Stable and selective dehydrogenation catalyst and a process for the preparation thereof

A process for the preparation of a catalyst for use in the dehydrogenation of saturated hydrocarbons to unsaturated hydrocarbons, said process comprising the steps of:

• a) incorporating within its spatial geometry on a percentage by weight basis, active elements comprising:
• i. from 0.1 to 5.0% of a noble metal;
• ii. from 0.1 to 5% of a metal of Group IV A;
• iii. from 0.1 to 6% of a metal of Group III A;
• iv. from 0.1 to 1% of a rare earth metal;
• v. from 0.1 to 10% of an alkali or an alkaline earth metal element;
• vi. from 0.01 to 10% of a halogen;
• and
• vii. from 0.1 to 5% of a Group VIII metal selected from Fe, Co and Ni;
• within an alumina mesoporous or macroporous support having a high surface area comprising a spheroidal gamma alumina support with a diameter of 1.4 to 2.0 mm, a surface area in the range of from 150 to 220 m2/g, with bimodal narrow pore size distribution, water adsorption capacity in the range of from 1.4 to 2.5 ml/g, gamma crystallinity in the range of 60 to 80% and a bulk density in the range of 0.25 to 0.4 g/ml, to form a composite;
• b) drying the composite to form a dried composite;
• and c) subjecting the dried composite to calcination to obtain the catalyst.

A process for the preparation of a catalyst for use in the dehydrogenation of saturated hydrocarbons to unsaturated hydrocarbons, said process comprising the steps of:

• a) incorporating within its spatial geometry on a percentage by weight basis, active elements comprising:
• i. from 0.1 to 5.0% of a noble metal;
• ii. from 0.1 to 5% of a metal of Group IV A;
• iii. from 0.1 to 6% of a metal of Group III A;
• iv. from 0.1 to 1% of a rare earth metal;
• v. from 0.1 to 10% of an alkali or an alkaline earth metal;
• vi. from 0.01 to 10% of a halogen;
• and
• vii. from 0.1 to 5% of a Group VIII metal selected from Fe, Co and Ni;
• within an alumina mesoporous or macroporous support having a high surface area comprising a spheroidal gamma alumina support with a diameter of 1.4 to 2.0 mm, a surface area in the range of from 150 to 220 m2/g, with bimodal narrow pore size distribution, water adsorption capacity in the range of from 1.4 to 2.5 ml/g, gamma crystallinity in the range of 60 to 80% and a bulk density in the range of 0.25 to 0.4 g/ml, to form a composite;
• b) drying the composite to form a dried composite;
• c) subjecting the dried composite to calcination to form a calcined composite;
• and
• d) subjecting further the calcined composite to steaming with a 20:80 steam-air mixture at a temperature of from 400 to 550° C. to decrease the halogen content to 0.07 to 0.1% by weight.

A process for the preparation of a catalyst for use in the dehydrogenation of saturated hydrocarbons to unsaturated hydrocarbons, said process comprising the steps of:

• a) incorporating within its spatial geometry on a percentage by weight basis, active elements comprising:
• i. from 0.1 to 5.0% of a noble metal;
• ii. from 0.1 to 5% of a metal of Group IV A;
• iii. from 0.1 to 6% of a metal of Group III A;
• iv. from 0.1 to 1% of a rare earth metal;
• v. from 0.1 to 10% of an alkali or an alkaline earth metal;
• vi. from 0.01 to 10% of a halogen;
• and
• vii. from 0.1 to 5% of a Group VIII metal selected from Fe, Co and Ni;
• within an alumina mesoporous or macroporous support having a high surface area comprising a spheroidal gamma alumina support with a diameter of 1.4 to 2.0 mm, a surface area in the range of from 150 to 220 m2/g, with bimodal narrow pore size distribution, water adsorption capacity in the range of from 1.4 to 2.5 ml/g, gamma crystallinity in the range of 60 to 80% and a bulk density in the range of 0.25 to 0.4 g/ml, to form a composite;
• b) drying the composite to form a dried composite;
• c) subjecting the dried composite to calcination;
• and
• d) subjecting further the calcined composite to treatment at a temperature in the range of from 10° C. to 80° C., for a period of from 0.5 to 10 hours, with an aqueous solution of an organic or inorganic compound, which undergoes hydrolysis to release sufficient base in said temperature range, to decrease the halogen content to 0.07 to 1.0% by weight.