This invention relates to a catalytic reforming process. Catalytic reforming of naphtha feed stocks has long been known in the petroleum industry, s naphtha feeds contain large amounts of naphthenes and paraffins and consequently have low octane numbers. Fy means of various'- hydrocarbon conversion reactions, catalytic reforming has improved the octane number of naphtha feed stocks. Some of the more .important conversion reactions that take place during catalytic reforming are dehydrogenation of naphthenes to aromatics, dehydrocyclization of paraffins to naphthenes and aromatics and isomerization of normal paraffins to isoparaffins. A less desirable reaction which also occurs during reforming is the hydrocracking of paraffins, naphthenes and dealkylation of alkylaromatics to gaseous hydrocarbons such as methane and ethane. The above reforming reactions have previously been catalyzed by catalysts comprising porous supports, such as alumina, that have dehydrogenation promoting metal components impregnated or admixed with the support. Platinum on alumina and, more recently, multi etallics, including bimetallics, such as platinum and rhenium on alumina, are examples of these catalysts. Representative multi etallic reforming catalysts are described in U.S. Patent Nos.

2,848,377, 3,415,737 and 3,953,368, among others.

Other known reforming catalysts are based on zeolites containing a noble metal component such as platinum. U.S. Patent No. 4,582,815 describes a method for preparing a silica-bound zeolite catalyst composition of improved crush strength relative to other silica-rich extrudates. According to this method, a mixture of silica and a zeolite such as ZSM-4 (Omega), ZS -5, ZSM-11, ZSM-12, ZS -23, ZSM-35, ZSM-38, ZSM-48, Eeta, X, Y, L, ferrierite,. mordenite, dachiardite, clinoptilolite, offretite, erionite,

g elinite or chabazite is mixed with water and an alkali metal base such as sodium hydroxide or a basic salt such as an alkali-metal carbonate, borate, phosphate or silicate as an extrusion aid followed by mulling, extruding and subsequently drying the extrudate. It is thought that substitution of alkali metal for hydrogen in the silanol groups on the surfaces of siliceous materials such as the foregoing zeolites is responsible for their improved crush strength. The resulting extrudate is said to possess superior crush strength and sufficient integrity to withstand treatment with acids so that it is possible to steam, acid extract or calcine them. To avoid trapping the alkali metal of the extrusion aid in the extrudate, the alkali metal is ordinarily removed by exchange under acidic conditions using dilute nitric acid in 1 ammonium nitrate solution. The silica-bound zeolite catalyst of U.S. Patent No. 4,582,815 is indicated to be useful in a variety of hydrocarbon conversions including reforming.

It has now been discovered that zeolites which are known to be useful in catalytic reforming operations, i.e., intermediate and large pore zeolites, when bound with a low acidity refracto../ oxide binder material and containing at least one metal species selected from the platinum group metals and employed in the reforming of naphtha range materials, show improved selectivity for the conversion of paraffins to aromatics compared to known and conventional bimetallic reforming catalysts such as platinum-rhenium on alumina.

Thus, in accordance with the present invention, a catalytic reforming process is provided which comprises contacting a naphtha range feed with a low acidity extrudate comprising a zeolite bound with a low acidity refractory oxide under reforming conditions to provide a reaction product of increased aromatic content, said extrudate having been prepared with at least an extrusion-facilitating amount of a low acidity refractory oxide in colloidal form and containing at least one metal species selected from the platinum group metals.

Due to the inherently low acidity of the refractory oxide binder, the catalyst composition employed in the foregoing process minimizes non-selective hydrocracking of the naphthenes to gaseous hydrocarbons such as methane and ethane while enhancing dehydrocyclization of paraffins to high-octane aromatics, a significant advantage compared to conventional reforming processes employing the relatively acidic alumina-supported bimetallic catalysts such as platinum-rhenium.

The zeolite component of the catalyst composition used in the reforming process of this invention is selected from those of the intermediate and large pore variety. Preferably the zeolite has a Constraint Index (see U.S. Patent No. 4016218) not more than 12.

