Reforming of C6 hydrocarbons on a PtAl2O3 catalyst

Isomerization, dehydrocyclization and hydrocracking of C₆ hydrocarbons on a commercial reforming PtAl₂O₃ catalyst were studied in a tubular reactor. The temperature was varied from 420 to 500°C, the pressure from 1.6 to 16 bar, the molar H₂/hydrocarbon inlet ratios from 1.5 to 20. Reaction rate equations of the Hougen—Watson type, corresponding to a bifunctional mechanism, were found to describe the experimental data. Parameter estimates for the reforming reactions were obtained by application of a generalized least square criterion to the calculated and observed production rates of the gas phase components. Electrobalance experiments showed that both the reforming reaction rates and the coking rate decrease exponentially with coke content. Multiplying the reaction rates with one common exponential deactivation function allowed the prediction of the observed conversions by one single set of kinetic parameters. The coking rate equation was derived by fitting the final coke content profiles obtained in the tubular reactor. The main contribution to coke formation was attributed to Me-cyclopentadienes.     

Kinetic investigations of the deactivation by coking of a noble metal catalyst in the catalytic hydrogenation of nitrobenzene using a catalytic wall reactor

The vapour phase hydrogenation of nitrobenzene to aniline is a highly exothermic reaction deactivated by coking of the palladium catalyst supported on -alumina carrier. For studying the deactivation of the catalyst a catalytic wall reactor was used in order to ensure isothermal reaction conditions for the kinetic measurements. Furthermore, the catalytic wall reactor allowed the determination of axial coke profiles by total carbon analysis of different wall segments. On the assumption that the main reaction and the deactivation of the catalyst can be assumed separable both the steady state and the unsteady state kinetics were studied. Nitrobenzene was identified as the relevant coke precursor whereas aniline has neither an influence on the main reaction nor on the deactivation. It could be shown that the hydrogenation of nitrobenzene to aniline follows a Langmuir–Hinshelwood mechanism considering the surface reaction of the adsorbed nitrobenzene molecule and one adsorbed hydrogen atom as the rate determining step. The differentiation of coke on the active sites and coke on the support must be taken into account to model the kinetics of coke formation with sufficient accuracy.     

Coking behavior and catalyst deactivation for catalytic pyrolysis of heavy oil

For the catalytic pyrolysis of heavy oil on catalyst CEP-1, coking behavior was investigated in a confined fluidized bed reactor. Coke content on the spent catalyst decreases with the increase of H/C mol ratio of feeds and catalyst-to-oil weight ratio, while it increases with the enhancement of reaction temperature. An empirical model is proposed to predict the coke content based on feed properties and operating conditions. The predicted coke content is close to the experimental data. The relationship between micro-activity index of catalysts and coke content is studied. A coking deactivation model for pyrolyzing catalysts is established, and then model parameters are determined by the least square regression analysis. According to the deactivation model, the variations of relative activity of catalysts with both residence time of catalysts and catalyst-to-oil weight ratio are predicted.     

渣油加氢裂化反应中油溶性催化剂的抑焦性能

以辽河常压渣油为研究对象,通过高压釜模拟渣油加氢裂化反应,对不同油溶性催化剂体系反应后的生焦量、生焦状况及产物进行分析,深入研究渣油加氢裂化反应中油溶性催化剂的抑焦性能.研究表明,随着活性金属含量的增大,油溶性单金属Co催化剂和Ni催化剂的生焦量减少,Co - Fe或Ni - Fe复配体系具有协同效应,抑焦性能增强,由...     

A reactor design simulation with reversible and irreversible catalyst deactivation

In Mobil's Methanol-to-Gasoline (MTG) Process, two types of catalyst deactivation occur. The first type is reversible coking of the zeolite; the coke is burned off during regeneration, restoring activity. The second type is permanent deactivation of the zeolite. We have developed a dynamic simulation of the MTG process to investigate the interaction between these two types of deactivations. In our simulation, the rate of the coking depends on the amount of irreversible deactivation that had previously occurred. Also, the permanent deactivation occurs both during the reaction and catalyst regeneration. With this type of deactivation interaction, we were able to predict experimental observations in our pilot plant studies; in particular, the second cycle on a given catalyst is longer than the first cycle. We have used the model to compare the overall catalyst cycle life for both adiabatic and isothermal reactor simulations.     

