SUPPORTED CATALYSTS FOR NON-OXIDATIVE DEHYDROGENATION OF ALKANES

Abstract

A supported non-oxidative alkane dehydrogenation catalyst and a method for making and using the same is disclosed. The supported non-oxidative alkane dehydrogenation catalyst can include a vanadium oxide, a rare earth metal oxide, an alkali metal oxide, and a support containing silica and alumina.

Claims

1. A supported non-oxidative alkane dehydrogenation catalyst comprising: a support comprising silica and alumina; a vanadium oxide; a rare earth metal oxide; and an alkali metal oxide.

2. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the rare earth metal oxide is a lanthanum oxide, cerium oxide, neodymium oxide, samarium oxide, or any combination thereof, preferably a lanthanum oxide and/or cerium oxide, more preferably a lanthanum oxide.

3. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the alkali metal oxide is a lithium oxide, sodium oxide, potassium oxide, rubidium oxide, or cesium oxide or any combination thereof, preferably a potassium oxide.

4. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the catalyst comprises 1 to 20 wt. % of the vanadium oxide represented as V.sub.2O.sub.5, 0.1 to 3 wt. % of the rare earth metal oxide, and 0.1 to 2 wt. % of the alkali metal oxide, based on the total weight of the catalyst.

5. The supported non-oxidative alkane dehydrogenation catalyst of claim 4, wherein the rare earth metal oxide is a lanthanum oxide, and/or a cerium oxide, preferably a lanthanum oxide and/or wherein the alkali metal oxide is a potassium oxide.

6. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the amount of silica is 0.1 to 5 wt.%, based on the total weight of the catalyst.

7. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the alumina in the catalyst support is a transition alumina, such as δ - alumina.

8. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, comprising: 0.1 to 5 wt. % of silica and 71 wt. % to 98.7 wt.% of alumina, based on the total weight of the catalyst; 1 to 20 wt. % of the vanadium oxide based on the total weight of the catalyst; 0.1 to 3 wt. % of the rare earth metal oxide based on the total weight of the catalyst; and 0.1 to 2 wt. % of the alkali metal oxide based on the total weight of the catalyst.

9. The supported non-oxidative alkane dehydrogenation catalyst of claim 8, wherein the alumina in the support comprises δ - alumina, the rare earth metal oxide is a lanthanum oxide, such as La.sub.2O.sub.3, and the alkali metal oxide is a potassium oxide, such as K.sub.2O.

10. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the catalyst has a specific surface area of at least 50 m.sup.2/g, such as 50 m.sup.2/g to 250 m.sup.2/g.

11. A process for producing of an alkene, the process comprising contacting a feed stream comprising an alkane with a supported non-oxidative alkane dehydrogenation catalyst of claim 1 under conditions sufficient to non-oxidatively dehydrogenate at least a portion of the alkane and produce a product stream comprising an alkene.

12. The process of claim 11, wherein the contacting conditions include a temperature of 400° C. to 800° C. and/or a pressure of 0.01 MPa to 0.5 MPa, and/or wherein the alkane is a C.sub.2 to C.sub.10 alkane, preferably a C.sub.2 to C.sub.4 alkane.

13. A process for producing a supported non-oxidative alkane dehydrogenation catalyst of claim 1, the process comprising: (a) impregnating a calcined support comprising alumina and silica with a vanadium precursor, a rare earth metal precursor and an alkali metal precursor to obtain an impregnated support; (b) drying the impregnated support to obtain a dried impregnated support; and (c) calcining the dried impregnated support to produce the supported non-oxidative alkane dehydrogenation catalyst.

14. The process of claim 13, wherein the process further comprises making the calcined support comprising: (d) contacting an alumina precursor with a silica precursor under conditions suitable to obtain a shapeable support precursor; (e) shaping the shapeable support precursor to obtain a wet shaped support precursor; (f) drying the wet shaped support precursor to obtain a dried shaped support precursor; and (g) calcining the dried shaped support precursor to obtain the calcined support.

15. The process of claim 13, wherein in step (c) the dried impregnated support is calcined at 500 to 850° C. and/or wherein shaping in step (e) comprises extruding the shapeable support precursor.

16. The supported non-oxidative alkane dehydrogenation catalyst of claim 1, wherein the amount of silica in the support is 0.1 to 6 wt. %, based on the weight of the support.

17. The process of claim 14, wherein in step (c) the dried impregnated support is calcined at 500 to 850° C. and/or wherein shaping in step (e) comprises extruding the shapeable support precursor.

18. A process for producing a supported non-oxidative alkane dehydrogenation catalyst of claim 2, the process comprising: (a) impregnating a calcined support comprising alumina and silica with a vanadium precursor, a rare earth metal precursor and an alkali metal precursor to obtain an impregnated support; (b) drying the impregnated support to obtain a dried impregnated support; and (c) calcining the dried impregnated support to produce the supported non-oxidative alkane dehydrogenation catalyst.

19. A process for producing a supported non-oxidative alkane dehydrogenation catalyst of claim 3, the process comprising: (a) impregnating a calcined support comprising alumina and silica with a vanadium precursor, a rare earth metal precursor and an alkali metal precursor to obtain an impregnated support; (b) drying the impregnated support to obtain a dried impregnated support; and (c) calcining the dried impregnated support to produce the supported non-oxidative alkane dehydrogenation catalyst.

