Description:FIELD OF THE INVENTION
[0001] The present disclosure relates to a CO combustion promoter additive catalyst. The present disclosure also relates to a process of preparation of CO combustion promoter additive catalyst. Specifically, the present disclosure relates to a catalyst to be used in Fluid Catalytic Cracking (FCC) units to promote CO combustion.

BACKGROUND OF THE INVENTION
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Fluid Catalytic Cracking (FCC) is widely used in the petrochemical industry to convert high-molecular weight hydrocarbons into low molecular weight hydrocarbons. During the FCC process, there is always technical limitations with respect to complete combustion of coke to CO2 and compete combustion of CO. Generally, alumina support-based CO combustion promoter additives are used to enhance combustion of coke by promoting CO oxidation and to reduce after burning issues in the FCC units. Some of the known catalysts and the process to promote the CO combustion in FCC units are discussed in detail.
[0004] US 20090050529 discloses a composition suitable for use in FCC processes and are capable of providing improved CO oxidation promotion activity along with NOx emission control. Generally, compositions are provided for promoting CO oxidation in FCC processes, wherein the compositions contain (i) a basic material support, (ii) at least one oxide of a lanthanide series element, (iii), optionally, at least one oxide of a transition metal selected from Groups Ib and IIb of the Periodic Table and (iv) at least one precious metal. The basic material support is preferably a hydrotalcite-like compound.
[0005] EP1879982 B1 discloses additive particulate composition suitable for promoting the oxidation of CO during catalyst regeneration in a fluid catalytic cracking process, said composition comprising (i) a particulate acidic oxide support, (ii) at least one precious metal for promoting CO oxidation, and (iii) metals or metal oxides capable of decomposing NOx, said at least one precious metal (ii) being primarily distributed in the central interior of said particulate additive and said metals or metal oxides (iii) primarily distributed throughout said particulate additive, including as a shell around said at least one precious metal.
[0006] US5164072 discloses a carbon monoxide oxidation catalyst especially useful as a co-catalyst in fluid catalytic cracking operations is made by impregnating particulate alumina with lanthana and a small amount of platinum. Cerium must be excluded.
[0007] EP 2929936 A1 discloses a CO oxidation promoter additive and a method of its preparation. The CO oxidation promoter additive is having improved apparent bulk density and attrition properties for use in hydrocarbon conversion during fluid catalytic cracking. The CO oxidation promoter additive has a better CO to CO2 conversion.
[0008] EP0742044A1 discloses a process for the preparation of a CO oxidation promoter which comprises in preparing a slurry of colloidal silica/clay and a binder with peptised pseudoboehmite. The slurry is then subjected to the step of spray drying to obtain microspheres. The microspheres are calcined and then impregnated with platinum.
[0009] US20040086442A1 discloses a compositions and methods to reduce NOx emissions from the flue gas of a fluid catalytic cracking (FCC) unit. The invention also provides methods for reducing CO emissions from the regenerator and/or the flue of an FCC unit. The compositions of the invention comprise copper and/or cobalt and a carrier. The carrier can be, for example, hydrotalcite like compounds, spinels, alumina, zinc titanate, zinc aluminate, zinc titanate/zinc aluminate, and the like.
[0010] US9677007B2 discloses a carbon monoxide combustion catalyst and a method of making the catalyst used in fluid bed catalytic cracking process. The catalyst can contain metals and other composites which promote oxidation of carbon monoxide to carbon dioxide during regeneration of spent FCC catalyst.
[0011] JP2019013859A discloses a carbon monoxide oxidation promoter is constituted with carrying platinum on a carrier consisting of aluminum oxide and cerium oxide.
[0012] WO2019195088A2 discloses a CO to CO2 combustion promoter comprising microsphere sized porous silica and/or alumina comprising particles further comprising on or more Group VIII noble metals wherein the noble metal is distributed in the particle as an eggshell such that a higher content of noble metal is present in the outer region of the particle as compared to the content of noble metal in the center of the particle.
