CATALYST INCLUDING AN ACTIVE PHASE OF NICKEL IN THE FORM OF SMALL PARTICLES DISTRIBUTED IN CRUST AND

专利摘要:
Catalyst for nickel and copper, and an alumina support, said catalyst being characterized in that: - the nickel is distributed both over a crust at the periphery of the support, and at the heart of the support, the thickness of said crust being between 2% and 15% of the diameter of the catalyst; - the nickel density ratio between the crust and the core is strictly greater than 3; - said crust comprises more than 25% by weight of the nickel element relative to the total weight of nickel contained in the catalyst; - the molar ratio between nickel and copper is between 0.5 and 5, - at least part of the nickel and copper is in the form of a nickel-copper alloy; - the nickel content included in the nickel-copper alloy is between 0.5 and 15% by weight of nickel element relative to the total weight of the catalyst; - the size of the nickel particles in the catalyst is less than 7 nm.
公开号:FR3099388A1
申请号:FR1908724
申请日:2019-07-31
公开日:2021-02-05
发明作者:Anne-Claire Dubreuil；Malika Boualleg
申请人:IFP Energies Nouvelles IFPEN；
IPC主号:

专利说明:

[0001] The present invention relates to a supported metal catalyst based on nickel and copper intended particularly for the hydrogenation of unsaturated hydrocarbons, and more particularly, for the selective hydrogenation of polyunsaturated compounds or for the hydrogenation of aromatics.
[0002] State of the art
[0003] Monounsaturated organic compounds such as ethylene and propylene, for example, are the source of the manufacture of polymers, plastics and other value-added chemicals. These compounds are obtained from natural gas, naphtha or gas oil which have been treated by steam cracking or catalytic cracking processes. These processes are operated at high temperature and produce, in addition to the desired monounsaturated compounds, polyunsaturated organic compounds such as acetylene, propadiene and methylacetylene (or propyne), 1-2-butadiene and 1-3 -butadiene, vinylacetylene and ethylacetylene, and other polyunsaturated compounds whose boiling point corresponds to the C5+ gasoline fraction (gasoline containing hydrocarbon compounds having 5 or more carbon atoms), in particular styrenic or indenic compounds . These polyunsaturated compounds are very reactive and lead to side reactions in the polymerization units. It is therefore necessary to eliminate them before recovering these cuts.
[0004] Selective hydrogenation is the main treatment developed to specifically remove unwanted polyunsaturated compounds from these hydrocarbon feedstocks. It allows the conversion of polyunsaturated compounds to the corresponding alkenes or aromatics while avoiding their total saturation and therefore the formation of the corresponding alkanes or naphthenes.
[0005] Selective hydrogenation catalysts are generally based on metals from group VIII of the periodic table, preferably palladium or nickel. The metal is in the form of metallic particles deposited on a support. The metal content, the size of the metal particles and the distribution of the active phase in the support are among the criteria which have an importance on the activity and the selectivity of the catalysts.
[0006] The macroscopic distribution of the metallic particles in the support constitutes an important criterion, mainly within the framework of rapid and consecutive reactions such as selective hydrogenations. It is generally desirable for these elements to be located in a crust at the periphery of the support in order to avoid intragranular material transfer problems which can lead to activity defects and a loss of selectivity. Such catalysts are also called "eggshell" catalysts according to Anglo-Saxon terminology.
[0007] Such catalysts are widely known in the case of selective hydrogenation catalysts based on palladium. Indeed, thanks to the low palladium content (generally less than 1% by weight (1% wt) of palladium relative to the catalyst) and the appropriate preparation processes, a fine crust of palladium at the periphery of the support grains can be obtained (FR2922784, US2010/217052).
[0008] It is often proposed to substitute palladium with nickel, a metal less active than palladium which it is therefore necessary to have in greater quantity in the catalyst. Thus, nickel-based catalysts generally have a metal content between 5 and 50% by weight of nickel with respect to the catalyst. In these catalysts, the nickel is generally distributed homogeneously within the support. One of the possible ways of improving these catalysts in terms of activity and selectivity is to control the distribution of the nickel within the support by depositing the nickel in a more concentrated manner on a crust, at the periphery of the support. Such catalysts are known from the state of the art.
[0009] Document US 4,519,951 describes an "eggshell" type catalyst with nickel on a porous support having a porous volume of the pores whose size is less than 11.7 nm of at least 0.2 ml/g and a volume porous pores larger than 11.7 nm of at least 0.1 ml/g. More than 50% of the nickel is in a crust whose thickness is equal to 0.15 times the radius of the support. This catalyst is used for the hydrogenation of fats.
[0010] Document CN101890351 describes a nickel-supported catalyst in which more than 90% of the nickel is in a crust 700 μm thick. The catalyst is prepared using an ammoniacal solution to dissolve the nickel salt. These catalysts are used in a selective hydrogenation application.
[0011] Document US2012/0065442 describes a nickel supported catalyst in which the nickel crystallite size distribution is bimodal with 30 to 70% of the nickel crystallites having an average size (diameter) of 1.0 to 2.5 nm, the remaining nickel crystallites having an average size (diameter) of 3.0 to 4.5 nm. The nickel is distributed both on a crust with a thickness of 3 to 15% of the diameter and at the core, the nickel concentration ratio between the crust and the core being between 3.0: 1 and 1.3: 1. At least 75% of the pore volume is in pores having a size greater than 5.0 nm.
[0012] Objects of the invention
[0013] Surprisingly, the Applicant has discovered that by applying a specific hydrothermal treatment after the addition of a particular organic additive to a catalyst based on nickel and copper (and in which an alloy based on nickel and copper on the support) comprising an alumina support obtained according to a very particular method, a catalyst is obtained in which at least part of the nickel is distributed over a crust at the periphery of the support, the other part of the nickel being distributed catalyst core. Without wishing to be bound by any theory, the hydrothermal treatment carried out after the step of bringing a specific organic additive into contact with the catalyst based on nickel and copper on a particular alumina support, having undergone a hydrothermal treatment in the presence of an acid solution, seems to cause the nickel to migrate at least in part from the interior of the support to the periphery of the support, thus forming a nickel crust. In addition, it has been observed by the Applicant that during the preparation of the catalyst, carrying out a step of bringing the support into contact with a solution containing simultaneously a metal precursor based on copper and a metal precursor based on nickel followed by a step of drying and reduction in the presence of a reducing gas at low temperature (between 150°C and 250°C) makes it possible to obtain a nickel-copper alloy (in reduced form) which allows unexpected to greatly improve the reducibility of the active phase of nickel on the support. Furthermore, the presence of copper in the catalyst makes it possible to maintain good activity and a longer life of the catalyst when the latter is brought into contact with a hydrocarbon feed comprising sulphur. Indeed, compared to nickel, the copper present in the catalyst more easily captures the sulfur compounds included in the charge, which limits the irreversible poisoning of the active sites.
[0014] The present invention thus relates to a new type of catalyst which, by virtue of its specific preparation process, makes it possible to obtain a catalyst comprising performance at least as good, or even better, in terms of activity and selectivity in the context of the reactions. selective hydrogenation of polyunsaturated compounds or hydrogenation of polyunsaturated aromatics, while using a lower quantity of nickel phase than that typically used in the state of the art, which is due to a better distribution of the active phase of nickel in the support, making the latter more accessible to reagents as well as a nickel particle size of less than 7 nm, conferring even greater intrinsic nickel activity. The presence of a NiCu alloy also makes it possible to carry out a stage of reduction of the metallic elements in the presence of a reducing gas at lower temperatures and shorter reaction times than those commonly used in the prior art. Advantageously, the use of less severe operating conditions than in the prior art makes it possible to carry out the reduction step directly within the reactor in which it is desired to carry out the selective hydrogenation of polyunsaturated cuts.
[0015] A first object according to the invention relates to a catalyst comprising nickel and copper, in an amount of 1 and 50% by weight in nickel element relative to the total weight of the catalyst, and a second metallic element of copper, in an amount of 0.5 to 15% by weight of copper element relative to the total weight of the catalyst, and an alumina support, said catalyst being characterized in that:
[0016] - the nickel is distributed both on a crust on the periphery of the support, and in the heart of the support, the thickness of said crust being between 2% and 15% of the diameter of the catalyst;
[0017] - the nickel density ratio between the crust and the core is strictly greater than 3;
[0018] - said crust comprises more than 25% by weight nickel element relative to the total weight of nickel contained in the catalyst;
[0019] - the molar ratio between nickel and copper is between 0.5 and 5;
[0020] - at least part of the nickel and the copper is in the form of a nickel-copper alloy;
[0021] - the nickel content included in the nickel-copper alloy is between 0.5 and 15% by weight of nickel element relative to the total weight of the catalyst,
[0022] - the size of the nickel particles in the catalyst is less than 7 nm.
[0023] Advantageously, the nickel density ratio between the crust and the core is between 3.8 and 15.
[0024] Advantageously, said crust comprises more than 40% by weight of nickel element relative to the total weight of nickel contained in the catalyst.
[0025] Advantageously, the transition interval between the core and the crust of the catalyst is between 0.05% and 3% of the diameter of the catalyst.
[0026] Advantageously, the sulfur content of the alumina support is between 0.001% and 2% by weight relative to the total weight of the alumina support, and the sodium content of said alumina support is between 0.001% and 2% by weight. relative to the total weight of said alumina gel.
[0027] Advantageously, the thickness of said crust is between 2.5% and 12% of the diameter of the catalyst.
[0028] Advantageously, the nickel density ratio between the crust and the core is greater than 3.5.
[0029] Another object according to the invention relates to a method for preparing a catalyst according to the invention, said method being characterized in that:
[0030] a) a gel is supplied;
[0031] b) the alumina gel of step a) is shaped;
[0032] c) the shaped alumina gel obtained at the end of step b) is subjected to a heat treatment comprising at least one hydrothermal treatment step in an autoclave in the presence of an acid solution, at a temperature between between 100 and 800° C., and at least one calcining step, at a temperature of between 400 and 1500° C., carried out after the hydrothermal treatment step, to obtain an alumina support;
[0033] d) the sequence of the following sub-steps is carried out: d1) the alumina support is brought into contact with at least one nickel precursor to obtain a catalyst precursor, d2) the catalyst precursor obtained at the end of step d1) is dried at a temperature below 250° C.; d3) the dried catalyst precursor obtained at the end of step d2) is brought into contact with at least one solution containing at least one organic additive chosen from aldehydes containing 1 to 14 carbon atoms per molecule, ketones or polyketones containing 3 to 18 carbon atoms per molecule, ethers and esters containing 2 to 14 carbon atoms per molecule, alcohols or polyalcohols containing 1 to 14 carbon atoms per molecule and carboxylic acids or polycarboxylic acids containing 1 to 14 carbon atoms per molecule, the molar ratio between the organic additive and the nickel being greater than 0.05 mol/mol; d4) a hydrothermal treatment of the catalyst precursor obtained at the end of step d3) is carried out at a temperature of between 100 and 200° C. for a period of between 30 minutes and 5 hours under a gas stream comprising between 5 and 650 grams of water per kg of dry gas;
[0034] e) the sequence of the following sub-steps is carried out: e1) the alumina support is brought into contact with at least one solution containing at least one copper precursor and one nickel precursor at a desired nickel concentration to obtain a content in the final catalyst of between 0.5 and 15% weight of nickel element relative to the total weight of the final catalyst; e2) at least one step of drying the catalyst precursor obtained at the end of step e1) is carried out at a temperature below 250° C.;
[0035] steps d) and e) being carried out separately in any order,
[0036] f) the alumina support is brought into contact with at least one solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function, or at least one ester function, or at least one amide function , or at least one amine function,
[0037] step f) being carried out, either at the same time as sub-step d1) of step d), or before or after step d), but before step g), it being understood that when the step f) is carried out before or after step d), then said step f) includes drying the catalyst precursor at a temperature below 250° C. after bringing the support into contact with said solution comprising at least one organic compound ;
[0038] g) the catalyst precursor from steps a) to f) is reduced by bringing said catalyst precursor into contact with a reducing gas at a temperature greater than or equal to 150°C and less than 250°C.
[0039] Advantageously, the molar ratio between said organic compound introduced in step f) and the nickel element also introduced in step d1) is between 0.01 and 5.0 mol/mol.
[0040] Advantageously, steps d1) and f) are carried out simultaneously.
[0041] Advantageously, the organic compound of step f) is chosen from oxalic acid, malonic acid, glycolic acid, lactic acid, tartronic acid, citric acid, tartaric acid, pyruvic acid, levulinic acid, ethylene glycol, propane-1,3-diol, butane-1,4-diol, glycerol, xylitol, mannitol, sorbitol, glycol, glucose , dimethyl carbonate, diethyl carbonate, formamide, N-methylformamide, acetamide, N-methylacetamide, N,N-dimethylmethanamide, 2-pyrrolidone, γ-lactam, lactamide, urea , alanine, arginine, lysine, proline, serine, EDTA. Advantageously, the copper precursor is chosen from copper acetate, copper acetylacetonate, copper nitrate, copper sulphate, copper chloride, copper bromide, copper iodide or copper fluoride. copper.
[0042] Advantageously, in step d3), the organic additive is chosen from formic acid, formaldehyde, acetic acid, citric acid, oxalic acid, glycolic acid, malonic acid, ethanol, methanol, ethyl formate, methyl formate, paraldehyde, acetaldehyde, gamma-valerolactone acid, glucose, sorbitol and trioxane.
[0043] Advantageously, the molar ratio between the organic additive introduced in step d2) and the nickel is between 0.1 and 5 mol/mol.
[0044] Advantageously, the organic compound of step f) is different from the organic additive of step d2).
[0045] Another object according to the invention relates to a process for the selective hydrogenation of polyunsaturated compounds containing at least 2 carbon atoms per molecule contained in a charge of hydrocarbons having a final boiling point less than or equal to 300° C., which process being carried out at a temperature of between 0 and 300°C, at a pressure of between 0.1 and 10 MPa, at a hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio of between 0.1 and 10 and at an hourly volumetric speed between 0.1 and 200 h ^-1 when the process is carried out in the liquid phase, or at a hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio of between 0.5 and 1000 and at an hourly volume rate between 100 and 40000 h ^-1 when the process is carried out in the gas phase, in the presence of a catalyst according to the invention.
[0046] Another object according to the invention relates to a process for the hydrogenation of at least one aromatic or polyaromatic compound contained in a charge of hydrocarbons having a final boiling point less than or equal to 650° C., said process being carried out in phase gaseous or in the liquid phase, at a temperature between 30 and 350°C, at a pressure between 0.1 and 20 MPa, at a hydrogen/(aromatic compounds to be hydrogenated) molar ratio between 0.1 and 10 and at a hourly volume velocity VVH of between 0.05 and 50 h ⁻¹ , in the presence of a catalyst according to the invention.
[0047] Description of figure
[0048] Figure 1 is a diagram showing the distribution of nickel in the catalyst. The abscissa axis corresponds to the thickness of the catalyst, measured from the edge of the catalyst (in µm). The ordinate axis corresponds to the nickel density (in grams of Ni/mm3). The nickel is distributed both on a crust at the periphery of the support, of thickness ep1, and at the heart of the support. The nickel density on the crust crust is greater than the nickel density at the core of the core support. The transition interval between the core and the crust of the catalyst has a thickness denoted ep2-ep1.
[0049] Detailed description of the invention
[0050] 1. Definitions
[0051] In the following, the groups of chemical elements are given according to the CAS classification (CRC Handbook of Chemistry and Physics, publisher CRC press, editor-in-chief D.R. Lide, 81st edition, 2000-2001). For example, group VIII according to the CAS classification corresponds to the metals of columns 8, 9 and 10 according to the new IUPAC classification.
[0052] In the present description, according to the IUPAC convention, micropores are understood to mean pores whose diameter is less than 2 nm, that is to say 0.002 μm; by mesopores pores whose diameter is greater than or equal to 2 nm, i.e. 0.002 µm and less than or equal to 50 nm, i.e. 0.05 µm and by macropores pores whose diameter is greater than 50 nm, i.e. 0.05 µm.