20. A process for producing a supported non-oxidative alkane dehydrogenation catalyst of claim 4, the process comprising: (a) impregnating a calcined support comprising alumina and silica with a vanadium precursor, a rare earth metal precursor and an alkali metal precursor to obtain an impregnated support; (b) drying the impregnated support to obtain a dried impregnated support; and (c) calcining the dried impregnated support to produce the supported non-oxidative alkane dehydrogenation catalyst.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings.

[0026] FIG. 1A shows isobutane conversion for the comparative catalysts (Examples 1, 2, and 3) and a catalyst (Example 4) according to an example present invention, before and after aging.

[0027] FIG. 1B shows isobutylene selectivity for the comparative catalysts (Examples 1, 2, and 3) and a catalyst (Example 4) according to an example present invention, before and after aging.

[0028] FIG. 1C shows isobutane yield for the comparative catalysts (Examples 1, 2, and 3) and a catalyst (Example 4) according to an example present invention, before and after aging.

[0029] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be to scale.

DETAILED DESCRIPTION OF THE INVENTION

[0030] A discovery has been made that provides a solution to at least some of the problems associated with supported vanadium catalysts used in non-oxidative dehydrogenation of alkanes to produce alkenes. As illustrated in a non-limiting manner in the Examples, the supported non-oxidative alkane dehydrogenation catalysts of the present invention have relatively less deactivation with aging.

[0031] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.

A. Supported Non-Oxidative Alkane Dehydrogenation Catalyst

[0032] The supported non-oxidative alkane dehydrogenation catalyst can include a vanadium oxide, a rare earth metal oxide, an alkali metal oxide supported on a support containing alumina and silica. In some aspects, the catalyst can include 1 to 20 wt.%, or at least any one of, equal to any one of, or between any two of 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.%, 14 wt.%, 15 wt.%, 16 wt.%, 17 wt.%, 18 wt.%, 19 wt.%, and 20 wt.% of a vanadium oxide, represented as V.sub.2O.sub.5. In some aspects, the catalyst can include one or more vanadium oxides. The vanadium oxide can include VO, V.sub.2O.sub.3, V.sub.2O.sub.4, or V.sub.2O.sub.5, or vanadate ions or any combination thereof. Non-limiting examples of vanadate ions can include VO.sub.4.sup.3- , V.sub.2O.sub.7.sup.4-, V.sub.3O.sub.9.sup.3-, V.sub.4O.sub.12.sup.4-, V.sub.5O.sub.14.sup.3-, and the like. In some aspects, the vanadium oxide can include distinct phases of the vanadium oxides such as V.sub.nO.sub.2n+1, V.sub.nO.sub.2n-1, and non-stoichimetric vanadium oxygen phases. Phases with the general formula V.sub.nO.sub.2n+1, wherein n is a whole number greater than zero exist between V.sub.2O.sub.5 (vanadium (V) species) and VO.sub.2 (vanadium (IV) species). Examples of these phases include V.sub.3O.sub.7, V.sub.4O.sub.9 and V.sub.6O.sub.13. Phases with the general formula V.sub.nO.sub.2n-.sub.1, wherein n is a whole number greater than zero exist between VO.sub.2 (vanadium (IV) species) and V.sub.2O.sub.3 (vanadium (III) species). Examples of these phases include V.sub.4O.sub.7, V.sub.5O.sub.9, V.sub.6O.sub.11, V.sub.7O.sub.13 and V.sub.8O.sub.15. In some particular aspects, the vanadium oxide is V.sub.2O.sub.5. The alkali metal can be lithium, sodium, potassium, rubidium, or cesium or any combination thereof. In some particular aspect, the alkali metal can be potassium. In some aspects, the catalyst can include 0.1 to 5 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.%, 1.8 wt.%, 1.9 wt.%, 2 wt.%, 2.1 wt.%, 2.2 wt.%, 2.3 wt.%, 2.4 wt.%, 2.5 wt.%, 2.6 wt.%, 2.7 wt.%, 2.8 wt.%, 2.9 wt.%, 3.0 wt.%, 3.1 wt.%, 3.2 wt.%, 3.3 wt.%, 3.4 wt.%, 3.5 wt.%, 3.6 wt.%, 3.7 wt.%, 3.8 wt.