Abstract: Platinum-alumina catalysts deactivated by accumulations of sulfur and carbonaceous deposits are treated for removal of sulfur by contacting the deactivated catalyst with a hydrogen-rich gas, water or water precursor, a solution of liquid chlorinated hydrocarbon containing one to eight carbon atoms per molecule, in an oxygen-containing organic compound containing one to eight carbon atoms per molecule prior to contacting the deactivated catalyst with oxygen-containing regeneration gas for removal of coke deposits from the catalyst.

Abstract: Supported multi-metallic platinum-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by (1) contacting the catalyst with oxygen to burn at least a portion of the carbonaceous residues from the catalyst, (2) contacting the carbonaceous residue depleted catalyst with hydrogen at an elevated temperature to convert a substantial portion of the non-platinum component present in the catalyst to its metallic form, (3) contacting the reduced catalyst with dry hydrogen chloride in the absence of oxygen, (4) treatment of the hydrogen chloride treated catalyst with chlorine, and (5) reduction of the chlorine treated catalyst with a reducing agent, such as hydrogen.

Abstract: A process for regenerating, and reactivating, coked noble metal catalysts, especially platinum-containing polymetallic catalysts. A gas is employed for burning coke from the coked catalyst comprising an admixture of from about 0.1 percent to about 10 percent oxygen, and at least about 20 percent carbon dioxide, preferably from about 40 percent to about 99 percent, and more preferably from about 50 percent to about 99 percent carbon dioxide. Regeneration time can be considerably shortened, the frequency of reactor regeneration increased, and compression costs lowered by increasing, or maximizing, the carbon dioxide content of the gas used in the coke burnoff. The higher heat capacity of the carbon dioxide permits the use of a higher oxygen content regeneration gas, particularly during the primary coke burn, as contrasted with the regeneration gas used in conventional catalyst regeneration processes which contain large amounts of nitrogen and flue gas as inert gases.

Abstract: A multiple zone catalytic reforming process in which the C.sub.5 + yield or the catalyst run length in all reaction zones downstream of the first is increased by maintaining less than 1 weight percent coke on the catalyst in the first reaction zone by adjusting the frequency of regeneration or replacement.

Abstract: A hydrocarbon hydroconversion catalyst is regenerated by (a) combustion, (b) chlorination or oxychlorination and (c) treatment with an oxygen-containing gas, and the gas discharged from the regeneration zone, before re-use, is (a) cooled down to below 70.degree. C., (b) subjected to double washing and (c) dried to reduce the water content of the gas to less than 2,500 ppm. An apparatus is also disclosed, certain parts of which are made of a material strongly resistant chlorine and other parts of a less resistant material with respect thereto.

Abstract: The process comprises passing a hydrocarbon stream under reforming conditions through each of the reactors of the unit; when the catalyst in all of the reactors in the unit except the lead reactor has become deactivated to such an extent that the catalyst in all of the reactors other than the lead reactor must be regenerated, discontinuing the flow of the hydrocarbon stream through all of the reactors in said unit other than the lead reactor while continuing to pass the hydrocarbon stream through the lead reactor; regenerating the beds of catalyst in each of the reactors of said unit other than the lead reactor to remove the carbonaceous deposits from the catalyst in such beds and to restore at least partially the activity of the catalyst while continuing to pass the hydrocarbon stream through the lead reactor under reforming conditions; resuming the flow of the hydrocarbon stream through all of the reactors in the unit; and repeating all of the aforesaid steps until the catalyst in the lead reactor has becom

Abstract: A process for the redispersal or dispersal of a platinum group metal in a catalyst comprising an oxidized platinum group metal component and a refactory inorganic support comprises the steps of treating the oxidized catalyst with a stream of inert gas containing a sulphiding agent and reducing the sulphided catalyst in a stream of hydrogen-containing gas at a temperature in the range 200.degree. to 600.degree. C. to give a maximum catalyst temperature of 550.degree. C.

Abstract: In a reforming process wherein a feed naphtha is reformed, with hydrogen, over a reforming catalyst in a process unit, the improvement comprising the addition of infinitesimal, or small amounts of water or hydrogen halide, or both, or substance which can produce in situ water or hydrogen halide, or both, during the reforming operation to displace previously adsorbed sulfur, or to suppress the adsorption of sulfur by the catalyst to control the amount of sulfur added to the catalyst to a minimum effective level. It has been found, in the sequence of regeneration and reactivation, that the ability of a catalyst to operate in a hydrogenolysis mode can be effectively suppressed after the freshly prepared catalyst has been regenerated, and reactivated several times, generally above five times or more, by presulfiding the catalyst by the addition of a minimal amount of sulfur, preferably a maximum of about 0.01 weight percent sulfur on the catalyst.