[0053] In order to analyze the distribution of the metallic phase on the support, a crust thickness is measured by Castaing microprobe (or microanalysis by electron microprobe). The apparatus used is a CAMECA XS100, equipped with four monochromator crystals allowing the simultaneous analysis of four elements. Castaing's microprobe analysis technique consists of detecting X-rays emitted by a solid after its elements have been excited by a high-energy electron beam. For the purposes of this characterization, the catalyst grains are coated in epoxy resin pads. These studs are polished until they reach the cut to the diameter of the balls or extruded then metallized by depositing carbon in a metal evaporator. The electron probe is scanned along the diameter of five balls or extrudates to obtain the average distribution profile of the constituent elements of the solids. This method, well known to those skilled in the art, is defined in the publication by L. Sorbier et al. “ Measurement of palladium crust thickness on catalyst by EPMA” Materials Science and Engineering 32 (2012). It makes it possible to establish the distribution profile of a given element, here Nickel, within the grain. Furthermore, the Ni concentration is defined for each measurement and therefore for each analysis step. The density of Ni within the grain is therefore defined as the concentration of Ni per mm ³ .
[0054] The total pore volume is measured by mercury porosimetry according to the ASTM D4284-92 standard with a wetting angle of 140°, for example by means of an Autopore III™ model device from the Micromeritics™ brand.
[0055] The BET specific surface is measured by physisorption with nitrogen according to standard ASTM D3663-03, method described in the work Rouquerol F.; Rouquerol J.; Singh K. “Adsorption by Powders & Porous Solids: Principle, methodology and applications”, Academic Press, 1999.
[0056] The median mesoporous diameter is also defined as being the diameter such that all the pores, among all the pores constituting the mesoporous volume, of size less than this diameter constitute 50% of the total mesoporous volume determined by intrusion with a mercury porosimeter.
[0057] The term “size of the nickel particles” means the diameter of the crystallites of nickel in oxide form. The diameter of nickel crystallites in oxide form is determined by X-ray diffraction, from the width of the diffraction line located at the angle 2theta=43° (i.e. along the crystallographic direction [200 ]) using the Scherrer relation. This method, used in X-ray diffraction on powders or polycrystalline samples which links the width at mid-height of the diffraction peaks to the size of the particles, is described in detail in the reference: Appl. Crystal. (1978), 11, 102-113 "Scherrer after sixty years: A survey and some new results in the determination of crystallite size", J. I. Langford and A. J. C. Wilson.
[0058] The nickel and copper content is measured by X-ray fluorescence.
[0059] 2. Catalyst
[0060] The invention relates to a catalyst based on nickel and copper, at a rate of 1 and 50% by weight of nickel element relative to the total weight of the catalyst, and from 0.5 to 15% by weight of copper element relative to to the total weight of the catalyst, and an alumina support, said catalyst being characterized in that:
[0061] - the nickel is distributed both on a crust on the periphery of the support, and in the heart of the support, the thickness of the crust (also called ep1) being between 2% and 15% of the diameter of the catalyst, preferably between 2, 5% and 12% of the diameter of the catalyst, even more preferably between 3% and 10% of the diameter of the catalyst and even more preferably between 3% and 7.5% of the diameter of the catalyst;
[0062] - the nickel density ratio between the crust and the core (also called here d _crust /d _core ) is strictly greater than 3, preferably greater than 3.5 and preferably between 3.8 and 15;
[0063] - said crust comprises more than 25% by weight of nickel element relative to the total weight of nickel contained in the catalyst, preferably more than 40% by weight, more preferably between 45% and 90% by weight, and even more preferably between 60 and 90% by weight;
[0064] - the molar ratio between nickel and copper is between 0.5 and 5 mol/mol, preferably between 0.7 and 4.5 mol/mol, more preferably between 0.9 and 4 mol/mol;
[0065] - at least a part of the nickel and the copper is in the form of a nickel-copper alloy, advantageously corresponding to the formula Ni _x Cu _y with x between 0.1 and 0.9 and including between 0, 1 and 0.9;
[0066] - the nickel content included in the copper-nickel alloy is between 0.5 and 15% by weight of nickel element relative to the total weight of the catalyst, preferably between 1 and 12% by weight, and more preferably between 1 and 10% by weight;
[0067] - the size of the nickel particles, measured in oxide form, in the catalyst is less than 7 nm, preferably less than 5 nm, more preferably less than 4 nm, and even more preferably less than 3 nm.
[0068] Advantageously, the transition interval between the core and the crust of the catalyst (also called here the core/crust transition interval, or ep2-ep1 according to the notations of FIG. 1), linked to the variation in the density of nickel measured over the thickness of the catalyst from the edge of the catalyst to the center of the catalyst, is very abrupt. Preferably, the core/crust transition interval is between 0.05% and 3% of the diameter of the catalyst, preferably between 0.5% and 2.5% of the diameter of the catalyst.
[0069] The nickel content in said catalyst according to the invention is advantageously between 1 and 50% by weight relative to the total weight of the catalyst, more preferably between 2 and 40% by weight and even more preferably between 3 and 35% by weight and even more preferably 5 and 25% by weight relative to the total weight of the catalyst
[0070] The copper content is between 0.5 and 15% by weight of copper element relative to the total weight of the catalyst, preferably between 0.5 and 12% by weight, preferably between 0.75 and 10% by weight , and even more preferably between 1 and 9% by weight.
[0071] The catalyst according to the invention can be qualified as a “semi egg-shell” catalyst in which the concentration of nickel is higher at the periphery of the support than in the core of the support, said concentration of nickel in the core of the support being non-zero.
[0072] The specific surface of the catalyst is generally between 10 m ² /g and 200 m ² /g, preferably between 25 m ² /g and 110 m ² /g, more preferably between 40 m ² /g and 100 m ² /g.
[0073] The total pore volume of the catalyst is generally between 0.1 and 1 ml/g, preferably between 0.2 ml/g and 0.8 ml/g, and particularly preferably between 0.3 ml/g and 0.7ml/g.
[0074] The active phase of the catalyst does not include any Group VIB metal. In particular, it does not include molybdenum or tungsten.
[0075] Said catalyst (and the support used for the preparation of the catalyst) is in the form of grains advantageously having a diameter of between 0.5 and 10 mm. The grains can have any shape known to those skilled in the art, for example the shape of beads (preferably having a diameter of between 1 and 8 mm), extrudates, tablets, hollow cylinders. Preferably, the catalyst (and the support used for the preparation of the catalyst) are in the form of extrudates with a diameter of between 0.5 and 10 mm, preferably between 0.8 and 3.2 mm and very preferably between 1.0 and 2.5 mm and length between 0.5 and 20 mm. The term “diameter” of the extrudates is understood to mean the diameter of the circle circumscribed to the cross section of these extrudates. The catalyst can advantageously be presented in the form of cylindrical, multi-lobed, tri-lobed or quadri-lobed extrudates. Preferably, its shape will be trilobed or quadrilobed. The shape of the lobes can be adjusted according to all known methods of the prior art.
[0076] 3. Bracket
[0077] The characteristics of the alumina, mentioned in this section, correspond to the characteristics of the alumina before impregnation of the active phase of nickel, ie the alumina support obtained at the end of step c) of the process for preparing the catalyst according to the invention.
[0078] According to the invention, the support is an alumina, that is to say that the support comprises at least 95%, preferably at least 98%, and in a particularly preferred manner at least 99% by weight of alumina relative to the weight of the medium. Alumina generally has a crystallographic structure of the delta, gamma or theta alumina type, alone or in a mixture.
[0079] According to the invention, the alumina support may comprise impurities such as metal oxides of groups IIA, IIIB, IVB, IIB, IIIA, IVA according to the CAS classification, preferably silica, titanium dioxide, zirconium dioxide, zinc oxide, magnesium oxide and calcium oxide, or alternatively alkali metals, preferably lithium, sodium or potassium, and/or alkaline earth metals, preferably magnesium, calcium, strontium or barium or sulfur.
[0080] Advantageously, the sulfur content of the alumina support is between 0.001% and 2% by weight relative to the total weight of the alumina support, and the sodium content of said alumina support is between 0.001% and 2% by weight. relative to the total weight of said alumina gel.
[0081] The specific surface of the alumina is generally between 10 m ² /g and 250 m ² /g, preferably between 30 m ² /g and 200 m ² /g, more preferably between 50 m ² /g and 150 m ² /g.
[0082] The pore volume of the alumina is generally between 0.1 ml/g and 1.2 ml/g, preferably between 0.3 ml/g and 0.9 ml/g, and very preferably between 0.5ml/g and 0.9ml/g.
[0083] Catalyst Preparation Process
[0084] Another object according to the invention relates to a method for preparing a catalyst according to the invention comprising at least the following steps:
[0085] a) an alumina gel is supplied;
[0086] b) the alumina gel of step a) is shaped;
[0087] c) the shaped alumina gel obtained at the end of step b) is subjected to a heat treatment comprising at least one hydrothermal treatment step in an autoclave in the presence of an acid solution, at a temperature between between 100 and 800° C., and at least one calcining step, at a temperature of between 400 and 1500° C., carried out after the hydrothermal treatment step, to obtain an alumina support;
[0088] d) the sequence of the following steps is carried out: d1) the alumina support is brought into contact with at least one precursor of the active nickel phase to obtain a catalyst precursor, d2) the catalyst precursor obtained at the end of step d1) is dried at a temperature below 250° C.; d2′) optionally, a heat treatment is carried out on the dried catalyst precursor obtained at the end of step d2) at a temperature of between 250 and 1000° C. to obtain a calcined catalyst precursor; d3) the dried catalyst precursor obtained at the end of step d2) (optionally d2′) is brought into contact with at least one solution containing at least one organic additive chosen from aldehydes containing 1 to 14 carbon atoms per molecule, ketones or polyketones containing 3 to 18 carbon atoms per molecule, ethers and esters containing 2 to 14 carbon atoms per molecule, alcohols or polyalcohols containing 1 to 14 carbon atoms per molecule and carboxylic acids or polyacids carboxylic compounds containing 1 to 14 carbon atoms per molecule, the molar ratio between the organic additive and the nickel being greater than 0.05 mol/mol; d4) a hydrothermal treatment of the catalyst precursor obtained at the end of step d3) is carried out at a temperature of between 100 and 200° C. for a period of between 30 minutes and 5 hours under a gas stream comprising between 5 and 650 grams of water per kg of dry gas; d5) optionally, a drying step is carried out between 50 and 200° C. of the catalyst precursor obtained at the end of step d4) under a gas stream comprising a quantity of water strictly less than 5 grams of water per kilogram dry gas;
[0089] e) the sequence of the following steps is carried out: e1) the alumina support is brought into contact with at least one solution containing at least one copper precursor and one nickel precursor at a desired nickel concentration to obtain a content in the final catalyst of between 0.5 and 15% weight of nickel element relative to the total weight of the final catalyst; e2) at least one step of drying the catalyst precursor obtained at the end of step e1) is carried out at a temperature below 250° C.; e3) optionally, heat treatment of the catalyst precursor obtained at the end of step e2) is carried out at a temperature of between 250 and 1000° C., in the presence or absence of water;
[0090] steps d) and e) being carried out separately in any order,
[0091] f) the alumina support is brought into contact with at least one solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function, or at least one ester function, or at least one amide function , or at least one amine function,
[0092] step f) being carried out, either at the same time as sub-step d1) of step d), or before or after step d), but before step g), it being understood that when the step f) is carried out before or after step d), then said step f) includes drying the catalyst precursor at a temperature below 250° C. after bringing the support into contact with said solution comprising at least one organic compound ;
[0093] g) reducing the catalyst precursor from steps a) to f) by bringing said catalyst precursor into contact with a reducing gas at a temperature greater than or equal to 150°C and less than 250°C.
[0094] Intermediate steps can be interspersed (in particular additional drying steps) and certain steps can be carried out several times in succession (for example step d1). Finally, it is possible to add additional steps before using the catalyst at the end of step g).
[0095] Preferably, a drying and then calcining step is carried out at the end of step b) of shaping (but before carrying out step c).
[0096] Preferably, steps d2′) and d5) are not optional.
[0097] Steps a) to g) of said preparation process are described in detail below.
[0098] Step a) – Alumina gel
[0099] The catalyst according to the invention comprises an alumina support which is obtained from an alumina gel (or alumina gel) which essentially comprises a precursor of the aluminum oxy(hydroxide) type (AlO(OH)) – also called Boehmite.
[0100] According to the invention, the alumina gel (or otherwise called boehmite gel) is synthesized by precipitation of basic and/or acidic solutions of aluminum salts induced by a change in pH or any other method known to those skilled in the art. (P. Euzen, P. Raybaud, X. Krokidis, H. Toulhoat, JL Le Loarer, JP Jolivet, C. Froidefond, Alumina, in Handbook of Porous Solids, Eds F. Schüth, KSW Sing, J. Weitkamp, Wiley- VCH, Weinheim, Germany, 2002, pp. 1591-1677).
[0101] Generally the precipitation reaction is carried out at a temperature between 5°C and 80°C and at a pH between 6 and 10. Preferably the temperature is between 35°C and 70°C and the pH is between 6 and 10.
[0102] According to one embodiment, the alumina gel is obtained by bringing an aqueous solution of an acid aluminum salt into contact with a basic solution. For example, the acid aluminum salt is chosen from the group consisting of aluminum sulphate, aluminum nitrate or aluminum chloride and, preferably, said acid salt is aluminum sulphate. The basic solution is preferably chosen from sodium hydroxide or potassium hydroxide.
[0103] Alternatively, an alkaline solution of aluminum salts which may be chosen from the group consisting of sodium aluminate and potassium aluminate can be brought into contact with an acid solution. In a highly preferred variant, the gel is obtained by bringing a solution of sodium aluminate into contact with nitric acid. The sodium aluminate solution advantageously has a concentration of between 10 ^-5 and 10 ^-1 mol.L ^-1 and preferably this concentration is between 10 ^-4 and 10 ^-2 mol.L ^-1 .
[0104] According to another embodiment, the alumina gel is obtained by bringing an aqueous solution of acid aluminum salts into contact with an alkaline solution of aluminum salts.
[0105] Step b) – Formatting the support
[0106] The support can advantageously be shaped by any technique known to those skilled in the art. The shaping can be carried out, for example, by kneading-extrusion, by pelleting, by the oil-drop coagulation method, by granulation on a turntable or by any other method well known to those skilled in the art. The catalysts according to the invention can optionally be manufactured and used in the form of extrudates, tablets, beads. The advantageous shaping method according to the invention is extrusion and the preferred extrudate shapes are cylindrical, twisted cylindrical or multilobed (2, 3, 4 or 5 lobes for example).
[0107] In a particular embodiment, the alumina gel obtained at the end of step a) is subjected to a mixing step, preferably in an acid medium. The acid used may for example be nitric acid. This step is carried out by means of known tools such as Z-arm mixers, wheel mixers, single or twin continuous screws allowing the transformation of the gel into a product having the consistency of a paste. According to an advantageous embodiment, one or more compounds called "pore-forming agents" are added to the mixing medium. These compounds have the property of being degraded by heating and thus creating porosity in the support. For example, wood flour, charcoal, tars, plastic materials can be used as pore-forming compounds. The paste thus obtained after mixing is passed through an extrusion die. Generally the extrudates have a diameter between 0.5 and 10 mm, preferably between 0.8 and 3.2 mm and very preferably between 1.0 and 2.5 mm and a length between 0.5 and 20 mm . These extrudates can be of cylindrical, multi-lobed (for example tri-lobed or quadri-lobed) shape.
[0108] After it has been shaped, the support is optionally dried before undergoing the hydrothermal treatment according to step c) of the process. For example, the drying is carried out at a temperature between 50 and 200°C. The dried support is optionally calcined before undergoing the hydrothermal treatment according to step c) of the process. For example, the calcination is carried out at a temperature between 200 and 1000°C, in the presence or not of an air flow containing up to 150 of water per kilogram of dry air.
[0109] Step c) – Heat treatment
[0110] The support obtained at the end of step b) then undergoes a heat treatment step which makes it possible to give it physical properties corresponding to the application envisaged.
[0111] The term “hydrothermal treatment” designates a treatment by passing through an autoclave in the presence of water at a temperature above ambient temperature.
[0112] During this hydrothermal treatment, the shaped alumina can be treated in different ways. Thus, the alumina can be impregnated with an acid solution, prior to its passage through the autoclave, the hydrothermal treatment of the alumina being able to be carried out either in the vapor phase or in the liquid phase, this vapor or liquid phase of the autoclave may or may not be acidic. This impregnation, before the hydrothermal treatment, can be carried out dry or by immersing the alumina in an acidic aqueous solution. By dry impregnation is meant bringing the alumina into contact with a volume of solution less than or equal to the total pore volume of the treated alumina. Preferably, the impregnation is carried out dry.