%, 3.9 wt.%, 4.0 wt.%, 4.1 wt.%, 4.2 wt.%, 4.3 wt.%, 4.4 wt.%, 4.5 wt.%, 4.6 wt.%, 4.7 wt.%, 4.8 wt.%, 4.9 wt.%, and 5.0 wt.% of a alkali metal oxide, such as potassium oxide. In some aspects, the potassium oxide can be K.sub.2O. The rare earth metal can be lanthanum, cerium, neodymium, samarium, or any combination thereof, preferably lanthanum and/or cerium, more preferably lanthanum. In some aspects, the catalyst can include 0.1 to 3 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.% 1.1 wt.%, 1.2 wt.%, 1.5 wt.%, 2.0 wt.%, 2.5 wt.%, and 3.0 wt.%, of the rare earth metal oxide, such as a lanthanum oxide and/or cerium oxide, preferably a lanthanum oxide. In some aspects, the lanthanum oxide can be La.sub.2O.sub.3. In some aspects, the catalyst can include 0.1 to 2 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.%, 1.8 wt.%, 1.9 wt.%, and 2 wt.% of silica based on the total weight of the catalyst. In some aspects, the catalyst can include 80 to 95 wt.% or at least any one of, equal to any one of, or between any two of 80 wt. %, 81 wt.%, 82 wt.%, 83 wt.%, 84 wt.%, 85 wt.%, 86 wt.%, 87 wt.%, 88 wt.%, 89 wt.%, 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, and 95 wt.%, of alumina based on the total weight of the catalyst. In some aspects, the alumina can contain a transition alumina. The transition alumina can contain chi alumina, kappa alumina, rho alumina, gamma alumina, eta alumina, delta alumina, theta alumina or any combination thereof. In some particular aspect, the transition alumina can contain delta alumina. In some particular aspects, the catalyst can include i) 1 to 20 wt.%, or at least any one of, equal to any one of, or between any two of 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.%, 14 wt.%, 15 wt.%, 16 wt.%, 17 wt.%, 18 wt.%, 19 wt.%, and 20 wt.% of a vanadium oxide represented as V.sub.2O.sub.5, ii) 0.1 to 3 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.% 1.1 wt.%, 1.2 wt.%, 1.5 wt.%, 2.0 wt.%, 2.5 wt.%, and 3.0 wt.%, of a lanthanum oxide such as La.sub.2O.sub.3, and iii) 0.1 to 2 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.%, 1.8 wt.%, 1.9 wt.%, and 2 wt.% of a potassium oxide such as K.sub.2O, and iv) 0.1 to 5 wt.% or at least any one of, equal to any one of, or between any two of 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1.0 wt.%, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.%, 1.8 wt.%, 1.9 wt.%, 2 wt.%, 2.1 wt.%, 2.2 wt.%, 2.3 wt.%, 2.4 wt.%, 2.5 wt.%, 2.6 wt.%, 2.7 wt.%, 2.8 wt.%, 2.9 wt.%, 3.0 wt.%, 3.1 wt.%, 3.2 wt.%, 3.3 wt.%, 3.4 wt.%, 3.5 wt.%, 3.6 wt.%, 3.7 wt.%, 3.8 wt.%, 3.9 wt.%, 4.0 wt.%, 4.1 wt.%, 4.2 wt.%, 4.3 wt.%, 4.4 wt.%, 4.5 wt.%, 4.6 wt.%, 4.7 wt.%, 4.8 wt.%, 4.9 wt.%, and 5.0 wt.% of silica and 71 to 98.7 wt.% or at least any one of, equal to any one of, or between any two of 71 wt.%, 72 wt.%, 73 wt.%, 74 wt.%, 75 wt.%, 76 wt.%, 77, wt.%, 78 wt.%, 79 wt.%, 80 wt. %, 81 wt.%, 82 wt.%, 83 wt.%, 84 wt.%, 85 wt.%, 86 wt.%, 87 wt.%, 88 wt.%, 89 wt.%, 90 wt.%, 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.%, and 98.7 wt.% of delta alumina, where the wt. % is based on the total weight of the catalyst. In some aspects, the catalyst can have a specific surface area of at least 50 m.sup.2/g, such as 50 m.sup.2/g to 250 m.sup.2/g or at least any one of, equal to any one of, or between any two of 50, 60, 70, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, 200, 210, 220, 230, 240, and 250 m.sup.2/g. In some aspects, the catalyst can have an average pore diameter of 30 Å to 200 Å, or at least any one of, equal to any one of, or between any two of 30, 40, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 160, 170, 180, 190, and 200 Å. In some aspects, the catalyst does not include chromium and does not include gold, platinum or palladium. In some instances, the support for the catalysts of the present invention consists of or consists essentially of silica and alumina.