[0013] IN 202241008176 discloses a catalyst for promoting CO combustion in a Fluid Catalytic Cracking (FCC) unit, wherein, the catalyst comprises: an alumina-cerium-zirconium support comprising Al2O3, ZrO2 and CeO2, wherein the said alumina-cerium-zirconium support have a micro spherical shape; and active metals loaded on the said alumina-cerium-zirconium support, wherein, the active metals are selected from a platinum group metals (PGMs).
[0014] Most of these CO combustion promoter additives are alumina based. However, such conventional used alumina-based CO combustion promoter additives require high demand of air supply to combust CO to CO2 during regeneration process. However, high supply amount of air to the regenerator is a limiting factor in the FCC units. Accordingly, there is a need for an improved catalysts which can promote CO combustion in FCC units under normal/ minimum air supply condition.
[0015] Further, it is also clear from the literature that with growing regulations on CO emission in the environment and for circumventing the problem of afterburning associated with the FCC technology, improved catalysts as well as improved methods are continuously in demand which provides efficient oxidation of CO in regenerator dense bed of FCC units.
[0016] Thus, there is an urgent need to develop a catalyst that effectively promote CO combustion which can overcome the demerits of the prior art as discussed above.

OBJECTS OF THE INVENTION
[0017] An objective of the present invention is to provide a CO combustion promoter additive catalyst.
[0018] Another objective of the present invention is to provide a process of preparation of CO combustion promoter additive catalyst.
[0019] Still another objective of the present invention is to develop a Pt-based catalyst to make CO combustion promoter additive.
[0020] Yet another objective of the present invention is to develop a cost effective CO combustion promoter additive catalyst.

SUMMARY OF THE INVENTION
[0021] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in Detailed Description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0022] An aspect of the present disclosure is to provide a CO combustion promoter additive catalyst comprising: 5 to 50 % w/w of a spent active metal catalyst support of total weight of the catalyst; 50 to 95 % w/w of a high-density large pore alumina of total weight of the catalyst; and 1 to 20 % w/w of a promoter materials of total weight of the catalyst, wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron.
[0023] Another aspect of the present disclosure is to provide a process of preparation of CO combustion promoter additive catalyst comprising: mixing of 5 to 50 % w/w of a spent active metal catalyst support, 50 to 95 % w/w of a high-density binder grade alumina and 1 to 20 % w/w of a promoter materials to form a composite material; reacting the composite material with 0.1 to 10 % w/w of an inorganic acid binder at the temperature 10-50 oC for 2 to 5 h to obtain a peptized composite materials; converting the peptized composite material by spray drying to obtain a CO combustion promoter additive catalyst, wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.

DETAILED DESCRIPTION OF THE INVENTION
[0025] The following is a detailed description of embodiments of the disclosure. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0026] Unless the context requires otherwise, throughout the specification which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense that is as “including, but not limited to.”
[0027] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0028] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable.
[0029] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it is individually recited herein.
[0030] All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0031] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0032] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0033] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0034] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description that follows, and the embodiments described herein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.
[0035] It should also be appreciated that the present invention can be implemented in numerous ways, including as a system, a method or a device. In this specification, these implementations, or any other form that the invention may take, may be referred to as processes. In general, the order of the steps of the disclosed processes may be altered within the scope of the invention.
[0036] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0037] The present invention provides a catalyst for CO combustion promoting additive in a Fluid Catalytic Cracking (FCC) unit, a process for preparing the said catalyst, and a process for promoting the CO combustion in a Fluid Catalytic Cracking (FCC) unit by using the said catalyst along with a spent catalyst.