[0113] It is also possible to treat the extruded support without prior impregnation with an acid solution, the acidity being in this case provided by the aqueous liquid of the autoclave.
[0114] The acid aqueous solution comprises at least one acid compound making it possible to dissolve at least part of the alumina of the extrudates. The term "acid compound allowing to dissolve at least a part of the alumina of the extrudates", any acid compound which, brought into contact with the alumina extrudates, carries out the dissolving of at least a part of the aluminum ions . The acid should preferably dissolve at least 0.5% by weight of alumina in the alumina extrudates.
[0115] Preferably, this acid is chosen from strong acids such as nitric acid, hydrochloric acid, perchloric acid, sulfuric acid or a weak acid used at a concentration such that its aqueous solution has a pH less than 4, such as acetic acid, or a mixture of these acids.
[0116] According to a preferred mode, the hydrothermal treatment is carried out in the presence of nitric acid and acetic acid taken alone or in a mixture. The autoclave is preferably a rotating basket autoclave such as that defined in patent application EP-A-0 387 109.
[0117] The hydrothermal treatment can also be carried out under saturated vapor pressure or under a partial water vapor pressure at least equal to 70% of the saturated vapor pressure corresponding to the treatment temperature.
[0118] Preferably, the hydrothermal treatment is carried out at a temperature of between 100 and 800° C., preferably between 200 and 700° C., preferably between 30 minutes and 8 hours, more preferably between 30 minutes and 3 hours.
[0119] Preferably, the calcination step which takes place after the hydrothermal treatment by passage in an autoclave takes place at a temperature generally between 400 and 1500° C., preferably between 800 and 1300° C., preferably for 1 and 5 hours under air whose water content is generally between 0 and 700 g of water per kilogram of dry air.
[0120] At the end of step c), the alumina obtained has the specific textural properties as described above.
[0121] Step d)
[0122] Step d) includes the following sub-steps.
[0123] Step d1) – Bringing the support into contact with a precursor of the active phase of nickel
[0124] Bringing the support into contact with a solution containing a precursor of the active phase of nickel, in accordance with the implementation of step d1), can be carried out by impregnation, dry or in excess, or even by deposition – precipitation , according to methods well known to those skilled in the art.
[0125] Said step d1) is preferably carried out by impregnating the support, consisting for example of bringing the support into contact with at least one aqueous solution containing a nickel precursor. The pH of said solution may be modified by the possible addition of an acid or a base.
[0126] Preferably, said step d1) is carried out by dry impregnation, which consists in bringing the support into contact with at least one solution, containing, preferably consisting of, at least one nickel precursor, the volume of the solution of which is between 0.25 and 1.5 times the porous volume of the support to be impregnated.
[0127] Preferably, said nickel precursor is introduced in aqueous solution, for example in the form of nitrate, carbonate, acetate, chloride, oxalate, complexes formed by a polyacid or an acid-alcohol and its salts, complexes formed with acetylacetonates, or any other inorganic derivative soluble in aqueous solution, which is brought into contact with said support. Preferably, nickel nitrate, nickel chloride, nickel acetate or nickel hydroxycarbonate are advantageously used as nickel precursor. Very preferably, the nickel precursor is nickel nitrate.
[0128] According to another variant, the aqueous solution may contain aqueous ammonia or NH ₄ ⁺ ammonium ions.
[0129] The nickel concentration in solution is adjusted according to the type of impregnation (dry or excess impregnation) and the porous volume of the support so as to obtain for the supported catalyst a nickel content of between 1 and 50% by weight of nickel element per relative to the total weight of the catalyst, more preferably between 2 and 40% by weight and even more preferably between 3 and 35% by weight and even more preferably 5 and 25% by weight.
[0130] Step d2) - Drying
[0131] The drying step is carried out under a gas stream comprising a quantity of water of less than 150 grams of water per kilogram of dry gas, preferably less than 50 g of water per kilogram of dry gas, at a temperature of less than 250 °C, preferably between 15 and 240°C, more preferably between 30 and 220°C, even more preferably between 50 and 200°C, and even more preferably between 70 and 180°C, for a period typically comprised between 10 minutes and 24 hours. Longer durations are not excluded, but do not necessarily bring improvement.
[0132] The gas may contain oxygen, nitrogen or an inert gas and preferably the gas is air.
[0133] Step d2’) Calcination (optional)
[0134] The optional calcination step is carried out under a gas stream comprising a quantity of water of less than 150 grams of water per kilogram of dry gas, preferably less than 50 g of water per kilogram of dry gas, at a temperature between 250°C and 1000°C, preferably between 250 and 750°C. The duration of this heat treatment is generally between 15 minutes and 10 hours. Longer durations are not excluded, but do not necessarily bring improvement.
[0135] The gas may contain oxygen, nitrogen or an inert gas and preferably the gas is air.
[0136] At the end of steps d2) or d2′), the nickel is evenly distributed on the support.
[0137] Step d3) - Additive
[0138] According to stage d3) of the process for preparing the catalyst, the catalyst precursor obtained at the end of stage d2), optionally at the end of stage d2′), is brought into contact with at least one solution comprising at least one organic additive chosen from aldehydes containing from 1 to 14 carbon atoms per molecule (preferably from 2 to 12), ketones or polyketones containing from 3 to 18 (preferably from 3 to 12) carbon atoms per molecule, ethers or esters containing from 2 to 14 (preferably from 3 to 12) carbon atoms per molecule, alcohols or polyalcohols containing from 1 to 14 (preferably from 2 to 12) carbon atoms per molecule and carboxylic acids or polycarboxylic acids containing from 1 to 14 (preferably from 1 to 12) carbon atoms per molecule. The organic additive may be composed of a combination of the various functional groups mentioned above.
[0139] Preferably, the organic additive is chosen from formic acid HCOOH, formaldehyde CH ₂ O, acetic acid CH ₃ COOH, citric acid, oxalic acid, glycolic acid (HOOC-CH ₂ - OH), malonic acid (HOOC-CH ₂ -COOH), ethanol, methanol, ethyl formate HCOOC ₂ H ₅ , methyl formate HCOOCH ₃ , paraldehyde (CH ₃ -CHO) ₃ , acetaldehyde C ₂ H ₄ O, gamma-valerolactone acid (C ₅ H ₈ O ₂ ), glucose, sorbitol and trioxane.
[0140] Particularly preferably, the organic additive is formic acid.
[0141] It is essential that the step of adding the organic additive to the catalyst (step d3)) be carried out after the step of bringing the support into contact with the precursor of the active nickel phase.
[0142] Preferably, said step d3) is carried out by impregnating the catalyst precursor obtained at the end of the implementation of step d2) or of step d2′), with a solution comprising at least one organic additive as cited above. The impregnation is generally carried out in aqueous solution or in organic solution or in suspension in the aqueous or organic solution, preferably in aqueous solution. When operating in organic solution or suspension, an alcohol or polyalcohol, glycol or polyglycol will preferably be used as organic solvent.
[0143] Preferably, said step d3) is carried out by dry impregnation, which consists in bringing into contact the catalyst precursor obtained at the end of the implementation of step d2) or step d2 '), with a solution comprising at least one organic additive as mentioned above, the volume of the solution of which is between 0.25 and 1.5 times the pore volume of the catalyst precursor to be impregnated.
[0144] The impregnation is generally carried out at a temperature between 0 and 50° C., preferably between 10 and 40° C., and particularly preferably at room temperature.
[0145] According to the invention, the molar ratio between the organic additive and the nickel is greater than 0.05 mol/mol, preferably between 0.1 and 5 mol/mol, more preferably between 0.12 and 3 mol/ mol, and even more preferably between 0.15 and 2.5 mol/mol.
[0146] Step d4) – Hydrothermal treatment
[0147] According to step d4) of the process for preparing the catalyst according to the invention, a hydrothermal treatment of the product resulting from step d3) is carried out at a temperature between 100° C. and 200° C., preferably between 130° C. and 170° C., and more particularly around 150° C., under a gas stream comprising between 5 and 650 grams of water per kilogram of dry gas, preferably between 7 and 150 grams of water per kilogram of dry gas, so even more preferably between 10 and 50 grams of water per kilogram of dry gas. The gas may contain oxygen, nitrogen or an inert gas and preferably the gas is air.
[0148] The duration of the hydrothermal treatment is generally between 30 minutes and 5 hours, preferably between 1 to 3 hours.
[0149] Step d5) - Drying (optional)
[0150] Step d4) can be followed by a step d5) of drying between 50 and 200° C. under a gas stream comprising a quantity of water strictly less than 5 grams of water per kilogram of dry gas, advantageously for a period of between 30 minutes and 5 hours, preferably between 1 to 3 hours.
[0151] The gas may contain oxygen, nitrogen or an inert gas and preferably the gas is air.
[0152] At the end of step d4) or possibly step d5), a “semi-egg-shell” catalyst is obtained as shown schematically in FIG. 1 and whose characteristics are described above.
[0153] Step e)
[0154] Step e) includes the following sub-steps.
[0155] Step e1) Bringing a precursor of copper and nickel into contact with the support
[0156] The deposition of nickel and copper on the alumina support can be carried out by impregnation, dry or in excess, or by deposition-precipitation, according to methods well known to those skilled in the art.
[0157] Said step e1) is preferably carried out by impregnation of the catalyst precursor consisting for example of bringing said support into contact with at least one aqueous or organic solution (for example methanol or ethanol or phenol or acetone or toluene or dimethyl sulfoxide (DMSO)) or consisting of a mixture of water and at least one organic solvent, comprising, preferably consisting of, at least one nickel precursor and at least one copper precursor at least partially in the dissolved state, or even by bringing said catalyst precursor into contact with at least one colloidal solution comprising, preferably consisting of, at least one nickel precursor and one copper precursor in oxidized form (nanoparticles oxide, oxy(hydroxide) or hydroxide of nickel and copper) or in reduced form (metallic nanoparticles of nickel and copper in the reduced state). Preferably, the solution is aqueous. The pH of this solution can be modified by the possible addition of an acid or a base.
[0158] Preferably, said step e1) is carried out by dry impregnation, which consists in bringing the support of the catalyst precursor into contact with a solution, comprising, preferably consisting of, at least one precursor of nickel and at least one precursor of copper, the volume of the solution of which is between 0.25 and 1.5 times the porous volume of the support to be impregnated.
[0159] When the nickel precursor is introduced in aqueous solution, a nickel precursor is advantageously used in the form of nitrate, carbonate, acetate, chloride, hydroxide, hydroxycarbonate, oxalate, sulphate, formate , of complexes formed by a polyacid or an acid-alcohol and its salts, of complexes formed with acetylacetonates, of tetrammine or hexammine complexes, or of any other inorganic derivative which is soluble in aqueous solution, which is brought into contact with the said precursor of catalyst. Preferably, the nickel precursor used is advantageously nickel nitrate, nickel hydroxide, nickel carbonate, nickel chloride, or nickel hydroxycarbonate. Very preferably, the nickel precursor is nickel nitrate, nickel carbonate or nickel hydroxide.
[0160] When the copper precursor is introduced in aqueous solution, a copper precursor in mineral or organic form is advantageously used. In mineral form, the copper precursor can be chosen from copper acetate, copper acetylacetonate, copper nitrate, copper sulphate, copper chloride, copper bromide, copper iodide or copper fluoride. Very preferably, the copper precursor salt is copper nitrate.
[0161] According to the invention, the nickel precursor is supplied to stage e1) at a desired concentration to obtain on the final catalyst (ie obtained at the end of stage f) of reduction or of stage g) of passivation if the latter is carried out) a content of between 0.5 and 10% by weight of nickel element relative to the total weight of the final catalyst, preferably between 0.5 and 8% by weight, more preferably between 1 and 7% by weight, even more preferably between 1 and 5% by weight.
[0162] The quantities of the copper precursor(s) introduced into the solution according to step e1) are chosen such that the total copper content is between 0.5 and 15% by weight of copper element relative to the total weight of the catalyst. (ie obtained at the end of step f) reduction or step g) passivation if the latter is carried out), preferably between 0.5 and 12% by weight, preferably between 0 75 and 10% by weight, and even more preferably between 1 and 9% by weight.
[0163] Step e2) Drying of the impregnated support
[0164] Step e2) of drying the impregnated support is carried out at a temperature below 250°C, preferably between 15 and 180°C, more preferably between 30 and 160°C, even more preferably between 50 and 150°C, and even more preferably between 70 and 140° C., typically for a period of between 10 minutes and 24 hours. Longer durations are not excluded, but do not necessarily bring improvement.
[0165] The drying step can be carried out by any technique known to those skilled in the art. It is advantageously carried out under an inert atmosphere or under an atmosphere containing oxygen or under a mixture of inert gas and oxygen. It is advantageously carried out at atmospheric pressure or at reduced pressure. Preferably, this step is carried out at atmospheric pressure and in the presence of air or nitrogen.
[0166] Step e3) Heat treatment of the dried catalyst (optional step)
[0167] The dried catalyst precursor may undergo an additional heat treatment step, before step f) of reduction, at a temperature of between 250 and 1000° C. and preferably between 250 and 750° C., typically for a period of between 15 minutes and 10 hours, under an inert atmosphere or under an atmosphere containing oxygen, in the presence of water or not. Longer treatment times are not excluded, but do not bring necessary improvement.
[0168] The term “heat treatment” is understood to mean the temperature treatment respectively without the presence or in the presence of water. In the latter case, contact with water vapor can take place at atmospheric pressure or at autogenous pressure. Several combined cycles without the presence or with the presence of water can be carried out. After this or these treatment(s), the catalyst precursor comprises nickel in oxide form, that is to say in NiO form.
[0169] In the event of the presence of water, the water content is preferably between 150 and 900 grams per kilogram of dry air, and even more preferably between 250 and 650 grams per kilogram of dry air.
[0170] Implementation of step e) in relation to the other steps of the preparation process
[0171] The method for preparing the nickel catalyst comprises several modes of implementation. They are distinguished in particular by the order of introduction of the nickel and copper precursors constituting the NiCu alloy. It is possible for the nickel and copper precursors to be brought into contact with the support either after the nickel precursor has been brought into contact with the support, or before the nickel precursor has been brought into contact with the support.
[0172] A first mode of implementation consists in carrying out said step e) prior to said step d).
[0173] A second mode of implementation consists in carrying out said step d) prior to said step e).
[0174] When step e) is carried out before or after step d), said step e) includes drying the catalyst precursor at a temperature below 250° C. after bringing the support into contact with said solution comprising at least one organic compound.
[0175] Step f) Addition of the organic compound
[0176] Bringing said support into contact with at least one solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function, or at least one ester function, or at least one amide function, or at least one amine function in accordance with the implementation of said step f), can be carried out by any method well known to those skilled in the art. Indeed, it has also been observed that the catalysts according to the invention prepared in the presence of an organic compound (among those mentioned below) are more active than the catalysts prepared in the absence of this type of organic compound. This effect is linked to the decrease in the size of the nickel particles.
[0177] In particular, said step f) can be carried out by impregnation, dry or in excess according to methods well known to those skilled in the art. Preferably, said step f) is carried out by dry impregnation, which consists in bringing the catalyst support into contact with a volume of said solution of between 0.25 and 1.5 times the pore volume of the support to be impregnated.
[0178] Said solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function, or at least one ester function, or at least one amide function or at least one amine function, can be aqueous or organic (for example methanol or ethanol or phenol or acetone or toluene or dimethyl sulfoxide (DMSO)) or consisting of a mixture of water and at least one organic solvent. Said organic compound is previously at least partially dissolved in said solution at the desired concentration. Preferably, said solution is aqueous or contains ethanol. Even more preferably, said solution is aqueous. The pH of said solution may be modified by the possible addition of an acid or a base. In another possible embodiment, the solvent may be absent from the impregnation solution.