B. Process for Producing the Supported Non-oxidative Alkane Dehydrogenation Catalyst

[0033] The process can include the steps of impregnating a calcined support containing silica and alumina, with a vanadium precursor, a rare earth metal precursor, and an alkali metal precursor to form an impregnated support, drying the impregnated support to obtain a dried impregnated support, and calcining the dried impregnated support to obtain the supported non-oxidative alkane dehydrogenation catalyst. In some aspects, the calcined support prior to impregnation can be dried (e.g., heat treated) in presence of an oxidizing source (e.g., air, oxygen, or oxygen enriched air) at 70° C. to 150° C., or 115° C. to 125° C., or any range or value there between for a desired amount of time (e.g., 1 to 24 hours). The calcined support can have a specific surface area of 80 to 200 m.sup.2/g, or at least any one of, equal to any one of, or between any two of 80, 90, 100, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, and 200 m.sup.2/g. In some particular aspects, the alumina in the calcined support can contain delta alumina.

[0034] The impregnation method can be wet impregnation method or incipient wet impregnation method. In some aspects, the calcined support can be impregnated with a precursor solution containing the vanadium precursor, the rare earth metal precursor and the alkali metal precursor using wet incipient impregnation method. The precursor solution can be an aqueous solution containing the vanadium precursor, the rare earth metal precursor, and the alkali metal precursor. By way of example, the precursor solution can be prepared by dissolving the vanadium precursor, the rare earth metal precursor, and the alkali metal precursor in water. In some aspects, the vanadium precursor can be vanadyl oxalate (VOC.sub.2O.sub.4), ammonium metavanadate, ammonium vanadium oxalate, vanadium monocarboxylate, vanadium dicarboxylate, or vanadium tricarboxylate or any combination thereof. In some aspects, the rare earth metal precursor can be a lanthanum precursor and/or a cerium precursor, preferably a lanthanum precursor. In some particular aspects, the lanthanum precursor can be nitrate, sulfate and/or halide salt(s) of lanthanum (III). In some particular aspects, the lanthanum precursor can be lanthanum (III) nitrate hexahydrate. In some particular aspects, the cerium precursor can be nitrate, sulfate and/or halide salt(s) of cerium (III). In some aspects, the alkali metal precursor can be a potassium precursor. In some aspects, the potassium precursor can be potassium nitrate, potassium acetate (KC.sub.3H.sub.3O.sub.2), potassium citrate (K.sub.3C.sub.6H.sub.5O.sub.7), potassium oxalate (C.sub.2K.sub.2O.sub.4), or potassium carbonate (K.sub.2CO.sub.3) or any combination thereof. In some particular aspects, the calcined support can be impregnated with a precursor solution containing a vanadium precursor such as vanadyl oxalate, a lanthanum precursor such as lanthanum (III) nitrate hexahydrate and a potassium precursor such as potassium nitrate using wet incipient impregnation method. The amount of vanadium precursor, rare earth metal precursor and alkali metal precursor to be used can be calculated based on the weight percents of vanadium, the rare earth metal and the alkali metal, respectively, to be obtained in the final catalyst. In some aspects, the impregnation can be performed at 20 to 35° C. (e.g., room temperature) for a desired amount of time (e.g., at least 0.5 hours or 1 to 24 hours, 1 to 20 hours, 1 to 15 hours, preferably 12 hours).

[0035] In some aspects, the impregnated support can be dried at 70° C. to 180° C. or at least any one of, equal to any one of, or between any two of 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170 and 180° C. for 1 to 24 hours, or at least any one of, equal to any one of, or between any two of 1, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22 and 24 hours to obtain the dry impregnated support. In some particular aspects, the impregnated support can be dried at about 120° C. for about 16 hours to obtain the dry impregnated support. The dry impregnated support can be calcined in the presence of an oxidizing source, such as air, O.sub.2 enriched air, and/or O.sub.2 at a temperature of 500° C. to 1000° C., or 600° C. to 1000° C., or at least, equal to, or between any two of 500, 600, 650, 700, 750, 800, 850, 900, 950, and 1000° C. to obtain the supported non-oxidative alkane dehydrogenation catalyst.

[0036] In some aspects, the process can further include preparing the calcined support. The calcined support can be prepared by contacting an alumina precursor with a silica precursor to obtain a shapeable support precursor, shaping the shapeable support precursor to obtain a wet shaped support precursor, drying the wet shaped support precursor to obtain a dry shaped support precursor and calcining the dry shaped support precursor to obtain the calcined support.

[0037] In some aspects, the alumina precursor can be contacted with a solution such as a colloidal solution containing the silica precursor to obtain the shapeable support precursor. In some aspects, the alumina precursor can be aluminum hydroxide. In some aspects, the silica containing solution can contain a peptizing agent. In some aspects, the peptizing agent can be an acid such as nitric acid and/or acetic acid. In some aspects, the aluminum hydroxide can be gibbsite, bayerite, nordstrandite, boehmite, diaspore, tohdite, amorphous aluminum hydroxide, or any combination thereof. In some particular aspects, the aluminum hydroxide can be boehmite. In some aspects, the silica precursor can be a colloidal silica (e.g. LUDOX® AS-40 colloidal silica commercially available from Sigma-Aldrich). The shapeable support precursor of the current invention can be a sufficiently pliable semisolid mass, such as a dough that can be shaped with a shaping process to form the wet shaped support precursor having a desired geometric shape. In some aspects, the shaping process can be an extrusion process and the shapeable support precursor can be extruded (i.e., pushed and/or drawn through an extrusion die and/or an orifice) to form the wet shaped support precursor having a desired shape or configuration. The extrusion of the shapeable support precursor can be performed with any suitable extruder and/or suitable extrusion die and/or orifice, as will be appreciated by those of skill. The die opening and the cross-section of the wet shaped support precursor can have any suitable regular and/or irregular shape. Non-limiting shapes include circular, oval, square, rectangular, pentagonal, hexagonal, rounded square, rounded rectangular, rounded pentagonal, rounded hexagonal, and star shaped. The extrusion die can have one or more opening(s). The extrusion process can be carried out using a ram extruder, a single screw extruder, or a twin screw extruder. In some particular aspects, the extrusion die can have circular opening with 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 to 10 mm diameter.

[0038] In some aspects, the wet shaped support precursor can be dried at 70° C. to 180° C. or at least any one of, equal to any one of, or between any two of 70, 80, 90, 100, 110, 120, 130, 140 150, 160, 170, and 180° C. for 1 to 24 hours, or at least any one of, equal to any one of, or between any two of 1, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22 and 24 hours to obtain the dry shaped support precursor. In some particular aspects, the wet shaped support precursor can be dried at about 120° C. for about 16 hours to obtain the dry shaped support precursor. The dry shaped support precursor can be calcined in the presence of an oxidizing source, such as air, O.sub.2 enriched air, and/or O.sub.2 at a temperature of 500° C. to 1000° C. or 600° C. to 1000° C., or at least, equal to, or between any two of 500, 600, 650, 700, 750, 800, 850, 900, 950, and 1000° C. to obtain the calcined support.