[0038] An aspect of the present disclosure is to provide a CO combustion promoter additive catalyst comprising: 5 to 50 % w/w of a spent active metal catalyst support of total weight of the catalyst; 50 to 95 % w/w of a high-density large pore alumina of total weight of the catalyst; and 1 to 20 % w/w of a promoter materials of total weight of the catalyst, wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron. Preferably, the catalyst has attrition index in the range of 1 to 5 and apparent bulk density in the range of 0.95 -1.05 g/cc with particle size of 70-90 micron. The CO combustion promoter additive catalysts were shaped into microspheres.
[0039] The active metals are selected from metals of group 8 to group 10. In an embodiment, the active metal is selected from a group consisting of platinum (Pt), palladium (Pd), ruthenium (Ru), iridium (Ir), rhodium (Rh) and combination thereof. Preferably, the active metal is Pt.
[0040] In another embodiment, Pt is present in the range of 100-2000 ppm. Preferably, the total Pt content in the catalyst will be in the range of 200-1000 ppm. More preferably, the total Pt content in the catalyst will be in the range of 500-550 ppm.
[0041] In another embodiment, Pd is present in the range of 100-1500 ppm. Preferably, the total Pd content in the catalyst will be in the range of 200-1000 ppm. More preferably, the total Pd content in the catalyst will be in the range of 500-550 ppm.
[0042] In another embodiment, Ru is present in the range of 100-2000 ppm. Preferably, the total Ru content in the catalyst will be in the range of 200-1000 ppm. More preferably, the total Ru content in the catalyst will be in the range of 500-550 ppm.
[0043] In another embodiment, Ir is present in the range of 10-1000 ppm. Preferably, the total Ir content in the catalyst will be in the range of 200-1000 ppm. More preferably, the total Ir content in the catalyst will be in the range of 500-550 ppm.
[0044] In yet another embodiment, Rh is present in the range of 10-1000 ppm. Preferably, the total Rh content in the catalyst will be in the range of 200-1000 ppm. More preferably, the total Rh content in the catalyst will be in the range of 500-550 ppm.
[0045] In an embodiment, the promoter material is selected from a group consisting of cerium oxide, lanthanum oxide, iron oxide, cobalt oxide, copper oxide, magnesium oxide, titanium oxide, zirconium oxide and combination thereof. The precursor of Ce is cerium nitrate, preferably cerium nitrate hexahydrate.
[0046] In a specific embodiment, the present invention provides a CO combustion promoting additive catalyst in a Fluid Catalytic Cracking (FCC) unit. In an embodiment, the present invention discloses a catalyst from spent Pt catalyst support was mixed with high-density large pore alumina and promoter materials. The composite materials were shaped into microspheres in the range of 20-150 microns using spray drying techniques. The total Pt content on the catalyst will be in the range of 500-550 ppm.
[0047] Another aspect of the present disclosure is to provide a process of preparation of CO combustion promoter additive catalyst comprising: mixing of 5 to 50 % w/w of a spent active metal catalyst support, 50 to 95 % w/w of a high-density binder grade alumina and 1 to 20 % w/w of a promoter materials to form a composite material; reacting the composite material with 0.1 to 10 % w/w of an inorganic acid binder at the temperature 10-50 oC for 2 to 5 hrs to obtain a peptized composite materials; converting the peptized composite material by spray drying to obtain a CO combustion promoter additive catalyst, wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron. Preferably, the catalyst has attrition index in the range of 1 to 5 and apparent bulk density in the range of 0.95 -1.05 g/cc with particle size of 70-90 micron. The CO combustion promoter additive catalysts were shaped into microspheres. Further, the CO combustion promoter additive catalyst of the present disclosure provides CO conversion of 99% at FCCU regenerator condition.
[0048] In a preferred embodiment, the composite material is reacted with inorganic acid binder at a temperature in the range of 10-25 oC for a period in the range of 2-3 hrs.
[0049] In an embodiment, the inorganic acid binder is selected from a group consisting of aluminium nitrate, aluminium chloride, nitric acid, sulphuric acid, hydrochloric acid and combination thereof. The precursor for aluminium nitrate is aluminium nitrate nonahydrate. The precursor for aluminium chloride is aluminiumchlorohydrol (23% Al2O3 content).
