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Naphtha Catalytic Upgrading for Production of Environmentally - Friendly

Gasoline

Article  in  Petroleum and Coal · June 2016

DOI: 10.4172/2157-7048.1000303

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Petroleum and Coal
Article Open Access

NAPHTHA CATALYTIC UPGRADING FOR PRODUCTION OF ENVIRONMENTALLY- FRIENDLY

GASOLINE

Saba A. Gheni 1*, Aysar T. Jarullah2, Amer D.Z.Albdiri 3, Ghassan H. Abdul Razak2
1 Chemical Engineering Department, University of Missouri Colombia, USA. [email protected]
2 College of Engineering, Tikrit University, Iraq
3 College of Engineering, Al-Qadisiyah University, Iraq

Received May 24, 2016; Accepted June 23, 2016

Abstract
The recent economic climate, impact of government regulation, and new market trends have
impacted the catalyst designers to improve the performance of catalyst. To achieve this goal, a
series of experiments were conducted to focus on the influence of Ga and Re addition on the
catalytic activity of Pt–Re/Al2O3 naphtha reforming catalysts. To supported γ-Al2O3 the Ga-Re-Pt
prepare by using incipient wetness impregnation method. Many characterization tests are used
such as scanning electron microscopy, temperature programmed desorption, X-ray diffraction and
BET surface area. The liquid product yield tested by PONA method. In this study the benzene
content is used as main performance criteria throughout many experiments performed at different
liquid hourly space velocity, hydrogen/hydrocarbon ratios and different operating temperature.
According to the catalyst characterization tests the co-impregnation method showed good result
in term of performance and properties. The catalyst exhibited good liquid product distribution and
significant minimization of benzene content.
Keywords: Gallium; octane number; catalyst; naphtha reforming.

1. Introduction
Now-a-days industries are searching for alternatives such as bio-based composites to
contribute in reducing global warming by reducing the use of petroleum based products. Bio-
composites are composite materials that are made from natural fibers and matrix. Gasoline is
subject to more demands and expectations than ever before. Regulatory agencies around the
world are increasingly exercising their powers to regulate motor gasoline characteristics and
mandate the use of deposit control additives. The main goals are to increase octane number
without the addition of aromatics and to reduce emissions. The quality of gasolines can vary
widely, depending on the crude source, sulfur content and octane number. It is desired to
improve octane number, which is a measure of resistance to impregnation, by using organic
additives.
Trimm et al. [1] have reported on the use of a Pt/CeO2 and a Pt-Ni commercial catalyst for
the autothermal reforming of gasoline. Use of commercial gasoline resulted in heavy coking
of the commercial catalyst and was abandoned in favor of analogous mixtures. The reactor
was arranged to have an oxidation section containing the Pt/CeO2 catalyst and a reforming
section containing the Pt-Ni commercial catalyst, separated by a quartz wool plug. Villegas et
al. [2] used a Pt/CeO2-ZrO2 catalyst for isooctane autothermal reforming. Villegas et al. [2]
concluded that catalyst worked well at a steam to carbon ratio of 2 and an oxygen to carbon
ratio of 1. Deactivation was observed under pure partial oxidation conditions, although carbon
deposition was light at 23 mg C/g catalyst. Pino et al. [3] have reported on a Ce(Pt)O2 catalyst
for partial oxidation of methane at an oxygen to carbon ratio of 1.0. Increasing Pt loading