[0039] The calcined support made through the shaping process such as the extrusion process can contain macro-sized particles. In some aspects, the macro-sized particles can have at least one dimension such as length, width, height, diameter greater than 0.3 mm. The calcined support (e.g., the macro-sized particles of the calcined support) can have a desired geometric shape. The desired geometric shape includes, but is not limited to, spherical, cube, cuboidal, cylindrical, puck, oval, buckyball, and oblong shapes. Macro-sized particles having other shapes can also be made. In some aspects, the macro-sized particles can have cylindrical shape with a circular, elliptical, ovular, triangular, square, rectangular, pentagonal, or hexagonal cross section, although cylindrical shaped macro-sized particles having a cross-section of other shapes can also be made.

C. Process for Non-Oxidative Dehydrogenation of Alkanes

[0040] The supported non-oxidative dehydrogenation catalyst of the present invention can catalyze non-oxidative dehydrogenation of an alkane to produce an alkene. In some aspects, a feed stream containing an alkane can be contacted with the supported non-oxidative alkane dehydrogenation catalyst under conditions sufficient to non-oxidatively dehydrogenate at least a portion of the alkane to produce a products stream containing an alkene. The supported non-oxidative dehydrogenation catalyst can be contacted with the feed stream in a dehydrogenation reactor. In some aspects, the dehydrogenation reactor can be a fixed bed reactor. In some aspects, supported non-oxidative dehydrogenation catalyst can be included in the reactor bed of the fixed bed dehydrogenation reactor and during the non-oxidative dehydrogenation of alkane, the feed stream can be passed through and/or over the reactor bed. In some aspects, the contacting condition (e.g., the reactor condition during non-oxidative dehydrogenation of alkane) can include i) a temperature of 400° C. to 800° C., or 500° C. to 700° C., or at least any one of, equal to any one of, or between any two of 400, 450, 500, 550, 600, 650, 700, 750, and 800° C., ii) a gas hourly space velocity (GHSV) of the feed stream of at least 0.1 L h.sup.-1 g.sup.-1 or 0.5 to 10 L h.sup.-1 g.sup.- 1, or at least any one of, equal to any one of, or between any two of 0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 L h.sup.-1 g.sup.-1 or iii) a pressure of 0.01 MPa to 0.5 MPa, or at least any one of, equal to any one of, or between any two of 0.01, 0.02, 0.05, 0.1, 0.2, 0.3, 0.4, and 0.5 MPa, or any combination thereof. The conditions for alkene production can be varied based on the reactor type and/or properties. In some aspects, the feed stream can include at least 50 vol.%, or 82 vol.% to 95 vol.%, or 88 vol.% to 92 vol.% at least any one of, equal to any one of, or between any two of 50 vol.%, 51 vol.%, 52 vol.%, 53 vol.%, 54 vol.%, 55 vol.%, 56 vol.%, 57 vol.%, 58 vol.%, 59 vol.%, 60 vol.%, 61 vol.%, 62 vol.%, 63 vol.%, 64 vol.%, 65 vol.%, 66 vol.%, 67 vol.%, 68 vol.%, 69 vol.%, 70 vol.%, 71 vol.%, 72 vol.%, 73 vol.%, 74 vol.%, 75 vol.%, 76 vol.%, 77 vol.%, 78 vol.%, 79 vol.%, 80 vol.%, 81 vol.%, 82 vol.%, 83 vol.%, 84 vol.%, 85 vol.%, 86 vol.%, 87 vol.%, 88 vol.%, 89 vol.%, 90 vol.%, 91 vol.%, 92 vol.%, 93 vol.%, 94 vol.%, and 95 vol.%, of the alkane. The feed stream (e.g., alkanes in the feed stream) can be obtained from other process units and/or from commercial sources.

[0041] The feed stream can contain one or more of a C.sub.2 to C.sub.10 alkane and correspondingly the products stream can contain one or more of a C.sub.2 to C.sub.10 alkene. C.sub.2 to C.sub.10 alkane refers to an alkane having from 2 to 10 carbon atoms, (e.g., including but not limited to ethane, propane, n-butane, iso-butane, n-pentane, iso-pentane, hexane, heptane, octane, nonane, decane). C.sub.2 to C.sub.10 alkene refers to an alkene having from 2 to 10 carbon atoms, (e.g., including but not limited to ethylene, propylene, n-butylene, iso-butylene, n-pentene, iso-pentene, hexene, heptene, octene, nonene, decene). Non-limiting examples of alkanes in the feed stream can include ethane, propane, n- butane, isobutane, n-pentane, isopentane, hexane, heptane, octane, nonane, decane, and all isomers thereof. In some particular aspects, the feed stream can contain ethane and the products stream can contain ethylene. In some particular aspects, the feed stream can contain propane and the products stream can contain propylene. In some particular aspects, the feed stream can contain n-butane and the products stream can contain n-butylene. In some particular aspects, the feed stream can contain iso-butane and the products stream can contain iso-butylene. In some particular aspects, the feed stream can contain n-pentane and the products stream can contain n-pentene. In some particular aspects, the feed stream can contain iso-pentane and the products stream can contain iso-pentene. In some particular aspects, the feed stream can contain ethane, propane, n-butane, iso-butane, n-pentane, or iso-pentane or any combination thereof, and correspondingly the products stream can contain ethylene, propylene, n-butylene, iso-butylene, n-pentene or iso-pentene or any combination thereof.

