ADDITIVE COMPOSITION FOR MIXED METAL OXIDE CATALYSTS AND ITS USE IN HYDROCARBON CONVERSION PROCESSES

Abstract

The present invention provides an additive composition having the general formula: A.sub.xB.sub.yC(.sub.1-y)D.sub.zO.sub.m wherein: A is one or more metal elements selected from the group consisting of Group IIA of the periodic table; B, C is one or more metal elements selected from the lanthanide group, series of the periodic table or Yttrium; D is one or more metal elements selected from the group consisting of Manganese, Cobalt, Copper, Nickel or Ruthenium; x is a number defined by 0.5<x<4; y is a number defined by 0<=y<=1; z is a number defined by 2<z<6; m is a number which renders the catalyst substantially neutral. The present invention also provides a process for preparing the afore-mentioned additive composition. The present invention further provides mixed metal oxide catalysts comprising additive composition and its use in hydrocarbon conversion processes.

Claims

1. An additive composition comprising mixed metal oxide having the general formula:
A.sub.xB.sub.yC(.sub.1-y)D.sub.zO.sub.m wherein: A is one or more metal elements selected from the group consisting of Group IIA of the periodic table; B, C is one or more metal elements selected from the lanthanide group series of the periodic table or Yttrium; D is one or more metal elements selected from the group consisting of Manganese, Cobalt, Copper, Nickel or Ruthenium; x is a number defined by 0.5<x<4 y is a number defined by 0<=y<=1 z is a number defined by 2<z<6 m is a number which renders the catalyst substantially neutral.

2. The additive composition as claimed in claim 1, wherein A is selected from the group consisting of Strontium, Magnesium, Barium or mixtures thereof.

3. The additive composition as claimed in claim 1, wherein B and C are selected from the group consisting of Cerium, Samarium, Ytterbium, Lanthanum, Neodymium, Yttrium or mixtures thereof.

4. The additive composition as claimed in claim 1, wherein A is Strontium, B is Cerium or Yttrium, C is Samarium or Ytterbium and D is Manganese or Ruthenium.

5. The additive composition as claimed in claim 1, wherein the mole percent of element A is in the range of 0.1<A<0.25; mole percent of elements B, C are in the range of 0.05<B, C<0.2; mole percent of element D is in the range of 0.1<D<0.35; and the valence charge of oxygen is such that the overall charge of the molecule is neutral.

6. A process for preparing the additive composition as claimed in claim 1 comprising: a) dissolving water soluble salts of A, B, C and D to obtain the general formula as claimed in claim 1; b) adding a precipitating agent to the resultant mixture of step (a); c) adjusting the pH of the solution of step (b) to about 9-12; d) filtering and washing the resulting precipitant of step (c); e) calcining the precipitant of step (d) at 300 C. to 600 C. for 1 hour to 6 hours to obtain the additive composition.

7. The process as claimed in claim 6, wherein the salts of A, B, C and D are selected from the group consisting of nitrate, acetate, chloride or sulfate.

8. The process as claimed in claim 6, wherein the process optionally comprises adding an oxidizing agent or a surfactant to the mixture of step (a).

9. The process as claimed in claim 8, wherein the oxidizing agent is selected from the group consisting of hydrogen peroxide, chlorate, perchlorate, hypochlorite, nitric acid, sulfuric acid, potassium permanganate or mixtures thereof.

10. The process as claimed in claim 8, wherein the oxidizing agent is added in an amount of 100% in excess of the moles of element D in the additive composition.

11. The process as claimed in claim 8, wherein the surfactant is selected from the group consisting of polyvinyl alcohol (PVA), Triton X-100, Pluronic F127, Polyethylene glycol (PEG), sodium salt of polyacrylic acid (Na-PAA) or mixtures thereof.

12. The process as claimed in claim 8, wherein the surfactant is added in an amount of 50% in excess of moles of element A present in the additive composition.

13. The process as claimed in claim 6, wherein the precipitating agent is selected from the group consisting of sodium hydroxide, sodium carbonate, oxalic acid, sodium oxalate, ammonium oxalate or mixtures thereof.

