures substantially or much higher than those used in the reactions of other hydrocarbons. There is however little doubt that some mechanistic similitudes exist and that the vast body of knowledge accumulated on the reaction of other hydrocarbons (including unsaturated ones) with oxygen will be useful for improving the efficiency of these difficult reactions. Nevertheless, the outstanding commercial success of the oxidations and ammoxidations of light olefins and that of the oxidation of butane to maleic anhydride has directed the fundamental research of the largest number of investigators to topics which are probably not the most relevant to the new challenges set by the selective oxidation of light alkanes. A much broader approach has certainly to be taken, compared to that used in former investigations. It is the aim of this contribution to highlight a few promising directions for research in the area of selective reactions of light alkanes with oxygen (oxidation and oxidative dehydrogenation). We shall emphasize three aspects: (i) new concepts have been recently developed in a field which seemed to be well established, namely the catalytic oxidation of olefins and butane, but where new powerful methods of action have been discovered. We shall show that these new concepts are applicable to the catalytic oxidation of the light saturated hydrocarbons, namely containing from one to five carbon atoms. We shall present, in some cases for the first time, results which strongly suggest that a cooperation between distinct phases in oxidation catalysts could play an important role in the oxidation of light hydrocarbons, even perhaps in the coupling of methane. (ii) we shall suggest, on the basis of new results from our and other laboratories, that the intervention of non catalysed gas phase reactions must be accounted for and should be investigated carefully. (iii) we shall also show that catalyst discovery and development in the field of heterogeneous oxidation of light hydrocarbons should be accompanied by innovative developments on the chemical engineering side. Before examining specifically these points, we shall "set the stage", namely attempt to give an overview of the results published in literature on the selective reactions of light alkanes with oxygen. The largest part of the contribution will consist in a critical overview of the parameters traditionally believed to be crucial for activity and selectivity. We shall show that one parameter, which probably has the largest importance, has been almost completely forgotten: this is the ability for separate phases, inactive or poorly active, to enhance the activity of potentially active and selective phases, via an oxygen spillover process. Results will be presented which strongly suggest that the same sort of cooperation between phases can operate in the reactions of light alkanes. At the end, we shall suggest that the existence of gas phase oxidation reactions, the occurrence of the phase cooperation mentioned above and the other particularities of light alkane oxidation are about to trigger new developments in chemical engineering which will probably be as innovative and crucial for viable processes as the development of fluidized bed reactors for oxidation or ammoxidation, and riser reactors (in the case of butane oxidation) has been during the remarkable development of catalytic oxidation in the last 25 years. 2. CATALYSTS ACTIVE IN THE SELECTIVE REACTION OF LIGHT ALKANES WITH OXYGEN The variety of catalysts which have been claimed to activate light alkanes is very large. The only conspicuous exception concerns the reaction of butane to maleic anhydride; this is, however, a special case considering the high stability of the product, namely maleic anhydride. But this large diversity of formulations exists even in the ammoxidation of propane to acrylonitrile, although the product is also particularly stable in this case. It cannot be therefore concluded that given oxidation reactions take place only on a single family of catalysts. In what follows, we present a series of tables concerning various reactions of light alkanes with oxygen. We wish, however, to underline the fact that the data contained in the tables are by no means comprehensive. We have selected them in view of our objectives, namely (i) to underline the variety of formulations proposed for a single reaction, (ii) to extract from these data a few conclusions and (iii) to speculate on the possible importance of some parameters. We have avoided to overburden the tables with information on reaction conditions. These are indeed very different, and correlating them with catalyst composition has little usefulness for the moment (except perhaps for propane ammoxidation, where investigation is more advanced). We do not present data concerning either methane or butane. In the case of methane oxidation and oxidative coupling, innumerable articles (more than 1000) have been published, together with many