[0042] Unlike oxidative dehydrogenation of alkanes, oxygen such as gas phase oxygen and/or lattice oxygen is not used during non-oxidative dehydrogenation of alkanes. In some aspects, the non-oxidative alkane dehydrogenation catalyst can be activated prior to contacting the catalyst with the feed stream and the feed stream can be contacted with the activated catalyst. In some particular aspects, the activation process can include contacting the catalyst in the dehydrogenation reactor with an oxidizing stream (e.g., a gaseous stream containing air, O.sub.2, and/or O.sub.2 enriched air) at a temperature 400 to 1000° C. for a desired amount of time (e.g., 0.01 hr to 1 hr) to form an oxidized catalyst, and contacting the oxidized catalyst with a reducing stream (e.g., a gaseous stream containing H.sub.2) at 400° C. to 800° C. for a desired amount of time (e.g., 0.01 hr to 1 hr) to form the activated catalyst. In some aspects, an inert gas can be passed through the dehydrogenation reactor containing the oxidized catalyst prior to contacting the oxidized catalyst with the reducing stream. In some aspects, an inert gas can be passed through the dehydrogenation reactor containing the activated catalyst prior to contacting the activated catalyst with the feed stream. In some aspects, the inert gas can be nitrogen (N.sub.2) and/or helium. In some aspects, a deactivated catalyst can be formed from the activated catalyst during and/or after the non-oxidative dehydrogenation of alkane. In some aspects, the deactivated catalyst can be activated using the activation process and the process for non-oxidative dehydrogenation of alkane can be repeated. In some aspects, the products stream can contain unreacted alkanes. In some aspects, at least a portion of the unreacted alkanes can be recycled and included in the feed stream to maximize the overall conversion of alkane to alkene via dehydrogenation. In some aspects, the alkenes produced can be further purified, stored and/or used in various processes.

[0043] The dehydrogenation reactor can include one or more heating and/or cooling devices (e.g., insulation, electrical heaters, jacketed heat exchangers in the wall) or controllers (e.g., computers, flow valves, automated values, etc.) that are used to control the reactant flow, reaction temperature, and/or pressure of the reaction mixture. While only one reactor is shown, it should be understood that multiple reactors can be housed in one unit or a plurality of reactors housed in one heat transfer unit.

EXAMPLES

[0044] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.

Comparative Example 1

Synthesis of Vanadium Oxide/K.SUB.2.O Supported on Delta Alumina Catalyst

[0045] Alumina extrudates mainly in delta-alumina (δ-Al.sub.2O.sub.3) form were prepared using following procedure. Boehmite (G-250) material was extrudated using acetic acid as a peptizing agent. To boehmite powder (500 g) was added dropwise 5% acetic acid (370 ml) and the mixture was mixed for about 30 minutes. The obtained dough was then extruded using a lab extruder (Sunsai), the dies being 3.5 mm in diameter. The prepared wet extrudates were dried at 120° C. for 16 hours in air oven. The dried extrudates (160 g) were calcined at 900° C. for 10 hours in muffle furnace with heating rate 5° C./min and air flow rate being 480±10 ml/min. The obtained extrudates (size: 3 mm diameter and 6-8 mm length) with surface area of 145 m.sup.2/g were used for catalyst preparation. The alumina extrudate support (about 100 g) was heat treated in an oven at 120° C. for 16 hours in the presence of air to remove moisture. The dried alumina extrudate support, after cooling to room temperature, was used for catalyst preparation by incipient wetness impregnation method. The catalyst was prepared by incipient wetness impregnation of the support with an aqueous solution of vanadyl oxalate, VOC.sub.2O.sub.42H.sub.2O (3.97 g) and potassium nitrate (0.386 g). The impregnation was carried out by contacting the impregnation solution (18 mL) with alumina extrudate support (27.93 g) at room temperature. The impregnated alumina support was then kept at room temperature for 12 hours and then dried at 120° C. for 16 hours. The dried sample was then calcined at 750° C. for 4 hours with heating rate 5° C./min in the presence of air (flow rate, 8 ml g.sup.-1min.sup.-1) in a down flow tubular furnace. After calcination, the catalyst was cooled in presence of air and the catalyst was stored in an air tight container. The final calculated composition of the catalyst corresponds to V.sub.2O.sub.5 - 6.3 wt. %, K.sub.2O - 0.6 wt. % with remaining part comprising δ-Al.sub.2O.sub.3.

Comparative Example 2

Synthesis of Vanadium Oxide - Lanthanum Oxide - K.SUB.2.O Supported Delta Alumina

[0046] Alumina extrudates mainly in delta-alumina (δ-Al2O3) form were prepared using following procedure. Boehmite (G-250) material was extrudated using acetic acid as a peptizing agent. To boehmite powder (500 g) was added dropwise 5% acetic acid (370 ml) and the mixture was mixed for about 30 minutes. The obtained dough was then extruded using a lab extruder (Sunsai), the dies being 3.5 mm in diameter. The prepared wet extrudates were dried at 120° C. for 16 hours in air oven. The dried extrudates (160 g) were calcined at 900° C. for 10 hours in muffle furnace with heating rate 5° C./min and air flow rate being 480±10 ml/min. The obtained extrudates (size: 3 mm diameter and 6-8 mm length) with surface area of 145 m.sup.2/g were used for catalyst preparation. The alumina extrudate support (about 100 g) was heat treated in an oven at 120° C. for 16 hours in the presence of air to remove moisture. The dried alumina extrudate support, after cooling to room temperature, was used for catalyst preparation by incipient wetness impregnation method. The catalyst was prepared by incipient wetness impregnation of the support with an aqueous solution of vanadyl oxalate, VOC.sub.2O.sub.42H.sub.2O (3.97 g), potassium nitrate (0.386 g) and lanthanum nitrate (0.399 g). The impregnation was carried out by contacting the impregnation solution (18 mL) with alumina extrudate support (27.93 g) at room temperature. The impregnated alumina support was then kept at room temperature for 12 hours and then dried at 120° C. for 16 hours. The dried sample was then calcined at 750° C. for 4 hours with heating rate 5° C./min in the presence of air (flow rate, 8 mlg.sup.-1min.sup.-1) in a down flow tubular furnace. After calcination, the catalyst was cooled in presence of air and the catalyst was stored in an air tight container. The final calculated composition of the catalyst corresponds to V.sub.2O.sub.5 - 6.3 wt. %, K.sub.2O - 0.6 wt. %, La.sub.2O.sub.3- 0.5 wt. % with remaining part comprising δ-Al.sub.2O.sub.3.