14. The process as claimed in claim 6, wherein the precipitating agent is added in an amount so as to obtain a final pH value of at least 9.

15. The process as claimed in claim 6, wherein the pH of solution of step (b) is adjusted using tetramethylammonium hydroxide (TMAOH).

16. The process as claimed in claim 6, wherein the precipitant of step (d) is calcined at 500 C. for 4 hours.

17. A mixed metal oxide catalyst comprising the additive composition as claimed in claim 1.

18. The mixed metal oxide catalyst as claimed in claim 17, wherein said mixed metal oxide catalyst is selected from the group consisting of Group III and Group IV of the periodic table.

19. The mixed metal oxide catalyst as claimed in claim 18, wherein said mixed metal oxide catalyst is selected from the group consisting of a sulfated or a tungsated metal oxide of Zirconium or Aluminum or mixtures thereof.

20. The mixed metal oxide catalyst as claimed in claim 17, wherein said mixed metal oxide catalyst optionally consists of a hydrogenating metal selected from the group consisting of Manganese, Iron, Gallium, Copper, Cobalt or mixtures thereof.

21. The mixed metal oxide catalyst as claimed in claim 17, wherein the additive composition is added to the mixed metal oxide catalyst prior to calcination.

22. The mixed metal oxide catalyst as claimed in claim 17, wherein about 0.5 to 25 weight percent of the additive composition is added to the mixed metal oxide catalyst.

23. The mixed metal oxide catalyst as claimed in claim 17, wherein said mixed metal oxide catalyst further comprises a Group VIII metal selected from the group consisting of Platinum, Palladium, Rhenium, Rhodium, Iridium, Ruthenium, Gold or mixtures thereof.

24. The mixed metal oxide catalyst as claimed in claim 23, wherein about 0.1% to 5% of Group VIII metal is present in the mixed metal oxide catalyst.

25. The mixed phase catalyst as claimed in claim 17, wherein the additive composition has a fluorite phase and/or a spinel phase and/or a mullite phase when characterized with Transmission Electron Microscopy (TEM) or Scanning Transmission Electron Microscopy (STEM)/Energy-disperisve X-ray Analyser (EDX) techniques.

26. A process for converting hydrocarbons by contacting a feed with the mixed metal oxide catalyst as claimed in claim 17.

27. The process for converting hydrocarbons as claimed in claim 26, wherein the hydrocarbon conversion process is selected from the group consisting of cracking, hydrocracking, aromatic alkylation, isoparaffin alkylation, isomerization, polymerization, reforming, hydrogenation, dehydrogenation, transalkylation or dealkylation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The following detailed description of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of assisting in the explanation of the invention, there are shown in the drawings embodiments which are presently preferred and considered illustrative. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown therein.

[0037] FIG. 1: X-ray diffraction pattern of additive composition for catalyst Z1 of the present invention which shows the onset of the crystal formation.

[0038] FIG. 2: X-ray diffraction pattern of additive composition for catalyst Z2 of the present invention which shows the onset of the crystal formation.

[0039] FIG. 3: X-ray diffraction pattern of additive composition for catalyst Z3 of the present invention which shows the onset of the crystal formation.

DETAILED DESCRIPTION OF THE INVENTION

[0040] For the purposes of the following detailed description, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification are to be understood as being modified in all instances by the term about. It is noted that, unless otherwise stated, all percentages given in this specification and appended claims refer to percentages by weight of the total composition.

[0041] Thus, before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or process parameters that may of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner.

[0042] The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification.

[0043] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control.

[0044] It must be noted that, as used in this specification and the appended claims, the singular forms a, an and the include plural referents unless the content clearly dictates otherwise.

[0045] The terms preferred and preferably refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the invention.

[0046] As used herein, the terms comprising including, having, containing, involving, and the like are to be understood to be open-ended, i.e., to mean including but not limited to.