review papers. Concerning butane, the numerous articles and review papers dealing with oxidation of maleic anhydride obscure the few scattered articles dealing with oxidative dehydrogenation; dehydrogenation of butane has mainly been done in reactions without oxygen. In the tables, we omit the chemical symbol of oxygen and list only the elements combined with oxygen in the catalysts, or oxygen when it is present in a phase indicated as such by the authors (e.g., supports: MgO, SIO2), except if there is good ground to believe that well defined metal oxide entities are crucial for catalytic activity (e.g., VO...). In addition to the systems listed in Table I for the oxidative dehydrogenation of ethane, other systems have been tested because they have proven to be active in other alkane oxidations; this is particularly the case of many catalysts used in the oxidative coupling of methane, VPO and magnesium phosphate catalysts (butane oxidation and propane dehydrogenation, respectively) and MoVO catalysts. Various zeolites have also been tested. This table, the largest to be presented here, perfectly illustrates the fact that no formulation seems convincingly better than the others. In the oxidative dehydrogenation of propane (Table II), the various magnesium vanadates have been the object of many studies, but other systems seem to have comparable performances (systems based on cerium, niobium, or vanadium, molybdates and noble metals on monoliths used with very short contact time). Because the direct dehydrogenation of isobutane to isobutene is now in operation industrially, it is not surprising that relatively few publications deal with the corresponding oxidative dehydrogenation to isobutene (about 20 in the past 6 years). On the whole, the catalysts used are similar to those mentioned in the previous tables: phosphates, chromates, molybdates. Active carbon has also been mentioned, but it is hard to imagine that the catalyst could work a long time in the presence of oxygen. Table III gives two examples of the results mentioned in literature. Mention has been made of the selective oxidation (yield = 65%) of isobutene on UV activated TiO2 50. Table I. Ethane oxidative dehydrogenation to ethylene Catalyst Conversion Yield Selectivity Ref. % % % Ca-Ni 25 93.6 1 ceramic foam monoliths + Pt, Rh, Pd 80 70 2 Cd-La-A1 35 84 3 MgO based catalysts 45 73.7 4 Ce2(CO3)3 90 5 Mo-Si, Si-W or P-W/A1203 90 6 Cr-Zr-P 20-30 50-60 7 Li-Na-Mg 38 86 8 Li/MgO 75-79 70 9 Sr-Ce-Yb 49 10 Na-Mn 76.8 86.5 11 zeolites 86-90 12 La203-B aF2 59.1 84.7 31 heteropolyacid 76-98 14 Pt-cordierite 70 72 51 (electrocatalytic) 10.6 96.9 16 Mo-V-Nb-Sb 22-57 72-82 71 Mo-V-Nb-Sb-M 34 86 81 Na-K-Zr 85 86.4 91 Li-Ti+Mo, Sn or Sb 54.9 86.3 20 Li-Ti-Mn 46.9 74.6 21 V-P-U 22.7 22 Zn2TiO4+Bi 71.2 67.5 23 Co-P+promoter 68.1 80.5 24 Mo-Te 100 25 Mo-Bi-Ti-Mn-Si 100 26 Li/M~D+promoter 75 76 27 It seems that very few investigations concern the oxidation or oxidative dehydrogenation of C5 alkanes. Oxidative dehydrogenation of isopentane to isoprene has been mentioned. Two articles deal with MnO2, CoO/CaO3, NaOH/A1203, but in the presence of HI 51,52; this obviously suggests the intervention of gas-phase reactions. The yields (Y) in isobutene were relatively high (e.g., Y = 50-60% with a selectivity of 65 to 95%). Pentane can also produce maleic anhydride and phthalic anhydride 53-57. Considering in a general way the activation of light alkane by oxygen, the ammoxidation of propane has certainly not to be forgotten. This process is already under industrial development. If we try to get an overview of the recent work on the selective reactions of light alkanes with oxygen, two remarks may be made: (cid:12)9 Several lines have been followed, all inspired by former successful lines of research. It is striking that the proposed catalysts are generally similar to those previously used in the selective reaction of alkanes with oxygen: oxidative coupling of methane or oxidation of butane to maleic anhydride. Many of them are also similar to catalysts used for the reactions of olefins with oxygen (molybdates) or for dehydrogenation without oxygen (chromium containing catalysts). Because of the success of vanadyl phosphate in butane oxidation, investigators tend to focus on vanadium containing catalysts also in the case of other alkanes. Nevertheless, the data available do not seem to exclude any other formulation. (cid:12)9 On the other hand, the reaction of ethane, propane, isobutane, and pentanes with oxygen described until now are poorly selective at high, and even at moderate conversions. One cannot exclude the empirical discovery of completely new catalysts with outstanding performances. However, a more systematic approach may also help find satisfactory catalysts. An in-depth understanding of the principles involved ni catalytic selective oxidation is necessary to improve activity, selectivity and resistance to ageing of catalysts. This is true as well for the