Comparative Example 3

Synthesis of Vanadium Oxide - K.SUB.2.O Supported on Silica Modified Delta Alumina

[0047] The silica modified alumina extrudates mainly in delta-alumina (δ-Al.sub.2O.sub.3) form were prepared using following procedure. Boehmite (G-250) material was extrudated using nitric acid as a peptizing agent. To boehmite powder (500 g) was added dropwise 5% nitric acid (370 ml) containing silica sol (9.25 ml of silica sol (AS-40) and the mixture was mixed for about 30 minutes. The obtained dough was then extruded using a lab extruder (Sunsai), the dies being 3.5 mm in diameter. The prepared wet extrudates were dried at 120° C. for 16 hours in air oven. The dried extrudates (160 g) were calcined at 950° C. for 5 hours in muffle furnace with heating rate 5° C./min and air flow rate being 480±10 ml/min. The obtained extrudates (size: 3 mm diameter and 6-8 mm length) with surface area of 145 m.sup.2/g were used for catalyst preparation. The alumina extrudate support (about 100 g) was heat treated in an oven at 120° C. for 16 hours in the presence of air to remove moisture. The dried alumina extrudate support, after cooling to room temperature, was used for catalyst preparation by incipient wetness impregnation method. The catalyst was prepared by incipient wetness impregnation of the support with an aqueous solution of vanadyl oxalate, VOC.sub.2O.sub.42H.sub.2O (3.97 g) and potassium nitrate (0.386 g). The impregnation was carried out by contacting the impregnation solution (18 mL) with alumina extrudate support (27.93 g) at room temperature. The impregnated alumina support was then kept at room temperature for 12 hours and then dried at 120° C. for 16 hours. The dried sample was then calcined at 750° C. for 4 hours with heating rate 5° C./min in the presence of air (flow rate, 8 ml g.sup.-1min.sup.-1) in a down flow tubular furnace. After calcination, the catalyst was cooled in presence of air and the catalyst was stored in an air tight container. The final calculated composition of the catalyst corresponds to V.sub.2O.sub.5 - 6.3 wt. %, K.sub.2O - 0.6 wt. %, SiO.sub.2 - 1 wt. % with remaining part comprising and δ-Al.sub.2O.sub.3.

Example 4

Synthesis of Vanadium Oxide - Lanthanum Oxide - K20 Supported on Silica Modified Delta Alumina

[0048] The silica modified alumina extrudates mainly in delta-alumina (δ-Al.sub.2O.sub.3) form were prepared using following procedure. Boehmite (G-250) material was extrudated using nitric acid as a peptizing agent. To boehmite powder (500 g) was added dropwise 5% nitric acid (370 ml) containing silica sol (9.25 ml of silica sol (AS-40) and the mixture was mixed for about 30 minutes. The obtained dough was then extruded using a lab extruder (Sunsai), the dies being 3.5 mm in diameter. The prepared wet extrudates were dried at 120° C. for 16 hours in air oven. The dried extrudates (160 g) calcined at 950° C. for 5 hours in muffle furnace with heating rate 5° C./min and air flow rate being 480±10 ml/min. The obtained extrudates (size: 3 mm diameter and 6-8 mm length) with surface area of 145 m.sup.2/g were used for catalyst preparation. The alumina extrudate support (about 100 g) was heat treated in an oven at 120° C. for 16 hours in the presence of air to remove moisture. The dried alumina extrudate support, after cooling to room temperature, was used for catalyst preparation by incipient wetness impregnation method. The catalyst was prepared by incipient wetness impregnation of the support with an aqueous solution of vanadyl oxalate, VOC.sub.2O.sub.42H.sub.2O (3.97 g), potassium nitrate (0.386 g) and lanthanum nitrate (0.399 g). The impregnation was carried out by contacting the impregnation solution (18 mL) with alumina extrudate support (27.93 g) at room temperature. The impregnated alumina support was then kept at room temperature for 12 hours and then dried at 120° C. for 16 hours. The dried sample was then calcined at 750° C. for 4 hours with heating rate 5° C./min in the presence of air (flow rate, 8 ml g.sup.-1min.sup.-1) in a down flow tubular furnace. After calcination, the catalyst was cooled in presence of air and the catalyst was stored in an air tight container. The final calculated composition of the catalyst corresponds to V.sub.2O.sub.5 - 6.3 wt. %, K.sub.2O - 0.6 wt. %, La.sub.2O.sub.3 - 0.5 wt %, SiO.sub.2 - 1.0 wt. % with remaining part comprising δ-Al.sub.2O.sub.3.