Combination of a Two-Zone Fluidized Bed Reactor with a Pd hollow fibre membrane for catalytic alkane dehydrogenation

The combination of a Pd hollow fibre membrane with a Two-Zone Fluidized Bed Reactor (TZFBR) is described for catalytic dehydrogenation of propane. This configuration aims to combine the in situ catalyst regeneration provided by the TZFBR with the increased conversion that can be achieved with a Pd membrane, which removes hydrogen from the reactor, thus enhancing the reaction rate and in theory allowing even higher than equilibrium conversion. The experiments show that the Pd hollow fibre membrane acts effectively removing hydrogen from the reaction media and that with a Pt–Sn/Al₂O₃ catalyst the TZFBR can achieve steady state operation in spite of the increased coking of the catalyst. However, with this catalyst the quicker coke formation caused by the removal of hydrogen outweighs the beneficial effect of hydrogen removal and the yield achievable for a given feed is lower in the presence of the membrane. A conclusion from these results is that a catalyst with lower coke tendency is needed to apply this combination of Pd membrane and TZFBR.     

Catalyst pore plugging effects on hydrocracking reactions in an Ebullated bed reactor operation

This paper analyzes the deactivation effects of NiMo/Al₂O₃ catalyst during the operation in an Ebullated bed reactor for Heavy residue hydrocracking. The spent catalysts were characterized by chemical analysis, ¹³C NMR, ESM, DRX, and by using thermal programmed oxidation and diffusion studies in a shallow bed micro-reactor. The deactivations were performed in a 5 l continuously stirred tank reactor, while the spent catalysts were tested in a 0.05 l micro-reactor. The study focused on determining the properties of the external layer of the catalyst and on evaluating the internal coke and metal deposition. The results indicated that initial deactivation is mainly due to coke depositions, while its impact on mass transfer reaction control depends on temperature. In long-term deactivation, the metal deposition plays a more important role in blocking the internal micro- and meso-structures and in building up the external layer of the pellets.     

Correlation of the deactivation of CoMo/Al2O3 in hydrodesulfurization with surface carbon species

The deactivation of CoMo/Al₂O₃ in the hydrodesulfurization (HDS) of dibenzothiophene (DBT) was investigated under laboratory conditions that allowed the accelerated deposition of coke on the catalyst. The coke deposition was enhanced at low H₂ pressures and when naphthalene was added to the reaction solution. Characterization of deactivated catalysts by elemental analysis (EA) and temperature-programmed oxidation (TPO) identified two types of carbonaceous species deposited on the catalysts, the reactive and the refractory species. The refractory deposit, or hard coke, was a major contributor to the deactivation and, therefore, the amounts of hard coke present on the catalyst determined the overall activity. A correlation was established in this study between the activity and the amounts of deposited hard coke based on the results of accelerated deactivation treatment. A similar relation was also observed between the two parameters when the catalyst was used in an industrial process for long periods. The above findings suggest that the reaction periods of two different scales, i.e., in laboratory and industrial processes, can be correlated with each other based on the amounts of hard coke when coking is the major mechanism of catalyst deactivation.     

Investigation of coke extraction from zeolite-HY under supercritical and near-critical conditions

In-situ regeneration of deactivated catalysts by dissolving coke or coke precursors with supercritical reaction fluids is of important economical significance. Investigations of coke extraction on zeolite-HY were performed in a gradientless reactor under supercritical and near-critical conditions with ethylbenzene disproportionation as a test reaction and n-butane or n-pentane as inert. Experimental results illustrate the large ability of coke extraction under supercritical conditions. The influences of the experimental conditions on the ethylbenzene disproportionation and the coke extraction are discussed. Under appropriate supercritical conditions the coking and the coke extraction can reach an equilibrium, so that no further deactivation of the catalyst was observed. Several regularities about coke extraction on the surface of the catalyst are proposed.     

ZnHZSM-5催化丙烷芳构化的失活动力学研究

在等温积分反应器中实验研究了由丙烷制取轻质芳烃BTX（苯、甲苯及二甲苯）的芳构化过程中，锌改性的HZSM－5催化剂的积炭失活对反应过程的影响，通过对常压、不同反应温度下的实验数据所进行的动力学分析，建立起了失活动力学模型，并通过拟合实验数据对模型做了筛选，最终确定了基于Langumir-Hinshelwood模型的反应速率方程和由独立失活机理推出的2级独立失活速率方程，该模型对深入了解轻烃芳构化反应及指导反应器设计均具有重要的意义。     

