Abstract: The present disclosure provides a process for preparing a reforming catalyst, said process comprising: (a) impregnating at least one support with at least one promoter metal and at least one active metallic component to obtain a second catalytic precursor; (b) contacting the second catalytic precursor with at least one non-metallic component to obtain a third catalytic precursor; (c) coating the third catalytic precursor with at least one silanizing agent to obtain a coated third catalytic precursor; and (d) drying the coated third catalytic precursor to obtain a dried third catalytic precursor followed by calcination of the dried third catalytic precursor to obtain the reforming catalyst. The present disclosure also provides a reforming catalyst. The process for catalytically reforming a hydrocarbon feed stream by using the reforming catalyst is also disclosed herein. Overall, the process of the present disclosure enhances the catalytic performance of the catalyst.
1/We Claim:
1. A process for preparing a reforming catalyst, said process comprising:
(a) impregnating at least one support with at least one promoter metal and at least one active metallic component to obtain a second catalytic precursor;
(b) contacting the second catalytic precursor with at least one non-metallic component to obtain a third catalytic precursor;
(c) coating the third catalytic precursor with at least one silanizing agent to obtain a coated third catalytic precursor; and
(d) drying the coated third catalytic precursor to obtain a dried third catalytic precursor followed by calcination of the dried third catalytic precursor to obtain the reforming catalyst.
2. The process as claimed in claim 1, wherein the at least one support is selected from a group consisting of alpha-aluminium oxide, beta-aluminium oxide, gamma-aluminium oxide, delta-aluminium oxide, theta-aluminium oxide, Si02, silica-alumina (SIRALs), titania, zirconia, zinc oxide, composites of alumina and zeolites, spinel structures, and combinations thereof and is co-impregnated or sequentially impregnated with at least one promoter metal and at least one active metallic component.
3. The process as claimed in claims 1 to 2, wherein impregnating the at least one support is done with an aqueous solution comprising at least one promoter metal to obtain a first catalytic precursor and depositing an aqueous solution comprising at least one active metallic component on the first catalytic precursor to obtain the second catalytic precursor.
4. The process as claimed in claim 1, wherein the at least one promoter metal is selected from a group consisting of tin, rhenium, germanium, iridium, thallium, lead, indium, and combinations thereof and the at least one active metallic component is selected from a group consisting of platinum, palladium, ruthenium, rhodium, osmium, iridium, and combinations thereof.
5. The process as claimed in claim 1, wherein the at least one non-metallic component is selected from a group consisting of chlorine, fluorine, bromine, aqueous HC1, perchloroethylene, and combinations thereof.
6. The process as claimed in claim 1, wherein the at least one silanizing agent is selected from a group consisting of tetramethyl orthosilicate, tetraethyl orthosilicate, tetrapropyl orthosilicate, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, and combinations thereof.
7. The process as claimed in claim 1, wherein the at least one support has a porosity in a range of 2-20 nm.
8. The process as claimed in claim 3, wherein impregnating the at least one support comprises: contacting the aqueous solution comprising the at least one promoter metal to the support is carried out at a pH in a range of 1-4 for a time period in a range of 40-120 minutes at a temperature in a range of 40-60°C at a speed in a range of 100-150 rpm, followed by drying at a temperature in a range of 40-120°C, under a pressure in a range of 30-200 mbar for a time period 20-90 minutes to obtain the first catalytic precursor.
9. The process as claimed in claim 3, wherein depositing the aqueous solution
comprising the at least one active metallic component on the first catalytic precursor
comprises: contacting the aqueous solution comprising the at least one active metallic
component to the first catalytic precursor for a time period in a range of 40-120 minutes
at a temperature in a range of 40-60°C at a speed in a range of 100-150 rpm, followed
by drying at a temperature in a range of 40-120°C, under a pressure in a range of 30-
200 mbar for a time period 20-90 minutes to obtain the second catalytic precursor.
10. The process as claimed in claim 1, wherein contacting the second catalytic
precursor with at least one non-metallic component is carried out at a temperature in
the range of 40-60°C and under pressure of 30-200 mbar followed by drying at a
temperature in a range of 60-120°C for a time period 10-20 hours to obtain the third catalytic precursor.
11. The process as claimed in claim 1, wherein contacting the second catalytic
precursor with at the least one non-metallic component is carried out at a temperature
in a range of 450-600 °C for a time period in a range of 1-8 hours followed by drying
at a temperature in a range of 60-120°C for a time period 10-20 hours to obtain the
third catalytic precursor.
12. The process as claimed in claim 1, wherein the third catalytic precursor is calcined prior to step (c).
13. The process as claimed in claim 1, wherein contacting the third catalyst precursor with the at least one silanizing agent is carried out at a temperature in a range of 20-35°C, under a pressure in a range of 30-200 mbar for a time period in a range of 20-130 minutes to obtain the coated third catalytic precursor.