[0179] In the embodiment in which step f) is carried out by impregnation, dry or in excess, preferably dry, the impregnation of the support with at least one solution containing at least said organic compound can be advantageously carried out via at least at least two impregnation cycles, using identical or different organic compounds for each cycle. In this case, each impregnation is advantageously followed by drying and possibly by heat treatment.
[0180] Advantageously, the molar ratio between said organic compound introduced in step f) and the nickel element also introduced in step d1) is between 0.01 and 5.0 mol/mol, preferably between 0.05 and 2.0 mol/mol, more preferably between 0.1 and 1.5 mol/mol and even more preferably between 0.3 and 1.2 mol/mol.
[0181] The organic compound according to step f) can comprise within the same molecule several organic carboxylic acid functions, alcohol esters, amides or amines, which are identical or different. The organic compound according to step f) can comprise a combination of several organic functions chosen from the organic functions of carboxylic acids, alcohol esters, amides or amines.
[0182] Preferably, the organic compound of step f) is different from the organic additive of step d2).
[0183] A) Organic compound comprising at least one carboxylic acid function
[0184] In one embodiment according to the invention, the organic compound comprises at least one carboxylic acid function.
[0185] Said organic compound comprising at least one carboxylic acid function can be an aliphatic, saturated or unsaturated organic compound, or an aromatic organic compound. Preferably, the aliphatic organic compound, saturated or unsaturated, comprises between 1 and 9 carbon atoms, preferably between 2 and 7 carbon atoms. Preferably, the aromatic organic compound comprises between 7 and 10 carbon atoms, preferably between 7 and 9 carbon atoms.
[0186] Said aliphatic organic compound, saturated or unsaturated, or said aromatic organic compound, comprising at least one carboxylic acid function can be chosen from monocarboxylic acids, dicarboxylic acids, tricarboxylic acids, tetracarboxylic acids.
[0187] Advantageously, the organic compound comprising at least one carboxylic acid function is chosen from ethanedioic acid (oxalic acid), propanedioic acid (malonic acid), pentanedioic acid (glutaric acid), hydroxyacetic acid (glycolic acid) , 2-hydroxypropanoic acid (lactic acid), 2-hydroxypropanedioic acid (tartronic acid), 2-hydroxypropane-1,2,3-tricarboxylic acid (citric acid), 2,3-dihydroxybutanedioic acid (tartaric acid), 2-oxopropanoic acid (pyruvic acid), 4-oxopentanoic acid (levulinic acid).
[0188] B) Organic compound comprising at least one alcohol function
[0189] In another embodiment according to the invention, the organic compound comprises at least one alcohol function.
[0190] Preferably, said organic compound comprises between 2 and 20 carbon atoms, preferably between 2 and 12 carbon atoms, and even more preferably between 2 and 8 carbon atoms.
[0191] Advantageously, the organic compound is chosen from methanol, ethanol, phenol, ethylene glycol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, glycerol, xylitol, mannitol, sorbitol, pyrocatechol, resorcinol, hydroquinol, diethylene glycol, triethylene glycol, polyethylene glycols having an average molar mass lower than 600 g/mol, glucose, mannose, fructose, sucrose, maltose, lactose, in any of their isomeric forms.
[0192] C) Organic compound comprising at least one ester function
[0193] In another embodiment according to the invention, the organic compound comprises at least one ester function. Preferably, said organic compound comprises between 2 and 20 carbon atoms, preferably between 3 and 14 carbon atoms, and even more preferably between 3 and 8 carbon atoms.
[0194] Said organic compound can be chosen from a linear or cyclic or unsaturated cyclic carboxylic acid ester, or a cyclic or linear carbonic acid ester or even a linear carbonic acid diester. In the case of a cyclic carboxylic acid ester, said compound is g-valerolactone.
[0195] In the case of an unsaturated cyclic ester (containing unsaturations in the cycle) of carboxylic acid, the compound can be furan or pyrone or any of their derivatives, such as 6-pentyl-α-pyrone .
[0196] In the case of a linear carboxylic acid ester, the compound may be a compound comprising a single ester function corresponding to the structural formula RCOOR', in which R and R' are alkyl groups, linear, branched, or cyclic, or alkyl groups containing unsaturations, or alkyl groups substituted by one or more aromatic rings, or aryl groups, each containing between 1 and 15 carbon atoms, and which may be identical or different. The group R can also be the hydrogen atom H. Said organic compound is preferably methyl laurate.
[0197] In another embodiment according to the invention, the organic compound may be a compound comprising at least two carboxylic acid ester functions. Preferably, said compound is dimethyl succinate.
[0198] In another embodiment according to the invention, the organic compound may be a compound comprising at least one carboxylic acid ester function and at least one second functional group chosen from alcohols, ethers, ketones, aldehydes.
[0199] Preferably, said compound is dimethyl malate.
[0200] Advantageously, said organic compound comprises at least one carboxylic acid ester function and at least one ketone or aldehyde function. In the case of a cyclic ester of carbonic acid, the compound is propylene carbonate. In the case of a linear carbonic acid ester, the compound is chosen from dimethyl carbonate, diethyl carbonate or diphenyl carbonate. In the case of a linear carbonic acid diester, the compound is chosen from dimethyl dicarbonate, diethyl dicarbonate, di-tert-butyl dicarbonate.
[0201] D) Organic compound comprising at least one amide function
[0202] In another embodiment according to the invention, the organic compound comprises at least one amide function, chosen from an acyclic amide function or a cyclic amide function, optionally comprising alkyl or aryl or alkyl substituents containing unsaturations. The amide functions can be chosen from primary, secondary or tertiary amides.
[0203] Advantageously, the organic compound comprising at least one amide function is chosen from formamide, N-methylformamide, N,N-dimethylformamide, N-ethylformamide , N,N-diethylformamide, acetamide, N-methylacetamide, N,N-dimethylmethanamide, N,N-diethylacetamide, N,N-dimethylpropionamide, propanamide, 2-pyrrolidone, N-methyl-2-pyrrolidone, γ-lactam, caprolactam, acetylleucine, N-acetylaspartic acid, aminohippuric acid, N-acetylglutamic acid, 4-acetamidobenzoic acid, lactamide and glycolamide, urea, N-methylurea, N,N′-dimethylurea, 1,1-dimethylurea, tetramethylurea in any of their isomeric forms.
[0204] E) Organic compound comprising at least one amine function
[0205] In another embodiment according to the invention, the organic compound comprises at least one amine function. Said organic compound comprises between 1 and 20 carbon atoms, preferably between 1 and 14 carbon atoms, and even more preferably between 2 and 8 carbon atoms.
[0206] In one embodiment according to the invention, said organic compound comprising at least one amine function corresponding to the formula C _x N _y H _z in which 1 ≤ x ≤ 20, 1 ≤ y ≤ x, 2 ≤ z ≤ 2x+ 2. More particularly, the organic compound is chosen from ethylenediamine, diaminohexane, tetramethylenediamine, hexamethylenediamine, tetramethylethylenediamine, tetraethylethylenediamine, diethylenetriamine, triethylenetetramine.
[0207] In one embodiment according to the invention, said organic compound comprises at least one amine function and at least one carboxylic acid (amino acid) function. When the compound is an amino acid, it is preferably chosen from alanine, arginine, lysine, proline, serine, threonine, EDTA.
[0208] Among all the embodiments above, the organic compound is chosen from oxalic acid, malonic acid, glycolic acid, lactic acid, tartronic acid, citric acid, tartaric acid, pyruvic acid, levulinic acid, ethylene glycol, propane-1,3-diol, butane-1,4-diol, glycerol, xylitol, mannitol, sorbitol, diethylene glycol , glucose, gamma valerolactone, dimethyl carbonate, diethyl carbonate, formamide, N-methylformamide, acetamide, N-methylacetamide, N,N-dimethylmethanamide, 2-pyrrolidone, γ- lactam, lactam, urea, alanine, arginine, lysine, proline, serine, EDTA.
[0209] Implementation of step f) in relation to the other steps of the preparation process
[0210] The method for preparing the nickel catalyst comprises several modes of implementation. They are distinguished in particular by the order in which the organic compound and the nickel precursor are introduced, it being possible for the organic compound to come into contact with the support either after the nickel precursor has been brought into contact with the support, or before the bringing the nickel precursor into contact with the support, or either at the same time as bringing the nickel into contact with the support.
[0211] A first mode of implementation consists in carrying out said step d) prior to said step f).
[0212] A second mode of implementation consists in carrying out said step f) prior to said step d).
[0213] When step f) is carried out before or after step d), said step f) includes drying the catalyst precursor at a temperature below 250° C. after bringing the support into contact with said solution comprising at least one organic compound.
[0214] Each step of bringing the support into contact with the nickel precursor (step d1), and of bringing the support into contact with at least one solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function , or at least one ester function, or at least one amide function or at least one amine function, (step f), is carried out at least once and can advantageously be carried out several times, optionally in the presence of a nickel precursor and / or of an identical or different organic compound at each step d1) and/or f) respectively.
[0215] A third mode of implementation consists in carrying out said step d1) and said step f) simultaneously (co-contacting). This mode of implementation can advantageously comprise the implementation of one or more steps d1), possibly with an identical or different nickel precursor at each step d1). In particular, one or more steps d1) advantageously precede(s) and/or follow(s) said co-contacting step, optionally with an identical or different nickel precursor at each step. This mode of implementation can also comprise several co-contacting steps: steps d1) and f) are carried out simultaneously on several occasions, optionally in the presence of a nickel precursor and/or of an identical organic compound (s) or different at each stage of co-contact.
[0216] Each contacting step can preferably be followed by an intermediate drying step. The intermediate drying step is carried out at a temperature below 250° C., preferably between 15 and 240° C., more preferably between 30 and 220° C., even more preferably between 50 and 200° C., and even more preferably more preferably between 70 and 180°C. Advantageously, when an intermediate drying step is carried out, an intermediate calcination step can be carried out. The intermediate calcination step is carried out at a temperature between 250°C and 1000°C, preferably between 250 and 750°C.
[0217] Advantageously, after each contacting step, whether it is a step of bringing the nickel precursor into contact with the support, a step of bringing the organic compound into contact with the support, or a step of bringing the precursor of nickel and organic compound simultaneously with the support, the impregnated support can be allowed to mature, optionally before an intermediate drying step. The maturation allows the solution to distribute itself homogeneously within the support. When a maturation step is carried out, said step is advantageously carried out at atmospheric pressure or at reduced pressure, under an inert atmosphere or under an atmosphere containing oxygen or under an atmosphere containing water, and at a temperature between between 10°C and 50°C, and preferably at room temperature. Generally, a maturation period of less than forty-eight hours and preferably between five minutes and five hours is sufficient. Longer durations are not excluded, but do not necessarily bring improvement.
[0218] Step g) Reduction with a reducing gas
[0219] Prior to the use of the catalyst in the catalytic reactor and the implementation of a hydrogenation process, a reducing treatment step g) is carried out in the presence of a reducing gas so as to obtain a catalyst comprising nickel in least partially in metallic form. This step is advantageously carried out in situ , that is to say after loading the catalyst into a hydrogenation reactor. This treatment makes it possible to activate said catalyst and to form metallic particles, in particular nickel in the zero valent state. Performing the catalyst reduction treatment in situ makes it possible to dispense with an additional step of passivation of the catalyst by an oxygenated compound or by CO ₂ , which is necessarily the case when the catalyst is prepared by carrying out a reduction treatment. ex-situ, that is to say outside the reactor used for the hydrogenation of aromatic or polyaromatic compounds. Indeed, when the reducing treatment is carried out ex-situ, it is necessary to carry out a passivation step in order to preserve the metallic phase of the catalyst in the presence of air (during transport and loading operations of the catalyst in the reactor of hydrogenation), then to carry out a new step of reduction of the catalyst.
[0220] The reducing gas is preferably hydrogen. The hydrogen can be used pure or in a mixture (for example a hydrogen/nitrogen, hydrogen/argon, hydrogen/methane mixture). In the case where the hydrogen is used as a mixture, all the proportions are possible.
[0221] According to an essential aspect of the preparation process according to the invention, said reducing treatment is carried out at a temperature greater than or equal to 150° C. and less than 250° C., preferably between 160 and 230° C., and more preferably between 170 and 220°C. The duration of the reducing treatment is between 5 minutes and less than 5 hours, preferably between 10 minutes and 4 hours, and even more preferably between 10 minutes and 110 minutes.
[0222] The presence of the nickel-copper alloy at least partially in reduced form makes it possible to use less severe operating conditions for reducing the active phase of nickel than in the prior art and thus makes it possible to directly carry out the reduction step within the reactor in which it is desired to carry out the hydrogenation of unsaturated aromatic compounds.
[0223] Furthermore, the presence of copper in the catalyst makes it possible to maintain good activity of the catalyst and good life of the catalyst when the latter is brought into contact with a hydrocarbon feedstock comprising sulfur. Indeed, compared to nickel, the copper present in the catalyst more easily captures the sulfur compounds included in the charge, which limits the irreversible poisoning of the active sites. The rise in temperature up to the desired reduction temperature is generally slow, for example fixed between 0.1 and 10° C./min, preferably between 0.3 and 7° C./min.
[0224] The hydrogen flow, expressed in L/hour/gram of catalyst precursor is between 0.01 and 100 L/hour/gram of catalyst, preferably between 0.05 and 10 L/hour/gram of catalyst precursor , even more preferably between 0.1 and 5 L/hour/gram of catalyst precursor.
[0225] Step h) Passivation (optional)
[0226] The catalyst prepared according to the process according to the invention can advantageously undergo a step of passivation by a sulfur compound which makes it possible to improve the selectivity of the catalysts and to avoid thermal runaways during the start-up of new catalysts (" run-away " according to Anglo-Saxon terminology). Passivation generally consists in irreversibly poisoning with the sulfur compound the most virulent active sites of nickel which exist on the new catalyst and therefore in attenuating the activity of the catalyst in favor of its selectivity. The passivation step is carried out by implementing methods known to those skilled in the art
[0227] The passivation step with a sulfur compound is generally carried out at a temperature of between 20 and 350° C., preferably between 40 and 200° C., for 10 to 240 minutes. The sulfur compound is for example chosen from the following compounds: thiophene, thiophane, alkylmonosulfides such as dimethylsulfide, diethylsulfide, dipropylsulfide and propylmethylsulfide or else an organic disulfide of formula HO-R ₁ -SSR ₂ -OH such as di-thio-di -ethanol of formula HO-C ₂ H ₄ -SSC ₂ H ₄ -OH (often called DEODS). The sulfur content is generally between 0.1 and 2% by weight of said element relative to the total weight of the catalyst.
[0228] In one embodiment according to the invention, the preparation of the catalyst is carried out ex-situ, that is to say before loading the catalyst into the reaction unit of the selective hydrogenation or aromatics hydrogenation process.
[0229] Selective hydrogenation process
[0230] The present invention also relates to a process for the selective hydrogenation of polyunsaturated compounds containing at least 2 carbon atoms per molecule, such as diolefins and/or acetylenics and/or alkenylaromatics, also called styrenics, contained in a charge of hydrocarbons having a final boiling point of less than or equal to 300°C, which process is carried out at a temperature of between 0 and 300°C, at a pressure of between 0.1 and 10 MPa, at a hydrogen/ (polyunsaturated compounds to be hydrogenated) of between 0.1 and 10 and at an hourly volume rate of between 0.1 and 200 h ^-1 when the process is carried out in the liquid phase, or at a molar hydrogen/(polyunsaturated compounds to be hydrogenated ) between 0.5 and 1000 and at an hourly volume rate between 100 and 40,000 h ^-1 when the process is carried out in the gas phase, in the presence of a catalyst obtained by the preparation process as described above in the describe option.
[0231] Monounsaturated organic compounds such as ethylene and propylene, for example, are the source of the manufacture of polymers, plastics and other value-added chemicals. These compounds are obtained from natural gas, naphtha or gas oil which have been treated by steam cracking or catalytic cracking processes. These processes are operated at high temperature and produce, in addition to the desired monounsaturated compounds, polyunsaturated organic compounds such as acetylene, propadiene and methylacetylene (or propyne), 1-2-butadiene and 1-3 -butadiene, vinylacetylene and ethylacetylene, and other polyunsaturated compounds whose boiling point corresponds to the C5+ cut (hydrocarbon compounds having at least 5 carbon atoms), in particular diolefinic or styrenic or indenic compounds. These polyunsaturated compounds are very reactive and lead to side reactions in the polymerization units. It is therefore necessary to eliminate them before recovering these cuts.