Abstract: This invention relates to improvements in a process for treating a catalyst, or bed of catalyst, comprised of a composite of an iridium metal or admixture of said metal with other metals, particularly platinum, or admixtures of iridium and platinum with other metals, halogen, and a refractory porous inorganic oxide, notably alumina which has been deactivated by coke deposition thereon, as commonly occurs in a hydroconversion reactions, notably as in upgrading virgin or cracked naphthas in catalytic reforming to produce higher octane products. The time required for reactivation of such catalyst can be shortened by deliberate agglomeration of the iridium, or admixture of iridium and other metal hydrogenation-dehydrogenation components, above about seventy percent, and preferably by essentially complete agglomeration of the iridium, or admixture of iridium and other metal hydrogenation-dehydrogenation components, prior to one or more cycles of sequential reduction/halogenation treatments.

Abstract: Catalytic process for reforming or production of aromatic hydrocarbons at a temperature from 480.degree. to 600.degree. C., wherein a charge of hydrocarbons and hydrogen is passed through two reaction zones, of the moving bed type, whose catalyst continuously flows downwardly and is withdrawn at the bottom thereof, is regenerated, treated with hydrogen and then with a sulfur compound, at respective temperatures lower than the reaction temperature, and thereafter fed back continuously to the reaction zone.

Abstract: A multiple-stage catalytic conversion system in which a hydrocarbonaceous charge stock and hydrogen flow serially through a plurality of catalytic reaction zones in each of which the catalyst particles are movable via gravity-flow. Dissimilar catalyst particles are utilized in the reactor systems which share a common regenerating tower through which the catalyst particles are also downwardly movable via gravity-flow. Dissimilarity of the catalyst particles stems from a difference in activity and stability characteristics. In turn, this difference may be attributed either to physical, or chemical changes between the two composites, or both.

Abstract: A multiple-stage catalytic conversion system in which a hydrocarbonaceous charge stock and hydrogen flow serially through a plurality of catalytic reaction zones in each of which the catalyst particles are downwardly movable via gravity-flow. Dissimilar catalyst particles are utilized in the reactor systems, each of which is integrated with separate regenerating towers through which the catalyst particles are also downwardly movable via gravity-flow. Dissimilarity of the catalysts stems from a difference in activity and stability characteristics. In turn, this difference may be attributed either to physical, or chemical changes between the two composites, or a combination of both.

Abstract: A process for reforming naphtha, with hydrogen, in a cyclic reforming unit which contains a plurality of catalyst-containing on-stream reactors in series, and a catalyst-containing swing reactor manifolded therewith which can be periodically placed in series and substituted for an on-stream reactor while the latter is removed from series for regeneration and reactivation of the catalyst contained therein. In the process, the ability of a catalyst to operate in a hydrogenolysis mode and effect sulfur release can be effectively suppressed after the freshly prepared catalyst has been regenerated, and reactivated several times, generally about five times or more, by the addition thereto of sufficient sulfur to maintain an equilibrium amount of sulfur on the catalyst, preferably a maximum of about 0.01 weight percent sulfur.

Abstract: A process wherein a bed of catalyst comprised of platinum and iridium is contacted and pretreated at elevated temperature in a zone, prior to the introduction and contact of the catalyst with feed, with hydrogen, water, halogen, suitably chlorine or hydrogen chloride, or both, and hydrogen sulfide. The bed of catalyst is treated up to, but not significantly beyond the point of breakthrough of hydrogen sulfide from the bed. In its preferred aspects, a bed of fresh or regenerated, reactivated catalyst is wetted with water and an admixture of hydrogen and halogen, preferably hydrogen chloride, saturated or near-saturated with water, is passed through the catalyst bed until the time that the bed has adsorbed, absorbed or has otherwise taken up these components, and they begin to appear in the exit gas. On breakthrough of the hydrogen chloride, the introduction of the hydrogen sulfide gas is continued to breakthrough from the exit side of the bed.

Abstract: An improved process minimizing the detrimental effects caused by inadvertently contacting a high sulfur, high water-containing hydrocarbon feedstock with a platinum group metal, halogen-containing catalyst is disclosed. The present process involves discontinuing the high sulfur, high water-containing feedstock-catalyst contacting while passing hydrogen over the catalyst. The catalyst halogen concentration is maintained or increased by the addition of halogen component, for example, during the hydrogen pass through. Once the sulfur contamination has been removed from the catalyst, normal hydrocarbon reforming is resumed.