14. The process as claimed in claim 1, wherein drying of the coated third catalytic precursor is carried out at a temperature in a range of 100-130°C to obtain the dried third catalytic precursor followed by calcination of the dried third catalytic precursor to obtain the reforming catalyst.
15. The process as claimed in claim 1, wherein calcination of the dried third catalytic precursor is carried out at a time period in a range of 3-7 hours at a temperature in a range of 400-600°C
16. A reforming catalyst prepared from the process as claimed in claim 1.
17. A reforming catalyst comprising at least one support selected from a group
consisting of alpha-aluminium oxide, beta-aluminium oxide, gamma-aluminium oxide,
delta-aluminium oxide, theta-aluminium oxide, Si02, silica-alumina (SIRALs), titania,
zirconia, zinc oxide, composites of alumina and zeolites, spinel structures, and
combinations thereof, having a weight percentage in a range of 83-98% with respect to
the reforming catalyst, at least one promoter metal selected from a group consisting of
tin, rhenium, germanium, iridium, thallium, lead, indium, and combinations thereof,
having a weight percentage in a range of 0.05-1% with respect to the reforming catalyst, and at least one active metallic component is selected from a group consisting of platinum, palladium, ruthenium, rhodium, osmium, iridium, and combinations thereof having a weight percentage in a range of 0.05-1% with respect to the reforming catalyst, and at least one non-metallic component selected from a group consisting of chlorine, fluorine, bromine, and combinations thereof having a weight percentage in a range of 0.6-10% with respect to the reforming catalyst, and a layer of silica oxide having a weight percentage in a range of 0.5-5.0%) with respect to the reforming catalyst.
18. The reforming catalyst as claimed in claim 17, wherein the catalyst comprises the
at least one promoter metal to the at least one active metallic component mole ratio is
in the range of 0.2:1-1.7:1.
19. The reforming catalyst as claimed in claim 17, wherein the catalyst further
comprises at least one alkali, alkaline earth metals, at least one transition metal, at least
one rare earth metals, and combinations thereof.
20. The reforming catalyst as claimed in claim 17, wherein the layer of silica oxide has a thickeness in a range of 1-2 nm.
21. A process for catalytically reforming a hydrocarbon feed stream, said process comprising: contacting the hydrocarbon feed stream with the reforming catalyst as claimed in claim 17 to obtain a reformed hydrocarbon stream.
| # | Name | Date |
|---|---|---|
| 1 | 202041006372-FORM 4 [24-08-2023(online)].pdf | 2023-08-24 |
| 1 | 202041006372-STATEMENT OF UNDERTAKING (FORM 3) [13-02-2020(online)].pdf | 2020-02-13 |
| 2 | 202041006372-IntimationOfGrant29-03-2023.pdf | 2023-03-29 |
| 2 | 202041006372-REQUEST FOR EXAMINATION (FORM-18) [13-02-2020(online)].pdf | 2020-02-13 |
| 3 | 202041006372-PatentCertificate29-03-2023.pdf | 2023-03-29 |
| 3 | 202041006372-FORM 18 [13-02-2020(online)].pdf | 2020-02-13 |
| 4 | 202041006372-PETITION UNDER RULE 137 [28-03-2023(online)].pdf | 2023-03-28 |
| 4 | 202041006372-FORM 1 [13-02-2020(online)].pdf | 2020-02-13 |
| 5 | 202041006372-Response to office action [28-03-2023(online)].pdf | 2023-03-28 |
| 5 | 202041006372-DRAWINGS [13-02-2020(online)].pdf | 2020-02-13 |
| 6 | 202041006372-DECLARATION OF INVENTORSHIP (FORM 5) [13-02-2020(online)].pdf | 2020-02-13 |
| 6 | 202041006372-ABSTRACT [17-01-2023(online)].pdf | 2023-01-17 |
| 7 | 202041006372-COMPLETE SPECIFICATION [13-02-2020(online)].pdf | 2020-02-13 |
| 7 | 202041006372-CLAIMS [17-01-2023(online)].pdf | 2023-01-17 |
| 8 | 202041006372-Proof of Right [26-03-2020(online)].pdf | 2020-03-26 |
| 8 | 202041006372-DRAWING [17-01-2023(online)].pdf | 2023-01-17 |
