The present invention relates to a process of producing a metal-containing catalyst. The process involves mixing a support material with one or more metals in a solution to produce a catalyst comprising a metal-loaded support. The catalyst comprising a metal-loaded support is treated with an atmosphere comprising 0.01 to 100% carbon-containing agents and 0-100% hydrogen at a temperature of 50 to 500° C. to produce a treated metal-containing catalyst on a support. Also disclosed is the resulting treated metal-containing catalyst and its use in a process for converting propane to propylene.

The invention relates to a catalyst composition comprising (a) a metal M selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), rhenium (Re), ruthenium (Ru) and iridium (Ir), (b) tin (Sn), (c) zinc (Zn), (d) alkaline earth metal and (e) a porous metal oxide catalyst support, wherein the amount of each of elements (a), (b) and (d) is independently chosen in the range of from 0.1 to 5 wt. % based on the porous metal oxide catalyst support and wherein the amount of element (c) is chosen in the range of from 0.1 to 2 wt. % based on the porous metal oxide catalyst support. Furthermore, the invention also relates to a process for the preparation of said catalyst composition and its use in non-oxidative dehydrogenation of an alkane, preferably propane.

The invention relates to a catalyst composition comprising (a) a metal M selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), rhenium (Re), ruthenium (Ru) and iridium (Ir), (b) tin (Sn), (c) zinc (Zn), (d) alkaline earth metal and (e) a porous metal oxide catalyst support, wherein the amount of each of elements (a), (b) and (d) is independently chosen in the range of from 0.1 to 5 wt. % based on the porous metal oxide catalyst support and wherein the amount of element (c) is chosen in the range of from 0.1 to 2 wt. % based on the porous metal oxide catalyst support. Furthermore, the invention also relates to a process for the preparation of said catalyst composition and its use in non-oxidative dehydrogenation of an alkane, preferably propane.

Disclosed is a process for the catalytic dehydrogenation of alkanes so as to form the corresponding olefins. The reaction mixture is subjected to membrane separation of hydrogen, in a separate unit. Preferably a plurality of alternating reaction and separation units is used. The process of the invention serves the purpose of reducing coke formation on the catalyst, and also of achieving a higher alkane conversion without a similar increase in coke formation. The process can also be used for the production of hydrogen.

Disclosed is a process for the catalytic dehydrogenation of alkanes so as to form the corresponding olefins. The reaction mixture is subjected to membrane separation of hydrogen, in a separate unit. Preferably a plurality of alternating reaction and separation units is used. The process of the invention serves the purpose of reducing coke formation on the catalyst, and also of achieving a higher alkane conversion without a similar increase in coke formation. The process can also be used for the production of hydrogen.

The presently disclosed subject matter relates to methods and systems for alkane dehydrogenation. In a particular non-limiting embodiment, the presently disclosed subject matter provides a system for the dehydrogenation of alkanes that includes two or more reactors configured to perform a dehydrogenation reaction of an alkane in the presence of a catalyst to produce an olefin and a catalyst regenerator, coupled to each of the two or more reactors through at least one transfer line to a regenerator, for the regeneration of spent catalyst.

The presently disclosed subject matter relates to methods and systems for alkane dehydrogenation. In a particular non-limiting embodiment, the presently disclosed subject matter provides a system for the dehydrogenation of alkanes that includes two or more reactors configured to perform a dehydrogenation reaction of an alkane in the presence of a catalyst to produce an olefin and a catalyst regenerator, coupled to each of the two or more reactors through at least one transfer line to a regenerator, for the regeneration of spent catalyst.

An improved catalytic dehydrogenation process which process comprises contacting an alkane or alkyl aromatic feedstream with a dehydrogenation catalyst under catalytic conditions in an up-flow fluidized reactor, wherein the fluidized reactor comprises one or more reactors, which catalytic conditions include a temperature within a range of from 500 to 800° C., a weight hourly space velocity within a range of from 0.1 to 1000, a gas residence time within a range of from 0.1 to 10 seconds, and, subsequent to the fluidized reactor, effecting separation of entrained catalyst from reactor effluent by use of a cyclonic separation system, wherein the improvement comprises interposing a cooling means between an up-flow fluidized reactor and the cyclonic separation system to substantially halt thermal reactions, thereby effectively increasing overall molar selectivity to alkene product is provided.

An improved catalytic dehydrogenation process which process comprises contacting an alkane or alkyl aromatic feedstream with a dehydrogenation catalyst under catalytic conditions in an up-flow fluidized reactor, wherein the fluidized reactor comprises one or more reactors, which catalytic conditions include a temperature within a range of from 500 to 800° C., a weight hourly space velocity within a range of from 0.1 to 1000, a gas residence time within a range of from 0.1 to 10 seconds, and, subsequent to the fluidized reactor, effecting separation of entrained catalyst from reactor effluent by use of a cyclonic separation system, wherein the improvement comprises interposing a cooling means between an up-flow fluidized reactor and the cyclonic separation system to substantially halt thermal reactions, thereby effectively increasing overall molar selectivity to alkene product is provided.

A method for operating an acetylene hydrogenation unit in an integrated steam cracking-fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from a steam cracking system and an FCDh effluent from an FCDh system into a hydrogenation feed and an acetylene-depleted stream, the hydrogenation feed comprising at least hydrogen, CO, and acetylene. During normal operating conditions, at least 20% of the CO in the hydrogenation feed is from the cracked gas. The method may include contacting the hydrogenation feed with an acetylene hydrogenation catalyst to hydrogenate at least a portion of the acetylene in the hydrogenation feed to produce a hydrogenated effluent. The steam cracking is operated under conditions that increase CO production such that a concentration of CO in the cracked gas is great enough that when a flowrate of the FCDh effluent is zero, a CO concentration in the hydrogenation feed is at least 100 ppmv.