Abstract: Process for regenerating hydrocarbon conversion catalysts, particularly for reforming and isomerization, which comprises superhalogenating the deactivated catalysts, burning the accumulated coke in a controlled manner preferably in a series of steps at different temperatures and oxygen percentages with an oxygen containing gas stream; treating the combusted catalyst with a further gas stream containing oxygen and a halogen (preferably chlorine), and thereafter reducing the catalyst with hydrogen in the practical absence of oxygen.

Abstract: A method for preparing an improved composition of matter whereby a solid catalyst comprising alumina derived from hydrous alumina predominating in alumina trihydrates and at least one platinum group component is used in hydrocarbon conversion service for a period of time to reduce the surface area of said solid catalyst to from about 20% to about 90% of the surface area of the original solid catalyst. This decreased area solid catalyst is treated with at least one metal promoter to produce a treated catalyst having improved properties. An improved method for hydrocarbon conversion using this treated catalyst is also disclosed.

Abstract: Continuous process for converting hydrocarbons in the presence of a granular catalyst including a metal from group VI a, VII a or VIII, deposited on a carrier, comprising passing a charge of hydrocarbons with hydrogen through a series of at least two vertical catalytic zones in which the catalyst bed moves progressively downwardly, withdrawing progressively the catalyst from the bottom of the last catalytic zone, and reintroducing the same, after regeneration, at the top of the first catalytic zone.

Abstract: A continuous method for regenerating deactivated catalyst particles in a regeneration zone through which the particles are downwardly movable by way of gravity-flow. Particles are initially introduced into an upper carbon-burning/halogenation zone wherein they are contacted, in a first section, with a first air stream and a first mixture of steam and a halogen, or halogen-containing compound. Partially regenerated/reconditioned particles are then contacted, in a lower second section, with a second air stream and second mixture of steam and halogen. From this two-sectioned, carbon-burning/halogenation zone, the catalyst particles flow via gravity into a drying zone wherein they are contacted by a substantially dry air stream.

Abstract: A continuous method for regenerating deactivated catalyst particles in a regeneration zone through which the particles are downwardly movable by way of gravity-flow. Particles are initially introduced into an upper carbon-burning/halogenation section wherein they are contacted by a first air stream and a halogen, or halogen-containing compound. Therefrom, the catalyst particles flow into a lower drying section, wherein they are contacted with a dry second air stream.

Abstract: A method for preparing an improved composition of matter whereby a solid catalyst comprising alumina derived from hydrous alumina predominating in alumina trihydrates and at least one platinum group component is used in hydrocarbon conversion service for a period of time to reduce the surface area of said solid catalyst to from about 20% to about 90% of the surface area of the original solid catalyst. This decreased area solid catalyst is treated with at least one metal promoter to produce a treated catalyst having improved properties. An improved method for hydrocarbon conversion using this treated catalyst is also disclosed.

Abstract: In the pressure testing of catalyst-loaded reactors with nitrogen gas at elevated temperatures, it is found that certain types of zeolite catalysts are substantially degraded in activity. The catalysts concerned comprises a Group VIII noble metal in an oxidized state, dispersed on a crystalline hydrogen zeolite, e.g., Y zeolite. It has now been discovered however that if such catalysts are first prereduced with a dilute, non-combustible mixture of nitrogen and hydrogen, damage on subsequent pressure testing with nitrogen is prevented or drastically reduced. Following pressure testing, the catalyst is activated by dehydration in a stream of hydrogen at elevated temperatures and pressures.

Abstract: A process for rejuvenating crystalline aluminosilicayte zeolite-containing catalysts which have become at least partially deactivated through use in a hydrocracking process. Used, deactivated catalysts are treated with ion-containing solutions, particularly those containing hydrogen ions and hydrogen precursors, at a pH of from 3.5 to about 9, such that the alkali metal content of the catalyst is substantially reduced to thereby rejuvenate the catalyst to at least its original fresh activity in a hydrocracking process.

Abstract: Supported iridium-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by contacting the residue-containing catalyst, prior to contact with oxygen at elevated temperature, with a chlorine-containing reagent to increase the catalyst chlorine content to a level in the range of from about 0.7 to 2.0 wt. %, based on anhydrous, carbonaceous residue-free catalyst, and thereafter contacting the catalyst with a substantially sulfur-free gaseous mixture containing oxygen at a temperature varying from about 775.degree. to 900.degree. F. for a time sufficient to burn at least a portion of the carbonaceous residue from the catalyst while maintaining at least 0.7 wt. % chlorine on the catalyst during contact with said gaseous mixture.