Suitable intermediate pore size zeolites include ZSM-5, ZSM-11, ZSM-23, ZSM-35 and ZSM-57. ZSM-5 is described in U.S. Patent Reissue No. 29,948 (of original U.S. Patent No. 3,702,886),

ZSM-11 is described in U.S. Patent No. 3,709,979, ZSM-23 is described in U.S. Patent No. 4,076,842, ZSM-35 is described in U.S.

Patent No. 4,016,245, and ZSM-57 is described in FP-A-174121. Such zeolites typically have a Constrai.it Index of 1 - 12. Representative of suitable large pore zeolites are ZSM-3 ,

ZSM-4, ZSM-12, ZSM-20, zeolite beta, zeolite L, zeolite X, zeolite Y, RFY, USY, RE-USY, mordenite, LZ-210, LZ-210-M, LZ-210-T, LZ-210-A, and mixtures thereof. ZSM-3 is described in U.S. Patent No. 3,415,736. ZSM-4 is described in U.K. Patent Specification No. 1,117,568. ZSM-12 is described in U.S. Patent No. 3,832,449.

ZSM-20 is described in U.S. Patent No. 3,972,983. Zeolite beta is described in U.S. Patent Reissue No. 28,341 (of original U.S. Patent No. 3,308,069). Zeolite L is described in U.S. Patent No. 3,216,789. Zeolite X is described in U.S. Patent No. 2,882,244. Zeolite Y is described in U.S. Patent No. 3,130,007. LZ-210,

LZ-210M, LZ-210-T, LZ-210-A and mixtures thereof are described in U.S. Patent No. 4,534,853. Such large pore zeolites typically have a Constraint Index below 1.

The zeolites used herein can contain one or more framework elements other than , or in addition to, aluminum, e .g . , the borosilicate zeoli tes , and/ or can be modified to alter their as- synthesized framework silica -alumina ratios . Py way of illustrating the latter, ultrastable zeolite Y ("USY") , prepared by any of the known and conventional methods , ^* e .g. , those disclosed in U. S. Patent Nos . 3,293 , 19.2; 5 ,375 ,065 ; 3 ,402,996; 3 ,449 ,070; and 3,595,611 and in Scherzer, Journal of Catalysis, 54, 285-288 (1978) , is advantageously employed in the reforming process of this invention. .

Also included among the useful zeolites are materials of similar structure or behavior, e.g. , crystalline metallophosphates such as those described in U.S. Patent No . 4 ,440 ,871.

The binder material can be selected from among any of the low acidity refractory oxides of elements of Groups IVA and IVB of the Periodic Table of the Elements . Particularly useful are the oxides of silicon , germanium, titanium and zirconium with silica being preferred. Combinations of such oxides with other oxides are also us ful provided that at least about 40 weight percent, and preferably at least 50 weight percent , of the total oxide is one or a combination of the aforesaid Group IVA and/ or Group IVB metal oxides . Thus , mixtures of oxides which can be used to provide the binder material herein include silica-alumina, silica-magnesia , silica-zirconia , silica-thoria , silica-beryllia , silica-titania , titania-zirconia, silica-alumina-thoria, silica-alumina- zirconia , silica-alumina-magnesia and silica-magnesia-zirconia . In preparing the low acidity refractory oxide-bound - intermediate and/or large pore zeolite catalyst employed herein , it is important that the refractory oxide binder contains at least ah extrusion-facilitating amount of the same and/or a different low acidity refractory oxide in colloidal form. The colloidal Group IVA and or Group IVB metal oxide component of the binder can represent anywhere from about 1 to 90 weight percent or more of the total

binder. For example, in the case of silica, amounts of colloidal silica ranging from 2 to 60 weight percent of the- total binder generally provide acceptable results.

The relative proportions of zeolite and low acidity refractory oxide binder on an anhydrous basis can vary widely with the zeolite content ranging from between 1 to 99 weight percent, and more usually in the range of from,.5 to 80 weight percent, of the dry composite.

Extrudates used in the present process typically have a crush strength of 7 to 34 N/mm ⁽ 40 to 192 lb/linear inch) and a high porosity, i.e., between 0.43 and 1 cc/gram (measured by mercury porosimeter and helium absorption).