[0050] In another embodiment, the spray drying with an inlet temperature in the range of 300 to 600 °C, preferably in the range of 300 to 500 °C and more preferably at 400 °C and an outlet temperature in the range of 150 to 200 °C. Preferably, the temperature in the range of 160 to 180 °C. More preferably, the temperature is 170 °C.
[0051] In yet another embodiment, the spray dried microsphere catalyst of CO combustion promoter additive is calcined at a temperature in the range of 400 to 800 °C for a period in the range of 3 to 6 hrs. Preferably, calcination is carried out at a temperature in the range of 500 to 700 °C for a period in the range of 4 to 5 hrs. More preferably, the calcination is carried out at a temperature in the range of 600 °C for 4 hrs.
[0052] The spent catalyst is having poor metal dispersion (distribution). During the process of making CO combustion promoter additive, the spent catalyst is mixed with inorganic chloride/ nitrate-based compounds along with high density dispersible alumina. The mixed slurry was spray dried at temperature above 150oC. During the decomposition of the inorganic compounds, the metal dispersion increased to 70% and more.
[0053] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
EXAMPLES
[0054] The present invention is further explained in the form of the following examples. However, it is to be understood that the following examples are merely illustrative and are not to be taken as limitations upon the scope of the invention.
Example 1
[0055] 571 grams of hydroxide of Ce-Zr (1:1 mole ratio), and 517 grams of high-density dispersible alumina were added in 1550 grams of DM water to prepare an alumina-cerium-zirconium slurry. The mixture i.e., alumina-cerium-zirconium slurry was transferred to ball mill and milled for 4 hours to reduce the particle size to less than 2 microns. After milling, the said slurry was transferred to a vessel attached with a stirrer. In the said vessel, 30 g for formic acid was added and continued the stirring for 1 hours. Then in the said vessel, 800 grams of Aluminium chlorohydrate solution was added to the slurry and continued the stirring for 1 hour. The final slurry was spray dried at a co-current spray drying operation unit with inlet temperature of 400oC and outlet temperature of 170oC. The spray dried microsphere named as CeO2-ZrO2-alumina support or alumina support were calcined at 600oC for 4 hours. After calcination, 500 ppm of Platinum (Pt) was impregnated on microspheres of CeO2-ZrO2-alumina support by an incipient wetness impregnation method. The said incipient wetness impregnation method includes adding a metal precursor containing solution to a microsphere shaped catalyst support for impregnation. The volume of the solution added is equal to the pore volume of the catalyst support. After impregnation, the catalyst of CO combustion promoter additive was dried at 100oC for 8 hours and calcined at 600oC for 2 hours.
Example 2
[0056] 875 g of high-density dispersible alumina, 263 g of platinum based spent catalyst, 126 g of cerium nitrate hexahydrate were added in 2720 g of DM water under stirring to make a slurry for ball milling. The mixture was transferred to a 3D ball mill and milled for 3 hours to reduce the particle size less than 2 microns. After milling, the slurry was transferred to a vessel attached with a stirrer. In the said vessel, 50 g for formic acid was slowly added and continued the stirring for 1 hour. The final slurry was spray dried at a co-current spray drying operation unit with an inlet temperature of 400oC and an outlet temperature of 170oC to produce a microsphere alumina support. The spray dried microsphere catalyst of CO combustion promoter additive was calcined at 600oC for 4 hours.