Abstract: An improved process for removing sulfur from a bed of deactivated and sulfur-contaminated platinum-alumina catalyst in a reactor in a hydrocarbon conversion system having a vessel associated with the reactor, including the steps of: treating the catalyst with an oxygen-containing gas to burn off deactivating substances and oxidize sulfur in the catalyst bed; passing a hydrogen-containing gas through the catalyst bed to remove sulfur from the bed and form gaseous sulfur compounds; and removing the resulting sulfur-containing gas from the reactor and the conversion system by a path that excludes the sulfur-containing gas from contact with the associated vessel.

Abstract: A process for reactivating or regenerating catalysts which have become inactivated due to accumulation of carbon deposits or sulfur-containing carbon deposits on the catalyst surface during the course of use in catalytically refining various petroleum oils is described.

Abstract: Hydrocarbon materials are converted to useful products by contacting the same at elevated temperatures with a catalyst comprising a refractory support in association with greater than 0.1 wt. % iridium, and 0.1 - 1.0 wt. % of at least one additional metal. The iridium and additional catalyst metal, preferably platinum, are present on the surface of the support preferably as highly dispersed polymetallic clusters with metal surface areas of at least 200 square meters per gram of metal. The catalyst is particularly effective for promoting naphtha reforming operations.

Abstract: A coke-deactivated acidic bimetallic hydrocarbon conversion catalyst, which is a combination of catalytically effective amounts of a platinum or palladium component, an iridium component and a halogen component with a porous carrier material, which is free of labile sulfur and which has been deactivated by a deposition of carbonaceous material thereon during a previous contacting with a hydrocarbon charge stock at hydrocarbon conversion conditions, is regenerated by the sequential steps of: (1) burning carbon from the deactivated catalyst at a relatively low temperature with a substantially sulfur-free first gaseous mixture containing relatively small amounts of oxygen, H.sub.2 O and HCl; (2) treating the resulting catalyst at a relatively high temperature with a second gaseous mixture containing O.sub.2, H.sub.

Abstract: The instant invention relates to a process for activating iridium-containing catalysts, said catalysts being inactive because of the presence of the iridium as large crystallites of low activity, and which comprises the step of contacting said catalyst with a halogen-containing gas in the presence of from 0.01 to 10% by volume oxygen, at a temperature of at least 300.degree.C. for a time sufficient to redisperse said large crystallites to crystallites having a substantially smaller particle size. Preferably, the catalyst is a reforming catalyst comprising iridium supported on alumina. In the most preferred embodiment of the instant invention an iridium: platinum on alumina catalyst, which has become deactivated by use in a reforming process wherein carbonaceous materials have deposited on the surface of the catalyst, is regenerated by (1) burning off said carbonaceous deposits by contacting said catalyst with oxygen at a temperature of at least 300.degree.C.

Abstract: A continuous method for regenerating deactivated catalyst particles in a regeneration zone through which the particles are downwardly movable via gravity-flow. Particles initially are introduced into a carbon-burning section, flow therefrom into a halogenation section and then into a drying section from which they are removed from the regeneration zone.

Abstract: This invention relates to the treatment of Group VIII, noble metal, catalysts, wherein said noble metal is present on a refractory support and where said noble metal exists as large agglomerated crystallites, e.g., greater than 50 A, which comprises contacting said catalyst with fluorine at a temperature and for a time sufficient to disperse said crystallites to crystallites having substantially smaller particle size. The noble metals which may be dispersed by this process include Pt, Pd, Ru, Ir and Rh. This invention is especially suitable for redispersing iridium-containing catalysts.

Abstract: Oxidation catalysts containing platinum or other noble metal components used in automobile exhaust emission control are reactivated, after thermal deactivation, by subjecting the catalyst to a halogen-containing gas at a temperature of from 500.degree.F. to about 1000.degree.F. The passing of carbonyl halide or a mixture of carbon monoxide and halogen, alone or in a carrier gas, over the catalyst reduces the CO-oxidation and hydrocarbon-oxidation temperature to almost that of fresh catalyst. Carbonyl chloride or the carbon monoxide-chlorine mixture is preferred. This treatment may also be used in the reactivation of noble metal-containing reforming catalysts.