To achieve a low acidity refractory oxide-bound zeolite catalyst employed herein, it is preferred that the acid activity, as measured by alpha activity of the zeolite, be controlled, i.e., reduced to minimize the amount of hydrocra eking, thereby increasing the gasoline yield. The alpha value, or alpha activity, is a measure of normal hexane cracking conversion relative to a silica-alumina cracking catalyst. The alpha test is described in a Letter to the Editor entitled "Superactive Crystalline

Aluminosilicate Hydrocarbon Cracking Catalyst" by P.P. eisz and J.N. Miale, Journal of Catalysis, Vol. 4, No. 4, August 1965, pages 527-529. Typically, the zeolite employed in the present process is selected so as to have an alpha value less than 50, preferably less than 20 and most preferably less than 5.

Low acidity zeolites can be synthesized directly at high ratios, with or without addition of alumina. Alternately, the acid activity of the zeolite can be reduced either before or after binding with a low acidity refractory oxide. The ^' reduction in acid activity of the catalyst can be achieved by any of the techniques or combinations thereof known to those skilled in the art. The aforementioned techniques include, for example, high temperature calcination as described in U.S. Patent No. 3,965,209;

exposure to steam at high temperature as described in U. S. Patent No . 4 ,016 , 218 ; and exchange with a suitable alkali metal as described in U.S. patent No. 4 ,634 ,518.

The expression "platinum group metals" includes , for example , platinum, palladium , osmium, iridiu , ruthenium , or rhodium and mixtures thereof . To these platinum group metals can also be added non-platinum group metals such as tin, indium and metals of Group VIIB such as rhenium. These metals can be readily introduced into the zeolite employing a variety of known and conventional techniques , e .g. , ion-exchange as disclosed in a number of patents including U. S. Patent Nos . 3 , 140,249; 3 , 140,251; and 3 , 140 ,253. As is recognized by those skilled in the art, it may be necessary to carry out ion-exchange within controlled pH parameters , e.g. , between 4 to 9 , to avoid irreversible loss of catalyst and/or binder integrity. The metals in the form of their oxides or salts can also be added to the low acidity refractory oxide during the mulling step with pH adjustment , if necessary, to stabilize the colloidal oxide component of the mixture.

The naphtha charge stocks which can be reformed in accordance with the process of this invention include typical reforming stocks , namely virgin naphthas , cracked naphthas , partially reformed naphthas and hydrotre ted naphthas . The charge stocks will normally be composed of - - C, ₂ hydrocarbon mixtures . The reforming process of the invention generally takes place at HSV of 0.5 to 50, preferably 1 to 20 , a temperature of 427 - 566°C (800° to 1050°F) , a pressure of 100 - 3550 kPa (0 to 500 psig) and a ratio of hydrogen to hydrocarbons of 1 - 10. The process can be carried out in a single reactor or in a series of reactors at least one of which contains the low acidity refractory oxide-bound zeolite extrudate described herein.

The invention will now be more particularly described with reference to the Examples and the accompanying drawings, in which:

Figs . 1 and 2 are graphical representations of experimental data showing , respectively, the selectivity and the stabil ity of a platinum-conta ining silica-bound USY catalyst employed in the reforming operation of Example 2 compared with that of a conventional alumina-supported platinum-rhenium catalyst employed under substantially s imilar reforming conditions .

EXAMPLE 1 .

This example illustrates the preparation of a s il ica-bound USY catalyst . -

Sixty-five weight percent of USY zeol ite (Z-14 US as supplied by W. R. Grace) in the form of a powder was mixed wi th 35 weight percent (dry basis ) of sil ica consisting of a mixture of 26.2 wei ght percent amorphous precipi tated s ilica (PPG Industries HiSi l 233 EP) and 8 .8 weight percent colloidal silica (Ludox, FS-30) . A homogeneous mi x was obtained by mull ing . The moisture content of the mix was adjusted to 42-47 weight percent with deionized water .