蜡油加氢裂化装置反应器飞温原因分析及对策

反应器飞温是加氢裂化装置最严重的生产事故之一,可导致催化剂结焦或失活,致使催化剂报废更换,造成巨大经济损失。因此预防加氢反应器飞温是保护催化剂,减少生产事故,减少经济损失的最有效途径。文章针对惠州炼油蜡油加氢裂化装置反应器飞温的一次事故,分析飞温原因,并提出处理对策,以防止类似事故发生,以及有效及时处理该类事故,避免衍生其它次生事故。     

加氢裂化催化剂失活与再生

利用XRD、XPS、TPR、ICP、IR、TEM 等技术, 测试和表征几种不同类型新鲜的、失活的和再生后工业用非贵金属加氢裂化催化剂的性能, 找出该催化剂失活的主要原因。经研究发现,加氢裂化预精制催化剂主要失活原因是积炭和金属聚集; 加氢裂化催化剂主要失活原因是积碳、所含沸石倒塌、金属聚集、孔结构堵塞及倒塌, 对于单段加氢裂化催化剂失活原因, 还包括酸中心中毒等。本文还探讨了器内与器外再生方式利弊及今后发展趋势。     

Pore network modeling of catalyst deactivation by coking,from single site to particle,during propane dehydrogenation

A versatile pore network model is used to study deactivation by coking in a single catalyst particle. This approach allows to gain detailed insights into the progression of deactivation from active site, to pore, and to particle—providing valuable information for catalyst design. The model is applied to investigate deactivation by coking during propane dehydrogenation in a Pt-Sn/Al₂O₃ catalyst particle. We find that the deactivation process can be separated into two stages when there exist severe diffusion limitation and pore blockage, and the toxicity of coke formed in the later stage is much stronger than of coke formed in the early stage. The reaction temperature and composition change the coking rate and apparent reaction rate, informed by the kinetics, but, remarkably, they do not change the capacity for a catalyst particle to accommodate coke. Conversely, the pore network structure significantly affects the capacity to contain coke. © 2018 The Authors. AIChE Journal published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers. AIChE J, 65: 140–150, 2019     

催化裂化结焦反应的研究进展

综述了近年来催化裂化结焦反应的研究进展情况,重点介绍了结焦反应的影响因素、焦炭对催化反应的影响、结焦机理以及焦炭的表征4个方面。研究认为,原料的性质、反应温度、催化剂的类型等因素均会对焦炭的生成产生影响。焦炭可以导致催化剂的失活,而位于孔道内部的焦炭对反应物或产物的扩散不利,进而影响产物的分布。研究表明,各种烃类组分形成焦炭的过程都必须经历芳香烃这一步。对于结焦催化剂可以采取多种表征手段,其中利用XPS以及GC-MS对焦炭进行表征的报道日益增多。尽管国内外对于催化裂化结焦反应的研究开展较早,然而探究焦炭的具体成分仍存在不小的困难,通过先进的表征手段鉴定焦炭中高缩合度芳烃组分以及如何减小催化裂化催化剂的结焦量将成为未来的研究方向。     

Co‐current and Countercurrent Configurations for a Membrane Dual Type Methanol Reactor

A dynamic model for a membrane dual‐type methanol reactor was developed in the presence of catalyst deactivation. This reactor is a shell and tube type where the first reactor is cooled with cooling water and the second one with feed synthesis gas. In this reactor system, the wall of the tubes in the gas‐cooled reactor is covered with a palladium‐silver membrane which is only permeable to hydrogen. Hydrogen can penetrate from the feed synthesis gas side into the reaction side due to the hydrogen partial pressure driving force. Hydrogen permeation through the membrane shifts the reaction towards the product side according to the thermodynamic equilibrium. Moreover, the performance of the reactor was investigated when the reaction gas side and feed gas side streams are continuously either co‐current or countercurrent. Comparison between co‐current and countercurrent mode in terms of temperature, activity, methanol production rate as well as permeation rate of hydrogen through the membrane shows that the reactor in co‐current configuration operates with lower conversion and also lower permeation rate of hydrogen but with longer catalyst life than does the reactor in countercurrent configuration.     

Effect of recycling the unconverted residue on a hydrocracking catalyst operating in an ebullated bed reactor

The effect of recycling the unconverted bottom on catalyst deactivation as a way to improve the hydrocracking conversion of heavy oil was analyzed using the experimental information obtained in a steady-state ebullated bed reactor. The recycle contained different amounts of partially converted (aged) material. Four sets of experiments were performed to demonstrate that after five passes through the reactor, the reactivity of the unconverted material decreased by 15% and its impact on catalyst deactivation increased by 30%. The results indicated that the higher the conversion, the lower is the reactivity and the higher is the catalyst deactivation. The production of an insoluble and refractory to convert material imposes a limit on the recycling benefit.     