[0047] In one aspect, the present invention provides an additive composition comprising mixed metal oxide having the general formula:

A.sub.xB.sub.yC(.sub.1-y)D.sub.zO.sub.m [0048] wherein: [0049] A is one or more metal elements selected from the group consisting of Group IIA of the periodic table; [0050] B, C is one or more metal elements selected from the lanthanide group series of the periodic table or Yttrium; [0051] D is one or more metal elements selected from the group consisting of Manganese, Cobalt, Copper, Nickel or Ruthenium; [0052] x is a number defined by 0.5<x<4 [0053] y is a number defined by 0<=y<=1 [0054] z is a number defined by 2<z<6 [0055] m is a number which renders the catalyst substantially neutral.

[0056] Element A is selected from the group consisting of Strontium, Magnesium, Barium or mixtures thereof. Elements B and C are selected from the group consisting of Cerium, Samarium, Ytterbium, Lanthanum, Neodymium, Yttrium or mixtures thereof. Preferably element A is Strontium, B is Cerium or Yttrium, C is Samarium or Ytterbium and D is Manganese or Ruthenium.

[0057] In an embodiment of the present invention, the mole percent of element A is in the range of 0.1<A<0.25; mole percent of elements B, C are in the range of 0.05<B, C<0.2; mole percent of element D is in the range of 0.1<D<0.35; and the valence charge of oxygen is such that the overall charge of the molecule is neutral.

[0058] In the most preferred embodiment, the additive composition has the general formula:

Sr.sub.xB.sub.yC(.sub.1-y)D.sub.zO.sub.m

wherein: [0059] B, C is one or more metal elements selected from the lanthanide group series of the periodic table or Yttrium; [0060] D is one or more metal elements selected from the group consisting of Manganese, Cobalt, Copper, Nickel or Ruthenium; [0061] x is a number defined by 0.5<x<4 [0062] y is a number defined by 0<=y<=1 [0063] z is a number defined by 2<z<6 [0064] m is a number which renders the catalyst substantially neutral.

[0065] In another aspect, the present invention provides a process for preparing the afore-mentioned additive composition comprising: [0066] a. dissolving water soluble salts of A, B, C and D to obtain the general formula of the afore-mentioned additive composition; [0067] b. adding a precipitating agent to the resultant mixture of step (a); [0068] c. adjusting the pH of the solution of step (b) to about 9-12; [0069] d. filtering and washing the resulting precipitant of step (c); [0070] e. calcining the precipitant of step (d) at 300 C. to 600 C. for 1 hour to 6 hours to obtain the additive composition.

[0071] In an embodiment of the present invention, the additive composition may be prepared by co-precipitation method or sequential precipitation method wherein suitable amounts of metal salt precursors such as but not limited to nitrate salts or acetate salts or chloride salts or sulfate salts are dissolved in water. The resultant mixture of metal cations is then precipitated using a precipitating agent. The precipitating agent may also act as a surfactant to create the desired crystal structure. Suitable precipitating agent may be selected from the group consisting of sodium hydroxide, sodium carbonate, oxalic acid, sodium oxalate, ammonium oxalate or mixtures thereof and may be added in an amount so as to obtain a final pH value of at least 9 or above.

[0072] The pH of solution of step (b) is adjusted between 9-12 using tetramethylammonium hydroxide (TMAOH). Additional TMAOH may be added to reestablish the pH of the solution. The resultant metal precipitant is filtered and washed using deionized water for three to four times. Finally, the metal precipitant is dried, processed and calcined at 500 C. for 4 hours.

[0073] The afore-mentioned process may optionally comprise adding an oxidizing agent or a surfactant to the mixture of step (a). Said oxidizing agent may be selected from the group consisting of hydrogen peroxide, chlorate, perchlorate, hypochlorite, nitric acid, sulfuric acid, potassium permanganate or mixtures thereof and may be added in an amount of 100% in excess of the moles of element D used in the additive composition. Said surfactant may be selected from the group consisting of polyvinyl alcohol (PVA), Triton X-100, Pluronic F127, Polyethylene glycol (PEG), sodium salt of polyacrylic acid (Na-PAA) or mixtures thereof and may be added in an amount of 50% in excess of the moles of element A used in the additive composition.