[0232] Selective hydrogenation is the main treatment developed to specifically remove unwanted polyunsaturated compounds from these hydrocarbon feedstocks. It allows the conversion of polyunsaturated compounds to the corresponding alkenes or aromatics while avoiding their total saturation and therefore the formation of the corresponding alkanes or naphthenes. In the case of steam cracked gasolines used as feed, selective hydrogenation also makes it possible to selectively hydrogenate alkenylaromatics into aromatics by avoiding the hydrogenation of aromatic rings.
[0233] The hydrocarbon feed treated in the selective hydrogenation process has a final boiling point less than or equal to 300°C and contains at least 2 carbon atoms per molecule and includes at least one polyunsaturated compound. The term “polyunsaturated compounds” means compounds comprising at least one acetylenic function and/or at least one diene function and/or at least one alkenylaromatic function.
[0234] More particularly, the feedstock is selected from the group consisting of a C2 steam cracking cut, a C2-C3 steam cracking cut, a C3 steam cracking cut, a C4 steam cracking cut, a C5 steam cracking cut and a steam cracking gasoline also called pyrolysis gasoline or C5+ cut.
[0235] The C2 cut from steam cracking, advantageously used for the implementation of the selective hydrogenation process according to the invention, has for example the following composition: between 40 and 95% by weight of ethylene, of the order of 0.1 to 5% by weight of acetylene, the remainder being essentially ethane and methane. In certain C2 cuts from steam cracking, between 0.1 and 1% by weight of C3 compounds may also be present.
[0236] The C3 steam cracking cut, advantageously used for the implementation of the selective hydrogenation process according to the invention, has for example the following average composition: of the order of 90% by weight of propylene, of the order of 1 to 8% by weight of propadiene and methylacetylene, the remainder being essentially propane. In some C3 cuts, between 0.1 and 2% by weight of C2 compounds and C4 compounds may also be present.
[0237] A C2-C3 cut can also be advantageously used for implementing the selective hydrogenation process according to the invention. It has for example the following composition: of the order of 0.1 to 5% by weight of acetylene, of the order of 0.1 to 3% by weight of propadiene and methylacetylene, of the order of 30% by weight of ethylene, of the order of 5% by weight of propylene, the remainder being essentially methane, ethane and propane. This filler may also contain between 0.1 and 2% by weight of C4 compounds.
[0238] The C4 cut from steam cracking, advantageously used for the implementation of the selective hydrogenation process according to the invention, has for example the following average mass composition: 1% weight of butane, 46.5% weight of butene, 51% weight of butadiene, 1.3% by weight of vinylacetylene and 0.2% by weight of butyne. In some C4 cuts, between 0.1 and 2% by weight of C3 compounds and C5 compounds may also be present.
[0239] The C5 cut from steam cracking, advantageously used for carrying out the selective hydrogenation process according to the invention, has for example the following composition: 21% by weight of pentanes, 45% by weight of pentenes, 34% by weight of pentadienes.
[0240] The steam cracking gasoline or pyrolysis gasoline, advantageously used for the implementation of the selective hydrogenation process according to the invention, corresponds to a hydrocarbon cut whose boiling point is generally between 0 and 300° C., from preferably between 10 and 250°C. The polyunsaturated hydrocarbons to be hydrogenated present in said steam cracked gasoline are in particular diolefinic compounds (butadiene, isoprene, cyclopentadiene, etc.), styrenic compounds (styrene, alpha-methylstyrene, etc.) and indene compounds (indene, etc.). ). Steam cracked gasoline generally comprises the C5-C12 cut with traces of C3, C4, C13, C14, C15 (for example between 0.1 and 3% by weight for each of these cuts). For example, a charge formed from pyrolysis gasoline generally has the following composition: 5 to 30% by weight of saturated compounds (paraffins and naphthenes), 40 to 80% by weight of aromatic compounds, 5 to 20% by weight of mono-olefins, 5 to 40% by weight of diolefins, 1 to 20% by weight of alkenylaromatic compounds, all the compounds forming 100%. It also contains from 0 to 1000 ppm by weight of sulphur, preferably from 0 to 500 ppm by weight of sulphur.
[0241] Preferably, the charge of polyunsaturated hydrocarbons treated in accordance with the selective hydrogenation process according to the invention is a C2 cut from steam cracking, or a C2-C3 cut from steam cracking, or a gasoline from steam cracking.
[0242] The selective hydrogenation process according to the invention aims to eliminate said polyunsaturated hydrocarbons present in said charge to be hydrogenated without hydrogenating the monounsaturated hydrocarbons. For example, when said feed is a C2 cut, the selective hydrogenation process aims to selectively hydrogenate acetylene. When said feed is a C3 cut, the selective hydrogenation process aims to selectively hydrogenate propadiene and methylacetylene. In the case of a C4 cut, the aim is to eliminate the butadiene, vinylacetylene (VAC) and the butyne, in the case of a C5 cut, the aim is to eliminate the pentadienes. When said feedstock is a steam cracked gasoline, the selective hydrogenation process aims to selectively hydrogenate said polyunsaturated hydrocarbons present in said feedstock to be treated so that the diolefinic compounds are partially hydrogenated to mono-olefins and the styrenic and indenic compounds are partially hydrogenated to the corresponding aromatic compounds avoiding the hydrogenation of the aromatic rings.
[0243] The technological implementation of the selective hydrogenation process is for example carried out by injection, in ascending or descending current, of the charge of polyunsaturated hydrocarbons and hydrogen into at least one fixed-bed reactor. Said reactor can be of the isothermal type or of the adiabatic type. An adiabatic reactor is preferred. The charge of polyunsaturated hydrocarbons can advantageously be diluted by one or more re-injection(s) of the effluent, from said reactor where the selective hydrogenation reaction takes place, at various points of the reactor, located between the inlet and the outlet of the reactor in order to limit the temperature gradient in the reactor. The technological implementation of the selective hydrogenation process according to the invention can also be advantageously carried out by the implantation of at least said supported catalyst in a reactive distillation column or in reactors – exchangers or in a reactor of the slurry type. . The hydrogen flow can be introduced at the same time as the charge to be hydrogenated and/or at one or more different points of the reactor.
[0244] The selective hydrogenation of the C2, C2-C3, C3, C4, C5 and C5+ cuts from steam cracking can be carried out in the gaseous phase or in the liquid phase, preferably in the liquid phase for the C3, C4, C5 and C5+ cuts and in the carbonated for C2 and C2-C3 cuts. A reaction in the liquid phase makes it possible to lower the energy cost and to increase the cycle time of the catalyst.
[0245] In general, the selective hydrogenation of a hydrocarbon charge containing polyunsaturated compounds containing at least 2 carbon atoms per molecule and having a final boiling point less than or equal to 300°C is carried out at a temperature between 0 and 300°C, at a pressure between 0.1 and 10 MPa, at a hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio between 0.1 and 10 and at an hourly volumetric speed VVH (defined as the ratio of the volume flow rate of charge to the volume of the catalyst) of between 0.1 and 200 h ^-1 for a process carried out in the liquid phase, or at a molar hydrogen/(polyunsaturated compounds to be hydrogenated) ratio of between 0.5 and 1000 and at an hourly volumetric speed VVH of between 100 and 40,000 h ^-1 for a process carried out in the gaseous phase.
[0246] In one embodiment according to the invention, when a selective hydrogenation process is carried out in which the feedstock is a steam cracked gasoline comprising polyunsaturated compounds, the molar ratio (hydrogen)/(polyunsaturated compounds to be hydrogenated) is generally comprised between 0.5 and 10, preferably between 0.7 and 5.0 and even more preferably between 1.0 and 2.0, the temperature is between 0 and 200°C, preferably between 20 and 200° C and even more preferably between 30 and 180°C, the hourly volume velocity (VVH) is generally between 0.5 and 100 h ^-1 , preferably between 1 and 50 h ^-1 and the pressure is generally between 0.3 and 8.0 MPa, preferably between 1.0 and 7.0 MPa and even more preferably between 1.5 and 4.0 MPa.
[0247] More preferably, a selective hydrogenation process is carried out in which the feedstock is a steam cracked gasoline comprising polyunsaturated compounds, the hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio is between 0.7 and 5.0, the temperature is between 20 and 200° C., the hourly volume velocity (VVH) is generally between 1 and 50 h ^-1 and the pressure is between 1.0 and 7.0 MPa.
[0248] Even more preferably, a selective hydrogenation process is carried out in which the feedstock is a steam cracked gasoline comprising polyunsaturated compounds, the hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio is between 1.0 and 2.0, the temperature is between 30 and 180° C., the hourly volume velocity (VVH) is generally between 1 and 50 h ^-1 and the pressure is between 1.5 and 4.0 MPa.
[0249] The hydrogen flow is adjusted in order to have a sufficient quantity of it to theoretically hydrogenate all the polyunsaturated compounds and to maintain an excess of hydrogen at the reactor outlet.
[0250] In another embodiment according to the invention, when a selective hydrogenation process is carried out in which the feed is a C2 cut from steam cracking and/or a C2-C3 cut from steam cracking comprising polyunsaturated compounds, the molar ratio ( hydrogen)/(polyunsaturated compounds to be hydrogenated) is generally between 0.5 and 1000, preferably between 0.7 and 800, the temperature is between 0 and 300°C, preferably between 15 and 280°C, the speed hourly volume (VVH) is generally between 100 and 40,000 h ^-1 , preferably between 500 and 30,000 h ^-1 and the pressure is generally between 0.1 and 6.0 MPa, preferably between 0.2 and 5, 0 MPa.
[0251] Aromatics hydrogenation process
[0252] The present invention also relates to a process for the hydrogenation of at least one aromatic or polyaromatic compound contained in a charge of hydrocarbons having a final boiling point less than or equal to 650° C., generally between 20 and 650° C. , and preferably between 20 and 450°C. Said hydrocarbon charge containing at least one aromatic or polyaromatic compound can be chosen from the following petroleum or petrochemical fractions: catalytic reforming reformate, kerosene, light gas oil, heavy gas oil, cracking distillates, such as FCC recycle oil, coker diesel, hydrocracking distillates.
[0253] The content of aromatic or polyaromatic compounds contained in the hydrocarbon charge treated in the hydrogenation process according to the invention is generally between 0.1 and 80% by weight, preferably between 1 and 50% by weight, and particularly preferably between 2 and 35% by weight, the percentage being based on the total weight of the hydrocarbon charge. The aromatic compounds present in said hydrocarbon charge are, for example, benzene or alkylaromatics such as toluene, ethylbenzene, o-xylene, m-xylene, or p-xylene, or alternatively aromatics having several aromatic (polyaromatic) rings such as naphthalene.
[0254] The sulfur or chlorine content of the charge is generally less than 5000 ppm by weight of sulfur or chlorine, preferably less than 100 ppm by weight, and in a particularly preferred manner less than 10 ppm by weight.
[0255] The technological implementation of the process for the hydrogenation of aromatic or polyaromatic compounds is for example carried out by injection, in ascending or descending current, of the hydrocarbon charge and hydrogen into at least one fixed-bed reactor. Said reactor can be of the isothermal type or of the adiabatic type. An adiabatic reactor is preferred. The hydrocarbon charge can advantageously be diluted by one or more re-injection(s) of the effluent, from said reactor where the hydrogenation reaction of the aromatics takes place, at various points of the reactor, located between the inlet and the outlet of the reactor in order to limit the temperature gradient in the reactor. The technological implementation of the process for the hydrogenation of aromatics according to the invention can also be advantageously carried out by the implantation of at least said supported catalyst in a reactive distillation column or in reactors-exchangers or in a reactor of the type slurries. The hydrogen flow can be introduced at the same time as the charge to be hydrogenated and/or at one or more different points of the reactor.
[0256] The hydrogenation of the aromatic or polyaromatic compounds can be carried out in the gas phase or in the liquid phase, preferably in the liquid phase. In general, the hydrogenation of aromatic or polyaromatic compounds is carried out at a temperature between 30 and 350° C., preferably between 50 and 325° C., at a pressure between 0.1 and 20 MPa, from preferably between 0.5 and 10 MPa, at a hydrogen/(aromatic compounds to be hydrogenated) molar ratio between 0.1 and 10 and at an hourly volumetric speed VVH of between 0.05 and 50 h ^-1 , preferably between 0, 1 and 10 h ^-1 of a hydrocarbon charge containing aromatic or polyaromatic compounds and having a final boiling point less than or equal to 650°C, generally between 20 and 650°C, and preferably between 20 and 450 °C.
[0257] The hydrogen flow is adjusted in order to have a sufficient quantity of it to theoretically hydrogenate all the aromatic compounds and to maintain an excess of hydrogen at the reactor outlet.
[0258] The conversion of the aromatic or polyaromatic compounds is generally greater than 20% by mole, preferably greater than 40% by mole, more preferably greater than 80% by mole, and in a particularly preferred manner greater than 90% by mole of the aromatic compounds or polyaromatics contained in the hydrocarbon charge. The conversion is calculated by dividing the difference between the total moles of the aromatic or polyaromatic compounds in the hydrocarbon feed and in the product by the total moles of the aromatic or polyaromatic compounds in the hydrocarbon feed.
[0259] According to a particular variant of the process according to the invention, a process is carried out for the hydrogenation of benzene from a hydrocarbon charge, such as the reformate from a catalytic reforming unit. The benzene content in said hydrocarbon charge is generally between 0.1 and 40% by weight, preferably between 0.5 and 35% by weight, and particularly preferably between 2 and 30% by weight, the percentage by weight being based on the total weight of the hydrocarbon charge.
[0260] The sulfur or chlorine content of the charge is generally less than 10 ppm by weight of sulfur or chlorine respectively, and preferably less than 2 ppm by weight.
[0261] The hydrogenation of the benzene contained in the hydrocarbon charge can be carried out in the gaseous phase or in the liquid phase, preferably in the liquid phase. When it is carried out in the liquid phase, a solvent may be present, such as cyclohexane, heptane, octane. In general, the hydrogenation of benzene is carried out at a temperature of between 30 and 250° C., preferably between 50 and 200° C., and more preferably between 80 and 180° C., at a pressure of between 0.1 and 10 MPa, preferably between 0.5 and 4 MPa, at a hydrogen/(benzene) molar ratio between 0.1 and 10 and at an hourly volumetric speed VVH of between 0.05 and 50 h ^-1 , preferably between 0.5 and 10 h ^-1 .
[0262] The conversion of benzene is generally greater than 50 mol%, preferably greater than 80 mol%, more preferably greater than 90 mol% and particularly preferably greater than 98 mol%.
[0263] The invention will now be illustrated via the examples below which are in no way limiting.
[0264] Examples
[0265] Example 1: Preparation of alumina AL-1
[0266] An alumina gel is synthesized via a mixture of sodium aluminate and aluminum sulphate. The precipitation reaction takes place at a temperature of 60° C., at a pH of 9, for 60 minutes and with stirring at 200 rpm.
[0267] The gel thus obtained undergoes mixing on a Z-arm mixer to provide the paste. Extrusion is carried out by passing the paste through a die fitted with 1.6 mm diameter holes in the shape of a trilobe. The extrudates thus obtained are dried under a flow of dry air at 150° C. for 12 hours then calcined at 450° C. under a flow of dry air for 5 hours.
[0268] The extrudate undergoes a hydrothermal treatment at 650°C in the presence of an aqueous solution containing acetic acid at 6.5% by weight relative to the weight of alumina for 3 hours in an autoclave, then is calcined in dry air. at 1000° C. for 2 hours in a tubular reactor. Alumina AL-1 is obtained.
[0269] Alumina AL-1 has a specific surface area of 80 m²/g, a pore volume (determined by Hg porosimetry) of 0.85 mL/g and a mesoporous diameter of 35 nm.
[0270] The sodium content is 0.0350% by weight relative to the total weight of the alumina and the sulfur content is 0.15% by weight relative to the total weight of the alumina.
[0271] Example 1a: Preparation of alumina AL-2
[0272] An alumina gel is synthesized via a mixture of sodium aluminate and aluminum sulphate. The precipitation reaction takes place at a temperature of 60° C., at a pH of 9, for 60 minutes and with stirring at 200 rpm.
[0273] The gel thus obtained undergoes mixing on a Z-arm mixer to provide the paste. Extrusion is carried out by passing the paste through a die fitted with 1.6 mm diameter holes in the shape of a trilobe. The extrudates thus obtained are dried under a flow of dry air at 150° C. for 12 hours then calcined at 450° C. under a flow of dry air for 5 hours. Alumina AL-2 is obtained.
[0274] Alumina AL-2 has a specific surface area of 255 m²/g, a pore volume (determined by Hg porosimetry) of 0.7 mL/g and a mesoporous diameter of 12 nm.
[0275] The sodium content is 0.0350% by weight relative to the total weight of the alumina and the sulfur content is 0.15% by weight relative to the total weight of the alumina.
[0276] Example 2: Preparation of an aqueous solution of Ni precursors
[0277] The aqueous solution of Ni precursors (solution S1) used for the preparation of catalyst A is prepared by dissolving 43.5 g of nickel nitrate (NiNO ₃ , supplier Stream Chemicals®) in a volume of 13 mL of distilled water. The solution S1 is obtained, the Ni concentration of which is 350 g of Ni per liter of solution.
