Catalysts Having an Improved Crush Strength and Methods of Making and Using Same

Abstract

A method of preparing a catalyst comprising selecting a zeolite having a mean particle size of equal to or less than about 6 microns, blending the zeolite with a binder and water to form a paste, shaping the paste into a bound zeolite support, adding a metal to the bound zeolite support to form a metalized catalyst support, and adding at least one halide to the metalized catalyst support to form the catalyst. A catalytic reforming process for converting hydrocarbons to aromatics comprising: contacting a catalyst comprising a silica bound zeolite, a Group VIII metal supported thereby, and at least one halide with a hydrocarbon feed in a reaction zone, wherein the silica bound zeolite comprises a zeolite having a mean particle size of equal to or less than about 6 microns and a median particle size of equal to or less than about 5 microns.

1 . A catalytic reforming process for converting hydrocarbons to aromatics comprising: contacting a catalyst comprising a bound zeolite support, a Group VIII metal supported thereby, and at least one halide with a hydrocarbon feed in a reaction zone under reforming conditions and recovering aromatics from the reaction zone, wherein the bound zeolite support comprises a zeolite having a mean particle size ranging from equal to or greater than 1.4 microns to equal to or less than about 6 microns and a median particle size of equal to or less than about 5 microns. 
     
     
         2 . The catalytic reforming process of  claim 1  wherein the hydrocarbon feed contains less than 100 ppb of sulfur. 
     
     
         3 . The catalytic reforming process of  claim 1  wherein the reaction zone comprises a fixed, moving, or fluidized bed of the catalyst. 
     
     
         4 . The catalytic process of  claim 1  wherein the zeolite comprises a large pore zeolite. 
     
     
         5 . The catalytic process of  claim 1  wherein the zeolite comprises L-zeolite. 
     
     
         6 . The catalytic process of  claim 1  wherein the binder comprises silica. 
     
     
         7 . The catalytic process of  claim 5  wherein the binder comprises silica. 
     
     
         8 . The catalytic process of  claim 6  wherein the catalyst or the bound zeolite support has a weight ratio of zeolite to silica in a range of from about 90:10 to about 70:30. 
     
     
         9 . The catalytic process of  claim 7  wherein the catalyst or the bound zeolite support has a weight ratio of zeolite to silica in a range of from about 90:10 to about 70:30. 
     
     
         10 . The catalytic reforming process of  claim 1  wherein the Group VIII metal comprises platinum and the at least one halide comprises fluoride, chloride, bromide, iodide, or combinations thereof. 
     
     
         11 . The catalytic reforming process of  claim 9  wherein the Group VIII metal comprises platinum and the at least one halide comprises fluoride, chloride, or both. 
     
     
         12 . The catalytic reforming process of  claim 1  wherein the catalyst or the bound zeolite support has a crush strength of equal to or greater than about 3.0 lb/mm. 
     
     
         13 . The catalytic reforming process of  claim 11  wherein the catalyst or the bound zeolite support has a crush strength of equal to or greater than about 3.0 lb/mm. 
     
     
         14 . The catalytic reforming process of  claim 1  wherein the zeolite has a mean particle size ranging from equal to or greater than 1.4 microns to equal to or less than about 5 microns. 
     
     
         15 . The catalytic reforming process of  claim 1  wherein the zeolite has a mean particle size ranging from equal to or greater than 1.4 microns to equal to or less than about 4 microns. 
     
     
         16 . The catalytic reforming process of  claim 1  wherein the zeolite has a mean particle size ranging from equal to or greater than 1.4 microns to equal to or less than about 3 microns. 
     
     
         17 . The catalytic reforming process of  claim 1  wherein the zeolite has a median particle size of equal to or less than about 4 microns. 
     
     
         18 . The catalytic reforming process of  claim 1  wherein the zeolite has a mean particle size ranging from equal to or greater than 1.4 microns to equal to or less than about 5 microns and a median particle size of equal to or less than about 4 microns. 
     
     
         19 . A catalytic reforming process for converting hydrocarbons to aromatics comprising: contacting a silica bound L-zeolite catalyst having a crush strength of equal to or greater than about 3.0 lb/mm with a hydrocarbon feed in a reaction zone under reforming conditions; and recovering aromatics from the reaction zone; wherein the silica bound L-zeolite catalyst further comprises a Group VIII metal, at least one halide and the L-zeolite has a mean particle size ranging from equal to or greater than 1.4 microns to less than or equal to about 6 microns and a median particle size of less than or equal to about 5 microns. 
     
     
         20 . The catalytic reforming process of  claim 19  wherein the Group VIII metal is platinum and the at least one halide is fluoride, chloride or both.