Disclosed are shaped dehydrogenation catalysts, methods for making the catalysts, and methods for dehydrogenating a hydrocarbon using the catalyst. A method for making the shaped dehydrogenation catalyst can include combining a group 13 metal precursor and a group 1 metal precursor with a catalyst support precursor to form a shapeable material, shaping the shapeable material to form a wet shaped material, drying the wet shaped material to form a dry shaped material, and calcining the dry shaped material to form the shaped dehydrogenation catalyst.

The present disclosure relates to mixed-bed systems comprising a particulate dehydrogenation catalyst based on one or more certain group 13 and 14 elements that further include additional metal components and a particulate non-catalytic additive comprising a heat-generating material, and to methods for dehydrogenating hydrocarbons using such systems. One aspect of the disclosure provides a mixed-bed system comprising a particulate dehydrogenation catalyst and a particulate non-catalytic additive. The particulate dehydrogenation catalyst includes a primary species P1 selected from Ga, In, TI, Ge, Sn Pb, and any mixture thereof; a primary species P2 selected from the lanthanides and any mixture thereof; a promoter M1 selected from Ni, Pd, Pt, La, Ir, Zn, Fe, Rh, Ru, Mn, Co, W, and any mixture thereof; and a promoter M2 selected from Li, Na, K, Rb, Cs, Be, Mg, Ca, Sr, Ba, and any mixture thereof on a support S1 selected from silica, alumina, zirconia, titania, yttria, and any mixture thereof. The particulate non-catalytic additive includes a heat-generating material and a carrier selected from inorganic oxides, clays, and any mixture thereof.

In the present disclosure, a composite oxide catalyst capable of effectively suppressing side reactions at the time of dehydrogenation of C4 hydrocarbons having single bonds or one double bond and a process for preparing butadiene, in particular 1,3-butadiene, with a high selectivity and a high yield using the same are described.

A catalyst for dehydrogenation of hydrocarbons includes a support including zirconium oxide and Linde type L zeolite (L-zeolite). A concentration of the zirconium oxide in the catalyst is in a range of from 0.1 weight percent (wt. %) to 20 wt. %. The catalyst includes from 5 wt. % to 15 wt. % of an alkali metal or alkaline earth metal. The catalyst includes from 0.1 wt. % to 10 wt. % of tin. The catalyst includes from 0.1 wt. % to 8 wt. % of a platinum group metal. The alkali metal or alkaline earth metal, tin, and platinum group metal are disposed on the support.

A method for processing a chemical stream includes contacting a feed stream with a catalyst in a reactor portion of a reactor system that includes a reactor portion and a catalyst processing portion. The catalyst includes platinum, gallium, or both and contacting the feed stream with the catalyst causes a reaction which forms an effluent stream. The method includes separating the effluent stream from the catalyst, passing the catalyst to the catalyst processing portion, and processing the catalyst in the catalyst processing portion. Processing the catalyst includes passing the catalyst to a combustor, combusting a supplemental fuel in the combustor to heat the catalyst, treating the heated catalyst with an oxygen-containing gas to produce a reactivated catalyst, and passing the reactivated catalyst from the catalyst processing portion to the reactor portion. The supplemental fuel may include a molar ratio of hydrogen to other combustible fuels of at least 1:1.

A catalytic composite comprises a first component selected from Group VIII noble metal components and mixtures thereof, a second component selected from one or more of alkali and alkaline earth metal components, and a third component selected from one or more of tin, germanium, lead, indium, gallium, and thallium, all supported on an alumina support comprising delta alumina having an X-ray diffraction pattern comprising at least three 2θ diffraction angle peaks between 32.0° and 70.0°. The at least three 2θ diffraction angle peaks comprise a first 2θ diffraction angle peak of 32.7°±0.4°, a second 2θ diffraction angle peak of 50.8°±0.4°, and a third 2θ diffraction angle peak of 66.7°±0.8°, wherein the second 2θ diffraction angle peak has an intensity of less than about 0.06 times the intensity of the third 2θ diffraction angle peak.

A double-layer structured catalyst for use in dehydrogenation of light hydrocarbon gas within a range of C3 to C6, configured such that platinum, tin, and an alkali metal are carried in a phase-changed carrier, wherein the tin component is present in an entire region inside the carrier, and the platinum and the tin form a single complex and are present in an alloy form within a range of a predetermined thickness from an outer periphery of the carrier.

Increase propane dehydrogenation activity of a partially deactivated dehydrogenation catalyst by heating the partially deactivated catalyst to a temperature of at least 660° C., conditioning the heated catalyst in an oxygen-containing atmosphere and, optionally, stripping molecular oxygen from the conditioned catalyst.

The present invention concerns a process (100) for the production of a butylene product (9) in which a component mixture (2) containing butane, butylene and hydrogen is provided using a butane dehydrogenation (10) to which a reaction feed (1) containing butane and hydrogen is subjected, the component mixture (2) or part thereof being subjected as a first separation feed to a first membrane separation (40), by means of which a first permeate (3) enriched in hydrogen with respect to the first separation feed and a first retentate (4) depleted in hydrogen with respect to the first separation feed and containing hydrogen, butane and butylene are formed, the first retentate (4) or part thereof being subjected to a second membrane separation (50) as a second separation feed, in which a second permeate (6) containing at least the predominant part of the hydrogen of the second separation feed and a second retentate containing at least the predominant part of the butane and the butylene of the second separation feed are formed, wherein the first membrane separation (40) is carried out using a sweep gas (5) containing butane and the first permeate (3) is obtained as permeate (3) charged with butane of the sweep gas (5) and/or the second membrane separation (50) is carried out using the sweep gas (5) containing butane and the second permeate (6) is obtained as permeate (6) charged with butane of the sweep gas (5), and wherein the first permeate (3) charged with butane of the sweep gas (5) and/or the second permeate (3) charged with butane of the sweep gas or one or more parts thereof is used in the formation of the reaction feed (1). A corresponding plant is also the subject of this invention.

Olefins may be produced from C.sub.4-C.sub.6 saturated hydrocarbons by systems and methods comprising passing a feed comprising C.sub.4-C.sub.6 saturated hydrocarbons and hydrogen into a dehydrogenation unit to produce a dehydrogenation effluent, passing at least a portion of the dehydrogenation effluent into a hydrogenation unit to produce a hydrogenation effluent, and passing at least a portion of the hydrogenation effluent into a cracking unit to produce a cracking effluent comprising olefins. The dehydrogenation unit includes a dehydrogenation catalyst, the hydrogenation unit includes a hydrogenation catalyst, and the cracking unit includes a cracking catalyst.