[0278] Example 3: Preparation of an aqueous solution of Ni precursors with organic compound (according to step xx)
[0279] The aqueous solution of Ni precursors (solution S2) used for the preparation of catalysts B to G is prepared by dissolving 43.5 g of nickel nitrate (NiNO ₃ , supplier Strem Chemicals®) and malonic acid (CAS 141 -82-2; Fluka® supplier) in a volume of 13 mL of distilled water. The additive/Ni molar ratio being 0.5. The solution S2 is obtained, the Ni concentration of which is 350 g of Ni per liter of solution.
[0280] Example 4: Preparation of an aqueous solution of the precursors of the NiCu alloy (5% Ni)
[0281] The aqueous solution of Ni precursors (solution S3) used for the preparation of catalysts C, D, E, and G is prepared by dissolving 14.5 g of nickel nitrate (NiNO ₃ , supplier Strem Chemicals®) in a volume of 13 mL of distilled water. A solution is obtained whose Ni concentration is 116.6 g of Ni per liter of solution. The copper nitrate precursor is then added in order to have in particular a Ni/Cu molar ratio of 3 (catalysts C to F). We obtain the solution S3. It makes it possible to introduce the precursors of the NiCu alloy with a mass content of Ni relative to the final catalyst of approximately 5% by weight.
[0282] Example 5: Preparation of a catalyst A
[0283] The solution S2 prepared in example 3 is impregnated dry, by adding it drop by drop, to 10 g of alumina AL-1 obtained according to example 1.
[0284] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0285] The dry air used in this example and in all the examples below contains less than 5 grams of water per kilogram of air
[0286] The catalyst precursor thus obtained is dry impregnated with an aqueous solution containing formic acid with the HCOOH/Ni molar ratio equal to 1 mol/mol.
[0287] After the impregnation of the aqueous solution containing formic acid, the catalyst precursor undergoes a heat treatment at 150° C., 2 hours under a flow of air containing 50 grams of water per kilogram of air. dry with a flow rate of 1 L/h/g of catalyst, then for 1 hour at 120° C. under a stream of dry air.
[0288] Then the solution S3 is dry impregnated on the catalyst precursor above. The Ni content aimed at in this stage is 5% by weight of Ni relative to the weight of the final catalyst. The solid thus obtained is then dried in an oven overnight at 120°C, then calcined under an air flow of 1 L/h/g of catalyst at 450°C for 2 hours.
[0289] The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0290] Catalyst A is obtained, the characteristics of which are reported in Tables 1 and 2 below.
[0291] Example 6: Preparation of a catalyst B according to the invention
[0292] The S3 solution is impregnated dry drop by drop onto 10 g of the AL-1 support. The Ni content aimed at in this stage is 5% by weight of Ni relative to the weight of the final catalyst. The solid thus obtained is then dried in an oven overnight at 120°C, then calcined under an air flow of 1 L/h/g of catalyst at 450°C for 2 hours. The precursor of the final catalyst, B′, is obtained.
[0293] Then, the solution S2 prepared in example 3 is impregnated dry, by adding it drop by drop, the final catalyst precursor B'.
[0294] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0295] The catalyst precursor obtained is dry impregnated with an aqueous solution containing formic acid with the HCOOH/Ni molar ratio equal to 1 mol/mol.
[0296] After the impregnation of the aqueous solution containing formic acid, the catalyst precursor undergoes a heat treatment at 150° C., 2 hours under a flow of air containing 50 grams of water per kilogram of air. dry with a flow rate of 1 L/h/g of catalyst, then for 1 hour at 120° C. under a flow of dry air. The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0297] Catalyst B is obtained, the characteristics of which are reported in Tables 1 and 2 below.
[0298] Example 7: Preparation of a catalyst C (non-compliant)
[0299] The S3 solution is impregnated dry drop by drop onto 10 g of the AL-1 support. The Ni content aimed at in this stage is 5% by weight of Ni relative to the weight of the final catalyst. The solid thus obtained is then dried in an oven overnight at 120°C, then calcined under an air flow of 1 L/h/g of catalyst at 450°C for 2 hours.
[0300] The precursor of the final catalyst, C′, is obtained.
[0301] The solution S1 prepared in Example 2 is then impregnated dry, by adding the precursor of the catalyst C′ drop by drop.
[0302] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0303] The catalyst precursor thus obtained is dry impregnated with an aqueous solution containing formic acid with the HCOOH/Ni molar ratio equal to 1 mol/mol.
[0304] After the impregnation of the aqueous solution containing formic acid, the catalyst precursor undergoes a heat treatment at 150° C., 2 hours under a flow of air containing 50 grams of water per kilogram of air. dry with a flow rate of 1 L/h/g of catalyst, then for 1 hour at 120° C. under a flow of dry air. The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0305] Catalyst C is obtained, the characteristics of which are given in Tables 1 and 2 below.
[0306] Example 8: Preparation of a catalyst D (non-compliant)
[0307] The S3 solution is impregnated dry drop by drop onto 10 g of the AL-2 support. The Ni content aimed at in this stage is 5% by weight of Ni relative to the weight of the final catalyst. The solid thus obtained is then dried in an oven overnight at 120°C, then calcined under an air flow of 1 L/h/g of catalyst at 450°C for 2 hours.
[0308] The precursor of the final catalyst, D', is obtained.
[0309] The solution S2 prepared in Example 3 is then impregnated dry, by adding it drop by drop, to the precursor of the final catalyst, D'.
[0310] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0311] The catalyst precursor thus obtained is dry impregnated with an aqueous solution containing formic acid with the HCOOH/Ni molar ratio equal to 1 mol/mol.
[0312] After the impregnation of the aqueous solution containing formic acid, the catalyst precursor undergoes a heat treatment at 150° C., 2 hours under a flow of air containing 50 grams of water per kilogram of air. dry with a flow rate of 1 L/h/g of catalyst, then for 1 hour at 120° C. under a flow of dry air. The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0313] Catalyst D is obtained, the characteristics of which are shown in Tables 1 and 2 below.
[0314] Example 9: Preparation of a catalyst E (non-compliant)
[0315] The solution S2 prepared in example 3 is impregnated dry, by adding it drop by drop, to 10 g of alumina AL-1 obtained according to example 1.
[0316] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0317] The dry air used in this example and in all the examples below contains less than 5 grams of water per kilogram of air
[0318] The catalyst precursor E' thus obtained is dry impregnated with an aqueous solution containing formic acid with the HCOOH/Ni molar ratio equal to 1 mol/mol.
[0319] After the impregnation of the aqueous solution containing formic acid, the catalyst precursor undergoes a heat treatment at 150° C., 2 hours under a flow of air containing 50 grams of water per kilogram of air. dry with a flow rate of 1 L/h/g of catalyst, then for 1 hour at 120° C. under a flow of dry air.
[0320] Catalyst E is obtained, the characteristics of which are reported in Tables 1 and 2 below.
[0321] The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0322] Example 10: Preparation of a catalyst F (non-compliant)
[0323] The S3 solution is impregnated dry drop by drop onto 10 g of the AL-1 support. The Ni content aimed at in this stage is 5% by weight of Ni relative to the weight of the final catalyst. The solid thus obtained is then dried in an oven overnight at 120°C, then calcined under an air flow of 1 L/h/g of catalyst at 450°C for 2 hours.
[0324] The precursor of the final catalyst, F′, is obtained.
[0325] The solution S2 prepared in example 3 is impregnated dry, by adding it drop by drop, to the catalyst precursor F′.
[0326] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours.
[0327] Catalyst F is obtained, the characteristics of which are reported in Tables 1 and 2 below below.
[0328] The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0329] Example 11: Preparation of a catalyst G (non-compliant)
[0330] The solution S2 prepared in example 3 is impregnated dry, by adding it drop by drop, to 10 g of alumina AL-1 obtained according to example 1.
[0331] The solid thus obtained is then dried in an oven for 12 hours at 120°C, then calcined under a flow of dry air of 1 L/h/g of catalyst at 450°C for 2 hours. The catalyst precursor is then reduced under the conditions as described in Example 9 below.
[0332] Catalyst G is obtained, the characteristics of which are reported in Tables 1 and 2 below below.
[0333] The catalyst precursor is then reduced under the conditions as described in Example 12 below.
[0334] Example 12: Characterization
[0335] All the catalysts contain the contents targeted during impregnation, i.e. 15% of nickel element (characterized by X-ray fluorescence) relative to the total weight of the catalyst, and the % of added copper (characterized by X-ray fluorescence) .
[0336] The amount of alloy obtained after the calcination then reduction step was determined by X-ray diffraction (XRD) analysis on catalyst samples in powder form.
[0337] The amount of nickel in metallic form obtained after the reduction step was determined by X-ray diffraction (XRD) analysis on catalyst samples in powder form. Between the reduction stage and throughout the duration of characterization by XRD, the catalysts are never released into the open air. The diffraction diagrams are obtained by X-ray crystallographic analysis using a diffractometer using the conventional powder method with Kα1 radiation from copper (λ=1.5406 Å).
[0338] The reduction rate was calculated by calculating the area of the Ni ⁰ line located around 52°2θ, on all the diffractograms of each sample of catalyst analyzed, then by subtracting the signal present from room temperature under the line at 52° and which is due to the alumina.
[0339] Table 1 below summarizes the reduction rates or even the metallic nickel content Ni° (expressed in % weight relative to the total weight of "active" nickel; ie without taking into account the nickel that makes up the alloy) for all the catalysts A to E characterized by XRD after a reduction step at 170° C. for 90 minutes under a flow of hydrogen. These values were also compared with the reduction rate obtained for catalyst A (Ni alone) after a conventional reduction step (i.e. at a temperature of 400°C for 15 hours under a flow of hydrogen) .
[0340] At room temperature on all the catalysts, after calcination, containing copper and nickel, we detect alumina in delta and theta form, and large lines of NiO and CuO.
[0341] We also detect after reduction a line corresponding to the alloy in the form of Ni _0.76 Cu _0.24.
[0342] In order to evaluate the rate of reducibility and therefore the formation of Ni ⁰ , we measure the area of the Ni ⁰ line located around 52°2θ, on all the diffractograms, by subtracting the signal present from room temperature under the line at 52° and which is due to the alumina. It is thus possible to determine the relative percentage of Ni ⁰ crystallized after the reduction.
[0343] Table 1 below summarizes the reducibility rates or the Ni° content for all the catalysts characterized by XRD after reduction at 170°C for 90 minutes under a hydrogen flow. These values were also compared with the reduction rate obtained for catalyst G (Ni alone) after a conventional reduction step (i.e. at a temperature of 400°C for 15 hours under a flow of hydrogen) .
[0344] Catalyst Final reduction Ni content for the ^1st imp. (% wt) Ni content for the ^2nd imp. (% wt) Ni/Cu molar ratio Percentage of Ni° alone (DRX) after reduction (%) A (invention) 170°C, 90 mins 15 5 3 90 B (invention) 170°C, 90 mins 5 15 3 95 C (comparative) 170°C, 90 mins 5 15 3 100 D (comparative) 170°C, 90 mins 5 15 3 100 E (comparative) 170°C, 90 mins - 15 - 0 F (comparative) 170°C, 90 mins 5 1595 G (comparative) 170°C, 90 mins 15 -70 G (comparative) 400°C, 3 p.m. 15 - - 0
[0345] Catalyst Support Addition NiCu Particle size (nm)* Crust thickness/ grain diameter (%) Density ratio in Ni between the crust and the core (dCcrust/ d)heart Ni content in the crust/Total Ni (%) AT AL-1 Post-impregnation 2.2 6.8 5 66 B AL-1 Pre-impregnation 2.1 5 11 72 VS (improper) AL-1 Pre-impregnation 14 4.2 6 65 D (improper) AL-2 Pre-impregnation 10.2 Homogeneous distribution - - E (improper) AL-1 - 3 7 8 68 F (improper) AL-1 Pre impregnation 2.5 Homogeneous distribution - - G (improper) AL-1 - 2.4 Homogeneous distribution - -
[0346] *Particle size of the 15% of Nickel that does not make up the alloy.
[0347] Example 13: Catalytic tests: performance in selective hydrogenation of a mixture containing styrene and isoprene (A _HYD1 )
[0348] Catalysts A to G described in the examples above are tested against the selective hydrogenation reaction of a mixture containing styrene and isoprene.
[0349] The composition of the charge to be selectively hydrogenated is as follows: 8% by weight styrene (Sigma Aldrich® supplier, purity 99%), 8% by weight isoprene (Sigma Aldrich® supplier, purity 99%), 84% by weight n-heptane (solvent ) (VWR® supplier, purity > 99% chromanorm HPLC). This composition corresponds to the initial composition of the reaction mixture. This mixture of model molecules is representative of a pyrolysis gasoline.
[0350] The selective hydrogenation reaction is carried out in a 500 mL stainless steel autoclave, equipped with mechanical stirring with magnetic drive and able to operate under a maximum pressure of 100 bar (10 MPa) and temperatures between 5°C and 200°C.
[0351] 214 mL of n-heptane (supplier VWR®, purity >99% chromanorm HPLC) and a quantity of 3 mL of catalyst are added to an autoclave. The autoclave is closed and purged. Then the autoclave is pressurized under 35 bar (3.5 MPa) of hydrogen. The catalyst is first reduced in situ , at 170°C for 90 minutes under a hydrogen flow of 1 L/h/g (temperature rise ramp of 1°C/min) for catalysts A to G ( which here corresponds to step g) of the preparation process according to the invention according to one embodiment). Then the autoclave is brought to the test temperature equal to 30°C. At time t=0, approximately 30 g of a mixture containing styrene, isoprene and n-heptane are introduced into the autoclave. The reaction mixture then has the composition described above and stirring is started at 1600 rpm. The pressure is kept constant at 35 bar (3.5 MPa) in the autoclave using a reservoir bottle located upstream of the reactor.
[0352] Another test was carried out for catalyst A, but with a catalyst reduction temperature of 400° C. for 15 hours.
[0353] The progress of the reaction is monitored by taking samples from the reaction medium at regular time intervals: the styrene is hydrogenated to ethylbenzene, without hydrogenation of the aromatic ring, and the isoprene is hydrogenated to methyl-butenes. If the reaction is prolonged longer than necessary, the methyl-butenes are in turn hydrogenated to isopentane. Hydrogen consumption is also monitored over time by the decrease in pressure in a reservoir bottle located upstream of the reactor. The catalytic activity is expressed in moles of H ₂ consumed per minute and per gram of Ni.
[0354] The catalytic activities measured for catalysts A to G are reported in Table 3 below. They are related to the catalytic activity (A _HYD1 ) measured for catalyst A prepared under conventional reduction conditions (at a temperature of 400° C. for 16 hours under a flow of hydrogen).
[0355] Example 14: Catalytic tests: performance in hydrogenation of toluene (A _HYD2 )
[0356] Catalysts A to G described in the examples above are also tested with respect to the hydrogenation reaction of toluene. The selective hydrogenation reaction is carried out in the same autoclave as that described in Example 13.
[0357] 214 mL of n-heptane (supplier VWR®, purity >99% chromanorm HPLC) and a quantity of 3 mL of catalyst are added to an autoclave. The autoclave is closed and purged. Then the autoclave is pressurized under 35 bar (3.5 MPa) of hydrogen. The catalyst is first reduced in situ , at 170°C for 90 minutes under a hydrogen flow of 1 L/h/g (temperature rise ramp of 1°C/min) for catalysts A to G ( which here corresponds to step g) of the preparation process according to the invention according to one embodiment). After adding 216 mL of n-heptane (VWR® supplier, purity > 99% chromanorm HPLC), the autoclave is closed, purged, then pressurized under 35 bar (3.5 MPa) of hydrogen, and brought to the test temperature equal to 80°C. At time t=0, approximately 26 g of toluene (SDS® supplier, purity > 99.8%) are introduced into the autoclave (the initial composition of the reaction mixture is then toluene 6% by weight / n-heptane 94% by weight) and stirring is started at 1600 rpm. The pressure is kept constant at 35 bar (3.5 MPa) in the autoclave using a reservoir bottle located upstream of the reactor.
[0358] The progress of the reaction is monitored by taking samples of the reaction medium at regular time intervals: the toluene is completely hydrogenated to methylcyclohexane. Hydrogen consumption is also monitored over time by the decrease in pressure in a reservoir bottle located upstream of the reactor. The catalytic activity is expressed in moles of H ₂ consumed per minute and per gram of Ni.
[0359] The catalytic activities measured for catalysts A to G are reported in Table 3 below. They are related to the catalytic activity (A _HYD2 ) measured for catalyst C . For comparison, catalyst G was also prepared under conventional reduction conditions (at a temperature of 400° C. for 16 hours under a flow of hydrogen in a flow reactor passed through ex situ).
[0360] Catalyst Reduction (°C) A _HYD1 (%) A _HYD2 (%) A (compliant) 170°C, 16h 180 175 B (compliant) 170°C, 16h 175 170 C (non-compliant) 170°C, 16h 100 100 D (non-compliant) 170°C, 16h 60 70 E (not compliant) 170°C, 16h <1 <1 F(not compliant) 170°C, 16h 55 45 G (non-compliant) 170°C, 16h <1 <1 G (non-compliant) 400°C, 4 p.m. 120 135
[0361] Table 3: Comparison of performances in selective hydrogenation of a mixture containing styrene and isoprene (A _HYD1 ) and in hydrogenation of toluene (A _HYD2 )
[0362] This clearly shows the improved performances in A _HYD1 and A _HYD2 of the catalysts A, B according to the invention, compared to the catalysts B to G which do not conform. Catalyst A and B are reduced to 170° C. by 90% and have small particle sizes distributed in “egg-shell”. Catalyst C has large particles due to the use of solution S2 without additives. Its catalytic activity remains interesting due to the presence of 80% of Ni reduced due to the addition of NiCu. Catalysts D and F indeed have small particles and are reduced to 90%, but they are not distributed in the crust, hence the reduced activity. Catalysts F and G despite small particles are not active. The absence of NiCu does not make it possible to obtain reduced Ni, the active phase in hydrogenation, at 170°C.