Example 3
[0057] 812 g of high-density dispersible alumina, 263 g of platinum based spent catalyst, 126 g of cerium nitrate hexahydrate were added in 2720 g of DM water under stirring to make a slurry for ball milling. The mixture was transferred to a 3D ball mill and milled for 3 hours to reduce the particle size less than 2 microns. After milling, the slurry was transferred to a vessel attached with a stirrer. In the said vessel, 365 g for aluminium nitrate nonahydrate with 365 g of DM water was added slowly and continued the stirring for 1 hour. 20 g 0.1 M nitric acid solution was added to the slurry and continued the stirring for 1 hour. The final slurry was spray dried at a co-current spray drying operation unit with an inlet temperature of 400oC and an outlet temperature of 170oC to produce a microsphere. The spray dried microsphere catalyst of CO combustion promoter additive was calcined at 600oC for 4 hours.
Example 4
[0058] 812 g of high-density dispersible alumina, 263 g of platinum based spent catalyst, 126 g of cerium nitrate hexahydrate were added in 2720 g of DM water under stirring to make a slurry for ball milling. The mixture was transferred to a 3D ball mill and milled for 3 hours to reduce the particle size less than 2 microns. After milling, the slurry was transferred to a vessel attached with a stirrer. In the said vessel, 217 g for aluminiumchlorohydrol (23% Al2O3 content) was added slowly and continued the stirring for 1 hour. 20 g 0.1 M hydrochloric acid solution was added to the slurry and continued the stirring for 1 hour. The final slurry was spray dried at a co-current spray drying operation unit with an inlet temperature of 400oC and an outlet temperature of 170oC to produce a microsphere. The spray dried microsphere catalyst of CO combustion promoter additive was calcined at 600oC for 4 hours.
Example 5
[0059] 812 g of high-density dispersible alumina, 263 g of platinum based spent catalyst, 126 g of cerium nitrate hexahydrate were added in 2720 g of DM water under stirring to make a slurry for ball milling. The mixture was transferred to a 3D ball mill and milled for 3 hours to reduce the particle size less than 2 microns. After milling, the slurry was transferred to a vessel attached with a stirrer. In the said vessel, 217 g for aluminiumchlorohydrol (23% Al2O3 content) was added slowly and continued the stirring for 1 hour. 10 g 0.1 M hydrochloric acid solution and 10 g of 0.1 M nitric acid were added to the slurry and continued the stirring for 1 hour. The final slurry was spray dried at a co-current spray drying operation unit with an inlet temperature of 400oC and an outlet temperature of 170oC to produce a microsphere. The spray dried microsphere catalyst of CO combustion promoter additivewas calcined at 600oC for 4 hours.
Example 6
[0060] The physico-chemical properties and evaluation results of the catalyst were presented in the Table-1. The evaluation was carried out in a short contact time reactor testing (SCT-RT) unit. Wherein, 0.05 g of CO combustion promoter additive or the said CO combustion promoter catalyst was thoroughly mixed with 24.95 g of spent catalyst. The reaction temperature was kept at 650oC and air flow rate was maintained at 300 SCCM. The flue gas generated from the reaction was analyzed through online IR analyzer. The % of CO conversion was calculated from the ratio of difference between the amount of CO in without catalyst/additive and with the said catalyst/additive.

Table 1: Comparative analysis of CO conversion (%) by using the prior art catalyst and present catalyst.
Run Description BASE Example 1
(Prior art) Example 2 (Prior art) Present invention
Example 3 Present invention
Example 4 Present invention
Example 5
Catalyst Description Lab made spent catalyst Spent+ commercial COP Spent + Spent Pt based catalyst as such Spent+ Act. spent catalyst of COP Spent+ Act. spent catalyst of COP Spent+ Act. spent catalyst of COP
Pt content, ppm - 541 540 545 538 540
Pt distribution, % - 64.6 33.7 70.7 77.5 72.5
Pt distribution, % after steam deactivation of 700oC/ 3h - 38.1 12.5 42.2 48.1 44.7
ABD, g/cc - 0.91 0.85 0.99 1.05 1.02
AI (ASTM 5757) - 5.7 18.2 4.0 2.7 3.3
Surface area, m2/g 198 156 160 159 155
Pore volume, m3/g 0.35 0.45 0.48 0.47 0.48
Average pore dia, Å 51 58 60 60 59
Run temperature (oC) 650 650 650 650 650 650
Air flow rate (SCCM) 300 300 300 300 300 300
Fresh catalyst CO conversion (%) - 32.41 16.34 40.82 48.50 45.3
Steam deactivated catalyst CO conversion (%) - 22.8 <15.0 38.4 46.2 44.1

[0061] From the above experimental data, it is evident that the percentage of CO conversion by using CO combustion promoter additive catalyst of the present invention is higher as compared to the prior art catalysts.