[0074] The additive composition may be partially calcined to start the formation of the desired crystals which when mixed with the mixed metal oxide catalyst such as the sulfated alumina zirconia catalyst will allow optimal crystal formation during final calcination procedure. In another embodiment of the present invention, the additive may not be fully calcined wherein X-ray diffraction does not reveal fully crystalline structures but only reveals partially crystalline and partially amorphous phases.

[0075] In another embodiment of the present invention, the additive composition may be prepared using the citric acid method. Said method includes dissolving suitable amounts of the different metal salts in water with 10% excess of molar amounts of citric acid. Optionally, all or a portion of the citric acid may be substituted with Ethylene diamine tetraacetic acid (EDTA) or a mixture of Polyvinyl alcohol (PVA) and sucrose. The mixture is stirred and heated until a viscous gel forms. The viscous gel is dried, processed, and calcined at 500 C. for 4 hours.

[0076] In another aspect, the present invention provides a mixed metal oxide catalyst comprising the afore-mentioned additive composition. Said mixed metal oxide catalyst is selected from the group consisting of Group III and Group IV of the periodic table.

[0077] In an embodiment of the present invention, the mixed metal oxide catalyst is selected from the group consisting of a sulfated or a tungsated metal oxide of Zirconium or Aluminum or mixtures thereof. Said mixed metal oxide catalyst may optionally consist of a hydrogenating metal selected from the group consisting of Manganese, Iron, Gallium, Copper, Cobalt or mixtures thereof.

[0078] The afore-mentioned mixed metal oxide catalyst may further comprise a Group VIII metal selected from the group consisting of Platinum, Palladium, Rhenium, Rhodium, Iridium, Ruthenium, Gold or mixtures thereof. In an embodiment of the present invention, about 0.1% to 5% of Group VIII metal may be present in the mixed metal oxide catalyst. Said Group VIII metal in small amounts may be added to the final mixed metal oxide catalyst by usual impregnation techniques known to those skilled in the art. One of the specific advantages of the additive composition of the present invention is to provide the optimal charge density on the surface catalyst to enable further ion doping. For example, most hydrocarbon processes require small quantities of Platinum group metals (PGM) to be further added to the final catalyst recipe to enhance long term performance. PGM is typically added to the catalyst by dry impregnation method which while cheaper does not give optimal control on the location of PGM on the surface of the catalyst leading to non-optimal performance. The additive composition described in the present invention when added to the catalyst will provide the interionic repulsive forces thus increasing the dispersion (or surface area) of the PGM metals on the surface, thus dramatically improving the PGM surface area. Larger PGM surface area results directly in increasing catalyst longevity and reactivity. Further, the additive also increases the metal support interactive forces thus decreasing the stronger binding forces of the PGM metals towards undesirable feed contaminants such as sulfur and nitrogen.

[0079] In an exemplary embodiment of the present invention, the additive composition may be directly added to sulfated zirconia catalysts as described in the open literatures titled 1) Effect of isopropanol aging of Zr(OH).sub.4 on n-hexane isomerization over PtSO.sub.4.sup.2/Al.sub.2O.sub.3ZrO.sub.2, Catalysis Today, October 2009, 148 (1-2), p 70-74, 2) Catalytic performance of Re/Ga.sub.2O.sub.3/WO.sub.3/ZrO.sub.2 catalyst for n-Hexane isomerization, Chi. J. of. Catal. September 2009, 30(9), p 859-863).

[0080] The additive composition can be directly added to mixed metal oxide catalysts in varying ratios to the sulfated zirconia catalyst such as PtSO.sub.4.sup.2/Al.sub.2O.sub.3/ZrO.sub.2 catalysts to obtain the desired results.

[0081] In an embodiment of the present invention, the additive composition is added to the mixed metal oxide catalyst prior to calcination and about 0.5 to 25 weight percent of the additive composition is added to the mixed metal oxide catalyst. In order for the final catalyst to be active, the sulfated mixture of Al.sub.2O.sub.3 and ZrO.sub.2 in their hydroxide form should be intimately mixed with the additive composition in ratios of 2 to 25% so as to obtain maximum benefit.