权利要求:
Claims (18)
[0001]
Catalyst comprising nickel and copper, in an amount of 1 and 50% by weight in nickel element relative to the total weight of the catalyst, and a second metallic element of copper, in an amount of 0.5 to 15% by weight in copper element relative to the total weight of the catalyst, and an alumina support, said catalyst being characterized in that: - the nickel is distributed both on a crust on the periphery of the support, and in the heart of the support, the thickness of said crust being between 2% and 15% of the diameter of the catalyst; - the nickel density ratio between the crust and the core is strictly greater than 3; - said crust comprises more than 25% by weight nickel element relative to the total weight of nickel contained in the catalyst; - the molar ratio between nickel and copper is between 0.5 and 5; - at least a part of the nickel and the copper is in the form of a nickel-copper alloy; - the nickel content included in the nickel-copper alloy is between 0.5 and 15% by weight of nickel element relative to the total weight of the catalyst, - the size of the nickel particles, measured in oxide form, in the catalyst is less than 7 nm.
[0002]
Catalyst according to Claim 1, in which the nickel density ratio between the crust and the core is greater than or equal to 3.5.
[0003]
Catalyst according to one of Claims 1 or 2, in which the said crust comprises more than 40% by weight of nickel element relative to the total weight of nickel contained in the catalyst.
[0004]
Catalyst according to any one of claims 1 to 3, in which the transition interval between the core and the shell of the catalyst is between 0.05% and 3% of the diameter of the catalyst.
[0005]
Catalyst according to any one of Claims 1 to 4, characterized in that the size of the nickel particles in the catalyst is less than 5 nm.
[0006]
Catalyst according to any one of Claims 1 to 5, in which the sulfur content of the alumina support is between 0.001% and 2% by weight relative to the total weight of the alumina support, and the sodium content of the said support of alumina is between 0.001% and 2% by weight relative to the total weight of said alumina gel.
[0007]
Catalyst according to any one of Claims 1 to 6, characterized in that the thickness of the said crust is between 2.5% and 12% of the diameter of the catalyst.
[0008]
Catalyst according to any one of Claims 1 to 7, characterized in that the nickel density ratio between the crust and the core is between 3.8 and 15.
[0009]
Process for the preparation of a catalyst according to any one of Claims 1 to 8, the said process being characterized in that: a) a gel is supplied; b) the alumina gel of step a) is shaped; c) the shaped alumina gel obtained at the end of step b) is subjected to a heat treatment comprising at least one hydrothermal treatment step in an autoclave in the presence of an acid solution, at a temperature between between 100 and 800° C., and at least one calcining step, at a temperature of between 400 and 1500° C., carried out after the hydrothermal treatment step, to obtain an alumina support; d) the sequence of the following sub-steps is carried out: d1) the alumina support is brought into contact with at least one nickel precursor to obtain a catalyst precursor, d2) the catalyst precursor obtained at the end of step d1) is dried at a temperature below 250° C.; d3) the dried catalyst precursor obtained at the end of step d2) is brought into contact with at least one solution containing at least one organic additive chosen from aldehydes containing 1 to 14 carbon atoms per molecule, ketones or polyketones containing 3 to 18 carbon atoms per molecule, ethers and esters containing 2 to 14 carbon atoms per molecule, alcohols or polyalcohols containing 1 to 14 carbon atoms per molecule and carboxylic acids or polycarboxylic acids containing 1 to 14 carbon atoms per molecule, the molar ratio between the organic additive and the nickel being greater than 0.05 mol/mol; d4) a hydrothermal treatment of the catalyst precursor obtained at the end of step d3) is carried out at a temperature of between 100 and 200° C. for a period of between 30 minutes and 5 hours under a gas stream comprising between 5 and 650 grams of water per kg of dry gas; e) the sequence of the following sub-steps is carried out: e1) the alumina support is brought into contact with at least one solution containing at least one copper precursor and one nickel precursor at a desired nickel concentration to obtain a content in the final catalyst of between 0.5 and 15% weight of nickel element relative to the total weight of the final catalyst; e2) at least one step of drying the catalyst precursor obtained at the end of step e1) is carried out at a temperature below 250° C.; steps d) and e) being carried out separately in any order, f) the alumina support is brought into contact with at least one solution containing at least one organic compound comprising at least one carboxylic acid function, or at least one alcohol function, or at least one ester function, or at least one amide function , or at least one amine function, step f) being carried out, either at the same time as sub-step d1) of step d), or before or after step d), but before step g), it being understood that when the step f) is carried out before or after step d), then said step f) includes drying the catalyst precursor at a temperature below 250° C. after bringing the support into contact with said solution comprising at least one organic compound ; g) the catalyst precursor from steps a) to f) is reduced by bringing said catalyst precursor into contact with a reducing gas at a temperature greater than or equal to 150°C and less than 250°C.
[0010]
Process according to Claim 9, in which the molar ratio between the said organic compound introduced in step f) and the nickel element also introduced in step d1) is between 0.01 and 5.0 mol/mol.
[0011]
Method according to one of Claims 9 or 10, in which steps d1) and f) are carried out simultaneously.
[0012]
Process according to any one of Claims 9 to 11, in which the organic compound of step f) is chosen from oxalic acid, malonic acid, glycolic acid, lactic acid, tartronic, citric acid, tartaric acid, pyruvic acid, levulinic acid, ethylene glycol, propane-1,3-diol, butane-1,4-diol, glycerol, xylitol , mannitol, sorbitol, diethylene glycol, glucose, gamma valerolactone, dimethyl carbonate, diethyl carbonate, formamide, N-methylformamide, acetamide, N-methylacetamide, N,N- dimethylmethanamide, 2-pyrrolidone, γ-lactam, lactamide, urea, alanine, arginine, lysine, proline, serine, EDTA.
[0013]
Process according to any one of Claims 9 to 12, in which the copper precursor is chosen from copper acetate, copper acetylacetonate, copper nitrate, copper sulphate, copper chloride, bromide copper, copper iodide or copper fluoride.
[0014]
Process according to any one of Claims 9 to 13, in which in step d3) the organic additive is chosen from formic acid, formaldehyde, acetic acid, citric acid, oxalic acid, glycolic acid, malonic acid, ethanol, methanol, ethyl formate, methyl formate, paraldehyde, acetaldehyde, gamma-valerolactone acid, glucose, sorbitol and trioxane .
[0015]
Process according to any one of Claims 9 to 14, in which the molar ratio between the organic additive introduced in step d2) and the nickel is between 0.1 and 5 mol/mol.
[0016]
Process according to any one of claims 9 to 15, in which the organic compound of step f) is different from the organic additive of step d2).
[0017]
Process for the selective hydrogenation of polyunsaturated compounds containing at least 2 carbon atoms per molecule contained in a charge of hydrocarbons having a final boiling point less than or equal to 300°C, which process is carried out at a temperature between 0 and 300°C, at a pressure of between 0.1 and 10 MPa, at a hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio of between 0.1 and 10 and at an hourly volume rate of between 0.1 and 200 h ^{- 1} when the process is carried out in the liquid phase, or at a hydrogen/(polyunsaturated compounds to be hydrogenated) molar ratio of between 0.5 and 1,000 and at an hourly volume rate between 100 and 40,000 h ^-1 when the process is carried out in the gas, in the presence of a catalyst according to any one of claims 1 to 8.
[0018]
Process for the hydrogenation of at least one aromatic or polyaromatic compound contained in a charge of hydrocarbons having a final boiling point less than or equal to 650°C, said process being carried out in the gaseous phase or in the liquid phase, at a temperature between 30 and 350°C, at a pressure between 0.1 and 20 MPa, at a hydrogen/(aromatic compounds to be hydrogenated) molar ratio between 0.1 and 10 and at an hourly volumetric speed VVH between 0.05 and 50 h ^-1 , in the presence of a catalyst according to any one of Claims 1 to 8.