After additional mull ing , the resulting paste was extruded to yield

0.16 mm diameter extrudates . The extrudates were sul iequentlv dried at 121 °C (250 °F) , typically for 18 hours in air , and then calcined at 540°C (1000°F) for 3 hours in flowing air . In this and al l subsequent calcining operations referred to herein unless otherwise indicated, air flow rates of about 5 v/v/min and heating rates of 3 °C/min (5 °F/min) were used . After ammonium exchanging three times at ambient temperature for 1 hour wάth 5 ml/g circulating IN ammonium nitrate , the extrudate was washed and dried at 121°C (250°F) in air and subsequently calcined at 540°C (1000°F) for 3 hours in flowing air. The s ilica-bound USY composition was then steamed for 10 hours at 650°C (1200°F) in 1 atm steam to dealuminate the zeolite and to further reduce the alpha activity to 6. To remove residual sodium and non-framework alumina resulting from steaming , the extrudate was exchanged twice at ambient temperature for 1 hr with 5 l/g circulating IN HN0 ₃ solution, dried at 121°C

(250 °F) and calcined for 3 hrs at 540°C (I000 °F) , the result being an alpha value of 38. Following steaming of the silica-USY composite at 650 °C (1200 °F) for 10 hours in 1 atm steam and exchanging twice at ambient temperature with 5 ml/g circulating IN HN0 ₃ solution , drying at 121°C (250°F) and calcining at 540°C

(1000°F) for 3 hrs, the silica-USY composited catalyst possessed an alpha activity of 3. The prqperties of the as-received USY zeolite - and the physical properties of the silica-USY catalyst resulting from these operations , identified as Catalyst A, are set forth in Tables 1 and. 2, respectively:

Table 1

Properties of USY Zeolite

Alumina, wt% 22.2

Silica, wt% 68.5

Si0 ₂ /AI ₂ θ3 (Molar) 5.3

Na, wt% 2.6

Surface Area , mVg 594

Crystallinity, I 110

Unit Cell Size, Angstroms 24.52

Sorption H ₂ 0 (P=12 torr (I600Pa) ) , wt% 27 .1

Sorption CyC ₆ (P=40 torr (5330Pa)) , wt% 18.1

Sorption nC ₆ (P=40 torr (5330Pa)) , wt% 17.1

Platinum was introduced into the silica-bound zeolite catalyst composition via excess solution ion exchange for 4 hrs with Pt(NH ₃ ) ₄ Cl ₂ /NH ₄ 0H solution while maintaining the pH of the exchange solution at 9. Following washing and drying at 121°C (250°F) , the catalyst was calcined at 350°C (660°F) for 3 hrs at a heating rate of l°C/min (2°F/min) to convert the platinum to the oxide.

The physical properties of the base composition prior to platinum addition (Catalyst A) and those of the platinum loaded s ilica-bound USY catalyst composition (Catalyst F) are set forth in Table 2 as follows:

Table 2

Catalyst P of Example 1 and a conventional reforming catalyst composition (Catalyst C: 0.6 wt combined platinum and rhenium on alumina) were evaluated for their effectiveness in a reforming operation carried out under the following conditions:

Pressure: 100 psig (790 kPa ) Temperacure: 950°F (510°C) HSV: 3 H2/HC ratio: 3/1

The catalysts were heated to 510°C (950°F) in flowing hydrogen and , once the des ired temperature and gas flows were achieved , the feedstock was introduced. For the initial comparisons , n-hexane was used as the feed and the products were analyzed on- line by gas chroma tography. The results set forth in Table 3 below show the improved aromatics selectivity of Catalyst B compared to conventional Catalyst C. While the two catalysts gave comparable C, -C ₄ gas yields , the use of Catalyst E resulted in significantly higher aromatics yields .

Table 3

The selectivity results listed in Table 3 are defined as the weight percent aromatics in the product divided by the sum of the aromatics plus C, through C, produced. The selectivity of Catalyst P is graphically compared to that of Catalyst C in Figure 1. Catalyst P maintained its high selectivity for the duration of the approximately 100 hrs evaluation . Furthermore, a comparison of aromatics yield as a function of total time on-strea , given in Figure 2 , clearly indicates greater stability for Catalyst B.