[0082] The additive composition of the present invention may be synthesized separately from the mixed metal oxide catalyst (such as sulfated alumina zirconia catalyst). The synthesis of the sulfated alumina zirconia catalyst along with some transition metal additive may be done through the processes as described in the open literature titled 1) Effect of isopropanol aging of Zr(OH).sub.4 on n-hexane isomerization over PtSO.sub.4.sup.2/Al.sub.2O.sub.3ZrO.sub.2, Catalysis Today, October 2009, 148 (1-2), p 70-74, and 2) Catalytic performance of Re/Ga.sub.2O.sub.3/WO.sub.3/ZrO.sub.2 catalyst for n-Hexane isomerization, Chi. J. of Catal., September 2009, 30(9), p 859-863. High surface area Zr(OH).sub.4 and pseudo boehmite may be mulled together and extruded using sulfate ion additive such as sulfuric acid or ammonium sulfate followed by drying at 120 C. for several hours. In addition a transition metal ion may be added to increase the hydrogenation ability of the catalyst.

[0083] In an embodiment of the present invention, the additive composition synthesized will have at least two phases namely a spinel phase and a mullite phase or a fluorite phase oxide when characterized with Transmission Electron Microscopy (TEM) or Scanning Transmission Electron Microscopy (STEM)/Energy-dispersive X-ray Analyser (EDX) techniques. In another embodiment, the spinel phase and/or the fluorite phase and/or the mullite phase can include one or more metals.

[0084] In a further embodiment of the present invention, the mixed phase catalyst additive composition may include a composite having two or more constituent materials with different physical or chemical properties which remain separate and distinct at the macroscopic or microscopic scale within the finished structure. For example, two particles with different compositions remain separate in TEM (Transmission Electron Microscopy) while they do have common interface.

[0085] In a further aspect, the present invention provides a process for converting hydrocarbons by contacting a feed with the mixed metal oxide catalyst having the additive composition.

[0086] Said hydrocarbon conversion process may be selected from the group consisting of cracking, hydrocracking, aromatic alkylation, isoparaffin alkylation, isomerization, polymerization, reforming, hydrogenation, dehydrogenation, transalkylation or dealkylation, preferably, isomerization, alkylation or transalkylation.

[0087] The additive composition described in the present invention enhances the performance of mixed metal oxide catalysts towards hydrocarbon processing reactions such as but not limited to isomerization. The additive composition of the present invention specifically [0088] (i) Creates optimal strength acid sites on the surface to facilitate low temperature operation of the catalyst, thus increasing product conversion. [0089] (ii) Increases metal support interaction to minimize the effect of feed contaminants. [0090] (iii) Aids in generating effective surface hydrogen by splitting gas phase hydrogen thus minimizing coke formation on the surface. [0091] (iv) Decelerates the catalyst growth during calcination phase of the catalyst synthesis to maximize the mesopores required for high product selectivity.

[0092] The following examples are provided to better illustrate the claimed invention and are not to be interpreted in any way as limiting the scope of the invention. All specific materials, and methods described below, fall within the scope of the invention. These specific compositions, materials, and methods are not intended to limit the invention, but merely to illustrate specific embodiments falling within the scope of the invention. One skilled in the art may develop equivalent materials, and methods without the exercise of inventive capacity and without departing from the scope of the invention. It is the intention of the inventors that such variations are included within the scope of the invention.

