Low metal loaded, catalyst compositions including acidic mixed metal oxide as support
The invention provides a catalyst composition composed of a support portion and a catalyst portion. The support portion includes an acidic mixed metal oxide including a transitional alumina and a second metal oxide. The transitional alumina can comprise delta or theta alumina, in combination with other transitional phases, or an alpha or gamma alumina. The second metal oxide has a weight percentage that is less than the weight percentage of alumina. The catalyst portion is 25 weight percent or less of the catalyst composition and is composed of nickel and rhenium. The catalyst portion includes nickel in an amount in the range of 2 to 20 weight percent, based upon total catalyst composition weight, and there is no boron in the catalyst portion.
1. A catalyst composition comprising:
(a) a support portion comprising an acidic mixed metal oxide comprising a transitional alumina and a second metal oxide, wherein the second metal oxide has a weight percentage that is less than the weight percentage of alumina; and
(b) a catalyst portion comprising nickel and rhenium, wherein:
the catalyst portion is deposited as a shell structure on the support portion in a manner effective to provide a localized concentration of nickel and rhenium on an outer surface of the catalyst composition,
the catalyst portion is 25 weight percent or less of the catalyst composition,
the catalyst portion comprises nickel in an amount in the range of 2 to 20 weight percent, based upon total catalyst composition weight, and
wherein boron constitutes less than 1 weight percent of the catalyst portion.
2. The catalyst composition according to claim 1 , wherein the transitional alumina comprises delta alumina.
3. The catalyst composition according to claim 2 , wherein the transitional alumina further comprises one or more of gamma, theta or alpha alumina.
4. The catalyst composition according to claim 1 , wherein the transitional alumina comprises theta alumina.
5. The catalyst composition according to claim 4 , wherein the transitional alumina may optionally further comprise one or more of gamma or alpha alumina.
6. The catalyst composition according to claim 1 , wherein the second metal oxide comprises at least one oxide selected from the group consisting of an oxide of silicon, lanthanum, magnesium, zirconium, boron, titanium, niobium, tungsten and cerium.
7. The catalyst composition according to claim 6 , wherein the second metal oxide comprises silicon.
8. The catalyst composition according to claim 1 , wherein the support portion comprises the second metal oxide in an amount in the range of 5 weight percent to less than 50 weight percent, based upon the weight of the support portion.
9. The catalyst composition according to claim 1 , wherein the support portion is an extrudate having an elongate morphology diameter of ⅛ inches (3.175 mm) or less.
10. The catalyst composition according to claim 1 , wherein the support portion is a sphere having a diameter of 3 mm or less.
11. The catalyst composition according to claim 1 , wherein the support portion is a trilobe having a diameter of ⅛ inches (3.175 mm) or less.
12. The catalyst composition according to claim 1 , wherein the catalyst portion is 20 weight percent or less of the catalyst composition.
13. The catalyst composition according to claim 1 , wherein the nickel and rhenium are present in the catalyst portion in a weight ratio in the range of 3:1 to 14:1.
14. The catalyst composition according to claim 1 , wherein the composition further comprises a selectivity promoter that is present at a promoter/nickel weight ratio of 0.5:1 or less.
15. The catalyst composition according to claim 1 , wherein the catalyst composition is an extrudate with an elongate morphology and has a diameter in the range from 0.8 mm to 3.1 mm.
16. The catalyst composition according to claim 1 , wherein there is no boron in the catalyst portion.