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FR3064500A1|2017-03-29|2018-10-05|IFP Energies Nouvelles|SELECTIVE HYROGENATION MULTILAYER CATALYST|

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FR3076746A1|2018-01-15|2019-07-19|IFP Energies Nouvelles|PROCESS FOR THE PREPARATION OF A PARTICULAR CATALYST OF SELECTIVE HYDROGENATION BY MIXING AND IMPREGNATION|

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FR3110865A1|2020-05-29|2021-12-03|IFP Energies Nouvelles|PROCESS FOR PREPARING A CATALYST COMPRISING AN ACTIVE PHASE OF NICKEL IN THE FORM OF SMALL PARTICLES DISTRIBUTED INTO A CRUST AND A NICKEL COPPER ALLOY|

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FR3112087A1|2020-07-03|2022-01-07|IFP Energies Nouvelles|PROCESS FOR PREPARING A CATALYST FOR HYDROGENATION OF AROMATIC COMPOUNDS OBTAINED FROM MELTED SALTS AND A NICKEL COPPER ALLOY|

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FR3112088A1|2020-07-03|2022-01-07|IFP Energies Nouvelles|PROCESS FOR THE PREPARATION OF A SELECTIVE HYDROGENATION CATALYST OBTAINED FROM MELTED SALTS AND A NICKEL COPPER ALLOY|

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2021-02-05| PLSC| Publication of the preliminary search report|Effective date: 20210205 |

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2021-07-26| PLFP| Fee payment|Year of fee payment: 3 |

优先权:

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申请号 | 申请日 | 专利标题

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FR1908724A|FR3099388B1|2019-07-31|2019-07-31|CATALYST INCLUDING AN ACTIVE PHASE OF NICKEL IN THE FORM OF SMALL PARTICLES DISTRIBUTED IN CRUST AND A NICKEL COPPER ALLOY|

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FR1908724|2019-07-31|FR1908724A| FR3099388B1|2019-07-31|2019-07-31|CATALYST INCLUDING AN ACTIVE PHASE OF NICKEL IN THE FORM OF SMALL PARTICLES DISTRIBUTED IN CRUST AND A NICKEL COPPER ALLOY|

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PCT/EP2020/070078| WO2021018600A1|2019-07-31|2020-07-16|Catalyst comprising an active nickel phase in the form of small particles distributed in a shell and a nickel-copper alloy|

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CN202080054926.2A| CN114126756A|2019-07-31|2020-07-16|Catalyst comprising an active nickel phase and a nickel-copper alloy in the form of small particles distributed in a shell|