EXAMPLES

Comparative Example 1: Catalyst A

[0093] Catalyst A was prepared using the well-established sulfated alumina zirconia synthesis route as known to those skilled in the art as shown in U.S. Pat. No. 6,448,198 B1. The corresponding references for the catalyst design have been provided for reference. Briefly, high surface area Zirconium hydroxide (Zr(OH).sub.4) and pseudo-boehmite were co-mulled together to form an intimate mixture. They were then extruded into 1 mm diameter and 2 mm length extrudes. The extrudes were then exposed to 1M sulfuric acid (15 ml/gm of extrudes) and subsequently vacuum filtered to remove the excess sulfate ions. The extrudes were then calcined at 600 C. for 3 hours to form crystalline sulfated alumina zirconia catalyst. The catalyst had 0.24 ml/g pore volume at the end of the calcination. Platinum with 0.3 wt % was then incorporated into the catalyst by wet impregnation technique as known to those skilled in the art. This catalyst was designated catalyst A.

[0094] 7 gm of catalyst A was loaded in a fixed bed reactor where it was calcined in air at 500 C. for 2 hours and subsequently reduced in Hydrogen for 1 hour. A reaction mixture containing the following composition was then flown on the catalyst at 30 bar and 135 C. for 200 hours. The result of the product sample drawn at 50 and 200 hours respectively is shown in Table 1.

TABLE-US-00001 TABLE 1 Feed composition for fixed bed reactor testing of the catalyst compositions for activity towards hydrocarbon isomerization Reactant Concentration n-Pentane ~32% n-Hexane ~55% CycloHexane ~8% Benzene ~5% 1-Propanethiol 7 ppm Water 10 ppm Pressure of operation 30 bar Temperature of operation 135 C.

Comparative Example 2: Catalyst B

[0095] Catalyst B was prepared using the popular metal doped sulfated zirconia catalyst synthesis route as known to those skilled in the art and also described in the patent, EP0532153B1. Briefly, high surface area zirconium hydroxide was prepared by rapidly mixing zirconium carbonate and ammonia solutions. After washing and sieving to desired size, Iron (Fe) and Manganese (Mn) nitrate solutions were added to the support material via incipient wetness impregnation method. The catalyst was subsequently dried and calcined at 725 C. for one hour. 0.3% Platinum was incorporated into the catalyst via incipient wetness impregnation method.

[0096] The testing procedure described in example 1 was used to evaluate catalyst B's performance. The results of which are detailed in Table 2.

Example 3: Catalyst Z

[0097] Base catalyst was synthesized using the method described in the open literature (reference provided in the previous sections). Briefly, high surface zirconium hydroxide and pseudo boehmite were co-mulled together and impregnated with 1N H.sub.2SO.sub.4 by using 15 ml/gm of the support material. Excess acid was drained and the sulfated support was dried at 120 C. for several hours. Gallium was then introduced into the support by adding its corresponding nitrate salt to achieve 3% loading by incipient wetness technique. The mixture was then dried and is labeled Catalyst Z.

Additive Composition 1Catalyst Z1

[0098] Additive for catalyst Z1 was first prepared by mixing nitrate salts of Strontium, Cerium, Samarium and Manganese. 25.5 gms of Mn(NO.sub.3).sub.2 50% solution, 5 gms of Sr(NO.sub.3).sub.2, 9.3 gms of Ce(NO.sub.3).sub.3.6H.sub.2O 1.1 gms of Sm(NO.sub.3).sub.3.6H.sub.2O were mixed together in desired amount of water. 13.4 gms of 35% H.sub.2O.sub.2 was added to the mixture while stirring. 2.4 gms of Oxalic acid was then added to the mixture. Finally 1 gm of Pluronic (F127) and 1 gm of PEG were added to final mixture and stirred for 1 hour. The pH of the final solution was brought to 10.5 using TMAOH. The product was filtered, washed and calcined at 500 C. The XRD profile of the product is shown in FIG. 1. The molecular formula of the additive Z1 thus formed is SrCe.sub.0.9Sm.sub.0.1Mn.sub.3O.sub.m where m is defined to render the overall charge neutral.

[0099] The additive thus produced is added to catalyst Z shown in example 1 and extruded into 1 mm diameter and 2 mm length extrudes. The final catalyst formulation was calcined at 700 C. for 3 hours. 0.3 wt % Platinum was added to the calcined extrudes by incipient wetness impregnation method. The catalyst is labeled Z1 and the isomerization test results with the feed shown in comparative example 1 are shown in Table 2.