Abstract: Supported iridium-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by (1) contacting the catalyst with oxygen to burn at least a portion of the carbonaceous residues from the catalyst, (2) contacting the carbonaceous residue-depleted catalyst with an elemental halogen-containing gas at a temperature of less than about 850.degree.F., (3) contacting the treated catalyst with hydrogen at elevated temperatures to reduce a substantial portion of the iridium present in the catalyst to its metallic form, and (4) contacting the catalyst from step (3) with an elemental halogen-containing gas at a temperature of at least about 850.degree.F. Steps (3) and (4) may be repeated, in sequence, at least one additional time to redisperse the iridium catalyst component to a highly active, high surface area state.

Abstract: In a process for redispersion of the iridium agglomerates (irridium and/or iridium oxide) of a deactivated iridium-containing catalyst, especially a platinum-iridium catalyst, in ferrous metal equipment, wherein the agglomerated iridium, or agglomerated platinum and iridium, is redispersed and the catalyst reactivated by sequential prereduction-halogen treatments, the improvement comprising adding and maintaining small amounts of water with the halogen to suppress ferrous metal corrosion and catalyst contamination during the required treatment with halogen.

Abstract: Supported iridium-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by (1) contacting the catalyst in a reaction zone with oxygen to burn at least a portion of the carbonaceous residues from the catalyst, (2) contacting the carbonaceous residuedepleted catalyst in a reaction zone with hydrogen at an elevated temperature to reduce a substantial portion of the iridium present on the catalyst to its metallic form, (3) contacting the treated catalyst in a reaction zone with an elemental halogen-containing gas in a reaction zone with an elemental halogen-containing gas at a temperature greater than about 850.degree.F.

Abstract: Supported iridium-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by contacting the catalyst, prior to contact with oxygen at elevated temperature, with a chlorine-containing reagent to increase the catalyst chlorine content to at least 1.0 wt. %, based on anhydrous catalyst, and thereafter contacting the catalyst with a gaseous mixture containing oxygen, a chlorine containing reagent, and water at a temperature of about 750.degree. to 1000.degree.F. for a time sufficient to burn at least a portion of the carbonaceous residues from the catalyst.

Abstract: A process for reactivating a catalyst comprising iridium, or iridium as a component of a multimetallic combination, particularly one which includes both iridium and platinum admixed one with the other, and with other metal components, and halogen, composited with a refractory porous inorganic oxide, previously inactivated by coke deposition thereon, possible loss of halogen content and agglomeration of the metal, or metals, or oxides thereof, such as occurs in a reforming process wherein such catalyst is contacted with a hydrocarbon feed at reforming conditions, and subsequently regenerated by burning accumulated coke deposits therefrom. A bed of the coke-depleted catalyst, wherein up to about 70 weight percent of the iridium of the catalyst is present as agglomerates of crystallite sizes greater than about 50A, is contacted in a plurality of cycles, an initial cycle of which includes, in sequence, (i) reduction of the coke-depleted catalyst, as by contact thereof with a stream of reducing gas, e.g.

Abstract: Supported iridium-containing hydrocarbon conversion catalysts which are at least partially deactivated due to the deposition of carbonaceous residues thereon during contact with hydrocarbons are regenerated by (1) contacting the catalyst with oxygen to burn at least a portion of the carbonaceous residues from the catalyst, (2) contacting the carbonaceous residue-depleted catalyst with hydrogen at an elevated temperature to convert a substantial portion of the iridium present in the catalyst to its metallic form, (3) contacting the reduced catalyst with an elemental halogen-containing gas at a temperature of at least about 300.degree.C., and (4) repeating steps (2) and (3), in sequence, at least one additional time to thereby redisperse the iridium catalyst component to a highly active, high surface area state.

Abstract: A deactivated hydrocarbon conversion catalyst, which is a combination of a platinum group component, a rhenium component, a halogen component, and a sulfur component with a porous carrier material and which has been deactivated by deposition of carbonaceous material thereon during a previous contacting with a hydrocarbon charge stock at hydrocarbon conversion conditions, is regenerated by the sequential steps of: (1) stripping the sulfur therefrom by contacting with a first gaseous mixture comprising hydrogen, H.sub.2 O, and HCl; (2) purging hydrogen from contact with the catalyst with an inert gas stream; (3) burning carbon from the resulting catalyst at a relatively low temperature and a relatively high pressure with a substantially sulfur-free second gaseous mixture containing relatively small amounts of oxygen, H.sub.