ADVANTAGES OF THE PRESENT INVENTION
[0062] A new catalyst additive technology was developed by using a spent Pt-based catalyst. In this process of developing new catalyst, spent Pt catalyst support was mixed with high-density binder grade alumina and promoter materials. The composite materials were shaped into microspheres in the range of 20-150 microns using spray drying techniques. The total Pt content on the catalyst will be in the range of 500-550 ppm.
[0063] In the conventional preparation method, CO combustion promoter additive is prepared by spray drying of alumina to form a microsphere, calcination, and followed by Pt metal impregnation. The final catalyst will be having Pt content of 500-550 ppm Pt.
[0064] Generally, the Pt-based spent catalyst will be sold out on the basis of Pt content for Pt recovery.
[0065] A new technology to use the spent Pt-based catalyst has been developed to make CO combustion promoter additive to build circular economy. The cost of the newly developed CO combustion promoter additive catalyst is cheaper than commercial CO combustion promoter additive.

, Claims:1. A CO combustion promoter additive catalyst comprising:
5 to 50 % w/w of a spent active metal catalyst support of total weight of the catalyst;
50 to 95 % w/w of a high-density large pore alumina of total weight of the catalyst; and
1 to 20 % w/w of a promoter materials of total weight of the catalyst,
wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron.
2. The catalyst as claimed in claim 1, wherein the active metal is selected from a group consisting of platinum (Pt), palladium (Pd), ruthenium (Ru), iridium (Ir), rhodium (Rh) and combination thereof.
3. The catalyst as claimed in claim 2, wherein Pt is present in the range of 100-2000 ppm.
4. The catalyst as claimed in claim 2, wherein Pd is present in the range of 100-1500 ppm.
5. The catalyst as claimed in claim 2, wherein Ru is present in the range of 100-2000 ppm.
6. The catalyst as claimed in claim 2, wherein Ir is present in the range of 10-1000 ppm.
7. The catalyst as claimed in claim 2, wherein Rh is present in the range of 10-1000 ppm.
8. The catalyst as claimed in claim 1, wherein the promoter material is selected from a group consisting of cerium oxide, lanthanum oxide, iron oxide, cobalt oxide, copper oxide, magnesium oxide, titanium oxide, zirconium oxide and combination thereof.
9. A process of preparation of CO combustion promoter additive catalyst comprising:
mixing of 5 to 50 % w/w of a spent active metal catalyst support, 50 to 95 % w/w of a high-density binder grade alumina and 1 to 20 % w/w of a promoter materials to form a composite material;
reacting the composite material with 0.1 to 10 % w/w of an inorganic acid binder at the temperature in the range of 10-50 oC for a period in the range of 2 to 5 hrs to obtain a peptized composite materials;
converting the peptized composite material by spray drying to obtain a CO combustion promoter additive catalyst,
wherein the catalyst has attrition index in the range of 1 to 6 and apparent bulk density in the range of 0.9 -1.05 g/cc with particle size of 20-150 micron.
10. The process as claimed in claim 9, wherein the inorganic acid binder is selected from a group consisting of aluminium nitrate, aluminium chloride, nitric acid, sulphuric acid and combination thereof.
11. The process as claimed in claim 9, wherein the spray drying is carried out at a temperature in the range of 150 to 200 °C.