Additive Composition 2Catalyst Z2

[0100] Additive for catalyst Z2 was first prepared by mixing nitrate salts of Strontium, Cerium, Ytterbium and Manganese. 25.5 gms of Mn(NO.sub.3).sub.2 50% solution, 5 gms of Sr(NO.sub.3).sub.2, 9.3 gms of Ce(NO.sub.3).sub.3.6H.sub.2O 1.1 gms of Yb(NO.sub.3).sub.3.6H.sub.2O were mixed together in desired amount of water. 13.4 gms of 35% H.sub.2O.sub.2 was added to the mixture while stirring. 2.4 gms of Oxalic acid was then added to the mixture. Finally 1 gm of Pluronic (F127) and 1 gm of PEG were added to final mixture and stirred for 1 hour. The pH of the final solution was brought to 10.5 using TMAOH. The product was filtered, washed and calcined at 500 C. The XRD profile of the product is shown in FIG. 2. The molecular formula of the additive Z2 thus formed is SrCe.sub.0.9Yb.sub.0.1Mn.sub.5O.sub.m where m is defined to render the overall charge neutral.

[0101] The additive thus produced is added to catalyst Z shown in example 1 and extruded into 1 mm diameter and 2 mm length extrudes. The final catalyst formulation was calcined at 700 C. for 3 hours. 0.3 wt % Platinum was added to the calcined extrudes by incipient wetness impregnation method. The catalyst is labeled Z2 and the isomerization test results with the feed shown in comparative example 1 is shown in Table 2.

Additive Composition 3Catalyst Z3

[0102] Additive for catalyst Z3 was first prepared by mixing nitrate salts of Strontium, Cerium, Ytterbium and Ruthenium. 17 gms of Ru(NO.sub.3).sub.2, 5 gms of Sr(NO.sub.3).sub.2, 9.3 gms of Ce(NO.sub.3).sub.3.6H.sub.2O 1.1 gms of Yb(NO.sub.3).sub.3.6H.sub.2O were mixed together in desired amount of water. 13.4 gms of 35% H.sub.2O.sub.2 was added to the mixture while stirring. 2.4 gms of Oxalic acid was then added to the mixture. Finally 1 gm of Pluronic (F127) and 1 gm of PEG were added to final mixture and stirred for 1 hour. The pH of the final solution was brought to 10.5 using TMAOH. The product was filtered, washed and calcined at 500 C. The XRD profile of the product is shown in FIG. 2. The molecular formula of additive thus formed is SrCe.sub.0.9Sm.sub.0.1Ru.sub.2O.sub.m where m is defined to render the overall charge neutral.

[0103] The additive thus produced is added to catalyst Z shown in example 1 and extruded into 1 mm diameter and 2 mm length extrudes. The final catalyst formulation was calcined at 700 C. for 3 hours. 0.3 wt % Platinum was added to the calcined extrudes by incipient wetness impregnation method. The catalyst is labeled Z2 and the isomerization test result with the feed shown in comparative example 1 is shown in Table 2.

TABLE-US-00002 TABLE 2 Performance results for the catalysts (Z1, Z2 and Z3) prepared as per the invention in comparison to those known to prior art (A and B) shown in comparative examples- [00001]$\frac{2.Math.\text{,}.Math.2-\mathrm{DMB}}{n-\mathrm{Hex}}$ [00002]$\frac{2.Math.\text{,}.Math.2-\mathrm{DMB}}{n-\mathrm{Hex}}$ Temperature Pressure of 20 hour 200 hour Catalyst of reaction reaction operation operation A 135 C. 30 bar 23% 12.0% B 135 C. 30 bar 24% 11.4% Z1 135 C. 30 bar 34.5% 34.4% Z2 135 C. 30 bar 33% 34.2% Z3 135 C. 30 bar 31% 30.5%

[0104] The catalysts prepared with the invention described herein, namely catalysts Z1, Z2 and Z3 exhibit excellent performance characteristics in terms of product conversion, low temperature operation and high tolerance to feed contaminants.