Example 5

Catalyst Testing and Aging

[0049] The dehydrogenation activities of the catalysts were measured in a tubular fixed-bed quartz reactor. The details of catalyst loading and reactor were as follows: catalyst weight = 4.0 g, catalyst particle size = 0.4-0.5 mm, reactor ID = 16 mm, reactor OD = 19 mm. Isobutane (99.9 vol. %) was used as the feed. Quartz chips with size of 1-1.4 mm were loaded above the catalyst bed. Nitrogen purge separated dehydrogenation and catalyst regeneration/oxidation and reduction with hydrogen. The total feed flow in the dehydrogenation step was corresponds to GHSV = 600 mLh.sup.-1g.sup.-1. The reactor outlet gases were analyzed by online gas chromatograph (Agilent 6890, Agilent Scientific Instruments, USA) equipped with a flame ionization detector for hydrocarbon analysis and thermal conductivity detector for hydrogen analysis. The reactant and products flow rates were measured using Ritter type wet gas flow meter. The reactor was operated at atmospheric pressure and in a cyclic mode with the following steps: [0050] 1. Oxidation in air at 650° C. for 20 min. [0051] 2. Purge with nitrogen at 650° C. for 5 min. [0052] 3. Reduction with H.sub.2 at 650° C. for 6 min. [0053] 4. Cooling with nitrogen from 650° C. to 585° C. with 20 min. hold at 585° C. [0054] 5. Dehydrogenation of isobutane at 585° C. for 21 min. [0055] 6. GC analysis at 20th minute from the start of the isobutane feed. [0056] 7. Heating with nitrogen from 585° C. to 650° C. with 5 min. hold at 650° C. [0057] 8. Steps 1-7 were repeated for 30 cycles before aging of the catalyst and 15 cycles after aging of the catalysts.

[0058] The catalyst aging protocol details are discussed below. Catalyst stability (for first two aging) evaluation was carried out by accelerated aging procedure in a cyclic mode of operation. The cycle included H.sub.2-isobutane-air passing stages with suitable time intervals. The aging was carried out at 700° C. for 3 days. The other details are as follows: catalyst weight = 4.0 g, GHSV for all gases = 600 ml g.sup.-1 h.sup.-1, except for air 1200 ml g.sup.-1 h.sup.-1 for first aging and 1800 ml g.sup.-1 h.sup.-1 for second aging. [0059] 1. Oxidation in air for 20 min. [0060] 2. Purge with nitrogen for 5 min. [0061] 3. Reduction with H.sub.2 for 6 min. [0062] 4. Purge with nitrogen for 5 min. [0063] 5. Iso-butane flow for 5 min. [0064] 6. Purge with nitrogen for 5 min. [0065] 7. Steps 1 to 6 were repeated for 75 cycles.

[0066] The third aging was carried out at 750° C. for 3 days (Comparative Example-3 and Example-4). The other details are as follows: catalyst weight = 4.0 g, GHSV for all gases = 600 mL g.sup.-1 h.sup.-1 except for air 1800 mL g.sup.-1 h.sup.-1. [0067] 1. Oxidation in air for 20 min. [0068] 2. Purge with nitrogen for 5 min. [0069] 3. Reduction with H.sub.2 for 6 min. [0070] 4. Purge with nitrogen for 5 min. [0071] 5. Iso-butane flow for 5 min. [0072] 6. Purge with nitrogen for 5 min. [0073] 7. Steps 1 to 6 were repeated for 50 cycles.

[0074] The fourth aging was carried out at 800° C. for 2 days (Comparative Example-3 and Example-4). The other details are as follows: catalyst weight = 4.0 g, GHSV for all gases = 600 mL g.sup.-1 h.sup.-1 except for air 1800 mL g.sup.-1 h.sup.-1. [0075] 1. Oxidation in air for 20 min. [0076] 2. Purge with nitrogen for 5 min. [0077] 3. Reduction with H2 for 6 min. [0078] 4. Purge with nitrogen for 5 min. [0079] 5. Iso-butane flow for 3 min. [0080] 6. Purge with nitrogen for 5 min. [0081] 7. Steps 1 to 6 were repeated for 50 cycles.

[0082] The fifth aging was carried out at 820° C. for 2 days (Comparative Example-3 and Example-4). The other details are as follows: catalyst weight = 4.0 g, GHSV for all gases = 600 mL g.sup.-1 h.sup.-1 except for except for air 1800 mL g.sup.-1 h.sup.-1 and IB 400 mL g.sup.-1 h.sup.-1. [0083] 1. Oxidation in air for 20 min. [0084] 2. Purge with nitrogen for 5 min. [0085] 3. Reduction with H.sub.2 for 6 min. [0086] 4. Purge with nitrogen for 5 min. [0087] 5. Iso-butane flow for 3 min. [0088] 6. Purge with nitrogen for 5 min. [0089] 7. Steps 1 to 6 were repeated for 50 cycles.

[0090] The isobutane dehydrogenation results are presented in FIG. 2A (conversion), 2B (selectivity), and 2C (yield) for comparative example-1, comparative example-2, comparative example-3 and example 4. Catalysts of comparative example-1 and comparative example-2 delivered lower conversion after 1.sup.st aging. Hence from 2.sup.nd aging onwards, further aging and reaction was continued for catalysts of comparative example-3 and example 4 only. FIGS. 2A, 2B and 2C show a catalyst according to an example of the present invention. Example 4 shows better catalyst performance (e.g., conversion, selectivity and yield) compared to the comparative catalysts (comparative examples 1, 2 and 3).

[0091] Although embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the above disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.