Study of accelerated deactivation of hydrotreating catalysts by vanadium impregnation method

The main causes of catalysts deactivation for hydrotreating are coking and metals deposition. In this present work, accelerated deactivation of hydrotreating catalysts was studied. In this respect, vanadium which is deposited with nickel during hydrotreating reaction was impregnated into the fresh hydrotreating catalyst. Different percentage of vanadium was impregnated and their hydrodemetalization (HDM) and hydrodesulfurization (HDS) activities were studied in bench-scale reactor of heavy crude oil. Accelerated deactivations for both HDM and HDS were observed on vanadium impregnated catalysts. The rate of HDS deactivation was faster than that of HDM reaction. The rapid deactivation of HDS may be due to the coverage of active sites by impregnated vanadium atom. The deactivation is slower when the V loading is low; but above 10 wt% loading a rapid deactivation is observed. A comparison of deactivation is made in between normal deactivation and the deactivation by vanadium impregnation. It was found that deactivation by vanadium impregnation is lower than that of normal deactivation. It suggests that at initial stage the formation of coke causes deactivation of the catalyst whereas at later stage when metals sulfides deposition is quite high, these sulfides take part in deactivation.     

Two-stage catalytic up-grading of vacuum residue of a Wandoan coal liquid

A successive two-stage hydrotreatment using a commercial Ni-Mo/Al₂O₃ catalyst (HDN-30) was applied to the vacuum residue of a Wandoan coal liquid to achieve high levels of hydrocracking, hydrodenitrogenation and hydrodeoxygenation. Two-stage hydrotreatment in 1-methylnaphthalene containing 20wt% fluoranthene as a solvent at solvent/coal liquid ratio of unity removed 83% (overall) of nitrogen and 90% (overall) of oxygen in the asphaltene (benzene-soluble fraction) at 380 °C for 3 h and at 420 °C for 3 under hydrogen pressure of 15 MPa and 14 MPa, respectively, while the single stage treatment at 420 °C for 3 h removed only 41% and 46%, respectively. The same two-stage treatment allowed the overall denitrogenation of 51% and the overall deoxygenation of 67% from a mixture of asphaltene and preasphaltene (THF-soluble fraction). Addition of the catalyst prior to the second stage reaction increased the removal of nitrogen and oxygen to 75 and 82%, respectively, indicating significant catalyst deactivation by the preasphaltene fraction in the first stage. Increasing the solvent/coal liquid ratio to 2 or addition of tetrahydrofluoranthene as a component of the solvent increased the removal of nitrogen and oxygen to 70 and 80%, respectively. Such two-stage hydrotreatment was also effective in refining the whole residue, allowing denitrogenations and deoxygenations of 68 and 75%, respectively using tetrahydrofluoranthene. The coke, unreacted coal and minerals in the residue may not cause acute catalyst deactivation. High dissolving ability of the reaction solvent is very effective to decrease catalyst deactivation by carbon deposition. The successive two-stage hydrotreatment also enhanced hydrocracking of polar and resin fractions in the residue into oils (conversion, 65%). The extensive hydrogenation of the former fractions in the first stage may allow more easy cracking and may suppress with the aid of solvents their irreversible adsorption on the catalyst which leads to their coking into the catalyst poisons.     

Study of the catalyst deactivation in an industrial gasoil HDS reactor using a mini-scale laboratory reactor

The activity of a hydrodesulphurization catalyst loaded in an industrial hydrotreater is studied at start up and end of run. Catalyst initial and final activity was determined by performing HDS experiments at industrial conditions in a laboratory mini-scale hydrotreater. The results show that the deactivation of the catalyst samples collected from three different places of the industrial reactor do not vary significantly, the maximum difference among the catalyst samples, being less than ±4%. The experimentally determined deactivation level of the catalyst samples is compared with the deactivation estimated for the same industrial reactor and the same load using a hybrid neural network model trained with operational data of the industrial and the results are in close agreement. Catalyst deactivation appears to be faster for hydrogen consumption reactions than for hydrodesulphurization reactions indicating a decreasing hydrogen consumption trend with time in operation for specific sulphur content in the product.