catalysts to be perhaps discovered as for those already cited. Table II. Propane oxidative dehydrogenation Reactant Product tsylataC Conversion Yield Selectivity Ref. % % % Propane Propene Nb based catalysts 7 58 82 Propane Propene VMg, VMg+Ag, 01 84, 86.9 29 lacimehcortcelE pumping of oxygen )POE( Propane Propene VMg and chloride of 23.1 03 Cu ,+ Li ,+ Ag ,+ Cd +2 Propane Propene noble metals (Pt,Pd) on 001 56 (total 13 enehtE ceramic foam shtilonom )snifelo at short contact time, 5 ms Propane Propene 4OoM59.0oC 91 60 32 Propane Propene =gM/V 33 1/2 32 46 2/2 32 95 3/2 32 49 Propane Propene VMgffiO2 52 60 43 Propane Propene 4OoMiN 20 12.5 62 53 34 14.8 34.5 Propane Propene 02sC/3FeC22OeC 41.3 33.5 81.1 36 Propane Propene FeV-supported Nd203 40.3 66.2 73 Propane Alkenes Vanadate stsylatac 50 50 83 enatuB Hexane Propane Propene 1A-dN-eF-V 40.3 66.2 26.7 93 Propane Propene gMV 01 56 40 Propane Propene CeO~CeF3 53.4 3 6.7 14 Propane Propene* 4OP3)3HN( + 21 *53 42 **elirtinolyrcA 3)3ON(ni + 36.7** Vanadyl phosphate Propane Propene NiMoOx (a=0.6-1.3; 29 1.81 34 x=number determined by Ni or Mo valency) Propane Propene 3021A supported 19 44 Pt/Cs/Sm Propane Propene MgV206 %05( 17 45 OgM+sO2V calcined ta 610 ~ Propane Propene 2OiS/4OoMoC 4.1 77.9 46 Propane Propene 1A/4OV3aN/OHaN 20.9 16.6 79.8 74 The next sections will therefore indicate some of these fundamental aspects and suggest the perspectives that some new f'mdings are opening. Table HI. Isobutane oxidative deh~,drosenation to isobutene. Catalyst Selectivity (S) Ref. Y203 + CeF3 high conversion 48 Ni2P207 S = 82 % 49 Zn2P207, Cr4(P207)3, M~2P207 S = 60-70 % 49 3. PARAMETERS TRADITIONALLY CONSIDERED IN SELECTIVE OXIDATION A very large amount of work has been devoted in the past to the oxidation of olefins Callylic" oxidation to unsaturated aldehydes) and butane (to maleic anhydride). This has led to the development of ideas and concepts which are quite naturally used in the new investigations concerning light alkanes. It is necessary to examine these ideas and concepts and to evaluate in a critical way their potential for discovering or improving catalysts in the new field that oxidation of light alkanes constitutes. This will be done here shortly on the basis of classical books or articles 53,58-62. 3.1. Doping The idea is to add foreign ions as a solid solution in already active oxide structures. This is logical. The oxidation of hydrocarbons involves oxygen from the catalyst lattice and replenishment of the latter by molecular oxygen after the hydrocarbon molecule has been dehydrogenated or oxidised. This is an oxido-reduction mechanism. Doping by elements of other valencies can in principle change the oxido-reduction level of the surface. More precisely, the really important parameters in the processes are the rates of (i) removal of oxygen by the reaction with the hydrocarbon and (ii) reoxidation by 02. In principle, doping can alter these rates, but very few measurements have been made along this line. Doping can also change surface acidity, a parameter essential for the activation of alkanes. Doping is certainly a good approach for modifying a catalyst. It should however be underlined that it has seldom been verified that the doping elements were really incorporated in the host oxide and did not spontaneously segregate out. There are indeed conspicuous instances of such segregations. For example, it had been claimed that antimony in solid solution in tin oxide SnO2 explained the high activity of Sb-Sn-O catalysts in oxidation. Actually, Sb has a strong tendency to segregate out of SnO2 during the catalytic reaction 63-65. But in other reactions, there seems to be indeed an effect of doping elements to alter the extent of oxidation- reduction in the near surface layers (e.g., cobalt in V-P-O catalysts) 66. It is therefore advisable to use the doping elements in quantities compatible with complete solubility in the host oxide, and to check that they do not segregate during the catalytic reaction. Cobalt, mentioned above as a useful dopant, could exert a catastrophic effect if segregated as cobalt oxide, because of the high activity of the latter in complete oxidation. 3.2. Supports It seems that supports have been considered with much circumspection in the early days of allylic oxidation. Progressively silica began to be used, but it is considered as being generally inert, and permitting only a better dispersion or a higher mechanical strength. However, real supports are progressively appearing in the field of catalytic oxidation, as suggested by the tables presented above. A conspicuous and well known example is TiO2 as a support for V205. The advantage of using TiO2 (e.g., in o-xylene oxidation to phthalic anhydride) is probably not to give isolated surface vanadium atoms, but rather to stabilise islets of a sub-oxide of vanadium, V6013 over a broader range of oxido-reduction conditions 67-69. This

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