| 9 | 202041006372-FER_SER_REPLY [17-01-2023(online)].pdf | 2023-01-17 |
| 9 | 202041006372-FORM-26 [26-03-2020(online)].pdf | 2020-03-26 |
| 10 | 202041006372-OTHERS [17-01-2023(online)].pdf | 2023-01-17 |
| 10 | 202041006372-Request Letter-Correspondence [08-06-2020(online)].pdf | 2020-06-08 |
| 11 | 202041006372-FER.pdf | 2022-09-14 |
| 11 | 202041006372-Power of Attorney [08-06-2020(online)].pdf | 2020-06-08 |
| 12 | 202041006372-Form 1 (Submitted on date of filing) [08-06-2020(online)].pdf | 2020-06-08 |
| 12 | 202041006372-FORM 3 [06-09-2022(online)].pdf | 2022-09-06 |
| 13 | 202041006372-AMENDED DOCUMENTS [25-01-2022(online)].pdf | 2022-01-25 |
| 13 | 202041006372-CERTIFIED COPIES TRANSMISSION TO IB [08-06-2020(online)].pdf | 2020-06-08 |
| 14 | 202041006372-FORM 13 [25-01-2022(online)].pdf | 2022-01-25 |
| 14 | 202041006372-Request Letter-Correspondence [10-08-2020(online)].pdf | 2020-08-10 |
| 15 | 202041006372-Form 1 (Submitted on date of filing) [10-08-2020(online)].pdf | 2020-08-10 |
| 15 | 202041006372-POA [25-01-2022(online)].pdf | 2022-01-25 |
| 16 | 202041006372-CERTIFIED COPIES TRANSMISSION TO IB [10-08-2020(online)].pdf | 2020-08-10 |
| 16 | 202041006372-FORM 3 [16-12-2020(online)].pdf | 2020-12-16 |
| 17 | 202041006372-Proof of Right [12-08-2020(online)].pdf | 2020-08-12 |
| 18 | 202041006372-FORM 3 [16-12-2020(online)].pdf | 2020-12-16 |
| 18 | 202041006372-CERTIFIED COPIES TRANSMISSION TO IB [10-08-2020(online)].pdf | 2020-08-10 |
| 19 | 202041006372-Form 1 (Submitted on date of filing) [10-08-2020(online)].pdf | 2020-08-10 |
| 19 | 202041006372-POA [25-01-2022(online)].pdf | 2022-01-25 |
| 20 | 202041006372-FORM 13 [25-01-2022(online)].pdf | 2022-01-25 |
| 20 | 202041006372-Request Letter-Correspondence [10-08-2020(online)].pdf | 2020-08-10 |
| 21 | 202041006372-AMENDED DOCUMENTS [25-01-2022(online)].pdf | 2022-01-25 |
| 21 | 202041006372-CERTIFIED COPIES TRANSMISSION TO IB [08-06-2020(online)].pdf | 2020-06-08 |
| 22 | 202041006372-Form 1 (Submitted on date of filing) [08-06-2020(online)].pdf | 2020-06-08 |
| 22 | 202041006372-FORM 3 [06-09-2022(online)].pdf | 2022-09-06 |
| 23 | 202041006372-FER.pdf | 2022-09-14 |
| 23 | 202041006372-Power of Attorney [08-06-2020(online)].pdf | 2020-06-08 |
| 24 | 202041006372-Request Letter-Correspondence [08-06-2020(online)].pdf | 2020-06-08 |
| 24 | 202041006372-OTHERS [17-01-2023(online)].pdf | 2023-01-17 |
| 25 | 202041006372-FER_SER_REPLY [17-01-2023(online)].pdf | 2023-01-17 |
| 25 | 202041006372-FORM-26 [26-03-2020(online)].pdf | 2020-03-26 |
| 26 | 202041006372-DRAWING [17-01-2023(online)].pdf | 2023-01-17 |
| 26 | 202041006372-Proof of Right [26-03-2020(online)].pdf | 2020-03-26 |
| 27 | 202041006372-CLAIMS [17-01-2023(online)].pdf | 2023-01-17 |
| 27 | 202041006372-COMPLETE SPECIFICATION [13-02-2020(online)].pdf | 2020-02-13 |
| 28 | 202041006372-ABSTRACT [17-01-2023(online)].pdf | 2023-01-17 |
| 28 | 202041006372-DECLARATION OF INVENTORSHIP (FORM 5) [13-02-2020(online)].pdf | 2020-02-13 |
| 29 | 202041006372-DRAWINGS [13-02-2020(online)].pdf | 2020-02-13 |
| 29 | 202041006372-Response to office action [28-03-2023(online)].pdf | 2023-03-28 |
| 30 | 202041006372-FORM 1 [13-02-2020(online)].pdf | 2020-02-13 |
| 30 | 202041006372-PETITION UNDER RULE 137 [28-03-2023(online)].pdf | 2023-03-28 |
| 31 | 202041006372-PatentCertificate29-03-2023.pdf | 2023-03-29 |
| 31 | 202041006372-FORM 18 [13-02-2020(online)].pdf | 2020-02-13 |
| 32 | 202041006372-REQUEST FOR EXAMINATION (FORM-18) [13-02-2020(online)].pdf | 2020-02-13 |
| 32 | 202041006372-IntimationOfGrant29-03-2023.pdf | 2023-03-29 |
| 33 | 202041006372-STATEMENT OF UNDERTAKING (FORM 3) [13-02-2020(online)].pdf | 2020-02-13 |
| 33 | 202041006372-FORM 4 [24-08-2023(online)].pdf | 2023-08-24 |
| 1 | 202041006372searchE_13-09-2022.pdf |