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from 0.5 wt% to 2.0 wt% increased the methane conversion, which approached equilibrium.
The catalyst was stable over 100 hours of operation, evidencing no carbon deposition [3].
Due to the vast growth of environmental regulation in various countries, many organizations
give massive attention towards health and pollutants, in different area, air, water, soil, fuel.
These organizations, like word bank and EPA (Environmental Protection Agency) legalize many
rules, and these rules become worldwide accepted. Refinery processes for the upgrading of
gasolines aim at the conversion of other hydrocarbons into aromatics and iso-paraffins.
Benzene has long been known to be a human carcinogen and has been classified as such by
the International Agency for Research on Cancer [4]. High exposure levels of benzene are
particularly prominent in workers employed in the oil, shipping, auto repair, and petro-
chemical industries, as well as shoe- and rubber-manufacturing plants [5-7]. Benzene has a
high vapor pressure at ambient temperatures, therefore exposure occurs mainly through
inhalation, although contamination of drinking water or dermal exposure can also occur [8-9].
Due to the known carcinogenic and toxic effects of high levels of benzene, progressive
reduction in the occupational exposure limits has occurred in North America and Europe.
Therefore, the main objective of this work is to prepare a Ga-Re-Pt catalyst supported
alumina and evaluate the performance of this catalyst in naphtha reforming reactions at
different operating conditions of temperature, hydrogen/ hydrocarbon ratios (H 2/HC) and
liquid hourly space velocity (LHSV) to produce an environment friendly gasoline with less
benzene content.
2. Experimental work
2.1. Catalyst preparation
The catalyst was prepared by incipient wetness impregnation method using hexachloro-
platinic acid (PtCl6H2, 8% Sigma Company, Germany) as a stock solution of active metal. γ-
Al2O3 (99.9%, 0.62 gm/cm3, 195 m2/gm) is used as received from Aldrich Company. The stock
solution is used to prepare 0.3% Pt solution; γ-Al2O3 is impregnated with that solution after
evacuation using a vacuum pump, drying at 150◦C overnight, and calcined at 450 oC in muffle
furnace (Humboldt, H 30160) for 4 h. Meanwhile, Re (10%) and Ga (4%) solutions are
prepared using rhenium sulphate (Re2(SO4)3.5H2O) and Ga2SO4 salts. Throughout 5 trials of
co-impregnation and testing, they doped concentration by atomic absorption spectroscopy,
0.3% Pt, 1 % Re and 0.25% Ga are impregnated on alumina and the calcination is performed
at temperature of 600◦C.
Fresh samples of the catalysts are exposed to a flowing gas mixture of pure H 2 at 650◦C for
12 h. This treatment is made to simulate accelerated ageing of the catalyst under reduction
conditions in refineries during ATR (i.e., high-temperatures and reducing atmospheres) [10].
The total acidity of the prepared catalyst is measured according to Alemdarouglu [11] and it
was 0.683 mmol/gm. The chemical composition of the prepared catalyst is examined in Atomic
absorption spectrophotometer manufactured by Perkin-Elmer (Optima 2000 DV Inductively
Coupled Plasma/Optical Emission Spectrometer (ICP/OES). Analytical Expert, pro multi-
purpose diffractometer, (MPD Philips X-Pert, Netherlands) which is equipped with a pixel
detector for data collection and both a Pt and Ga heating strip operate at 1500◦C and 2300oC
respectively. Textural properties of the catalyst are determined by Hitachi Scanning Electron
Microscope (S-570, Japan) at 7-124 kV after coating the rubbed particles with polyethylene cover.
2.2. Catalyst evaluation
The prepared catalyst has to be evaluated, this evaluation is achieved in a trickle bed
reactor rig consists of a surge tank for heavy naphtha. Heavy naphtha is fed to a jacketed 73
cm reactor length and 1.6 cm diameter S.S 316 L modified tube loaded with 15 gm fresh
catalyst (for each test) and inert glass bead. The reactor is heated by an electrical coil
controlled with a preset auto program. The catalyst reduction is performed by hydrogen at
520◦C for 4 hours at 12 bar, followed by 30 minutes sulfidation with 500 ppm H2S in hydrogen
stream, naphtha feed is charged to the reactor through a GC pump at 371◦C. The catalyst is

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reduced in hydrogen at 500ºC for 4 h. It needs 20 minutes to start naphtha feeding through
a dosing pump at 1, 1.25, 1.5, and 2 hr-1to 480, 500, 520 and 540 ºC controlled reactor (tem-
perature increment is set at 10ºC/min). Hydrogen is fed at 69 bar and different H2/HC, 4, 4.5,
5.0 and 5.5. The product leaves the catalytic reactor to a flush drum where the unconsumed
hydrogen is separated and recycled to the gas mixer to be mixed with fresh hydrogen, the
liquid reformate product is taken every 1 hour and analyzed in high performance liquid
chromatography (HPLC) (LTA 302 Butler): the system composed with two model P600 pumps,
a model UV600 UV-Vis absorbance detector, a Spark model 840 auto-sampler, and a column
oven manufactured by Labtech America and has to be used for analysis of compounds
absorbing UV-Vis light at a wavelength range of 190nm-600nm using water/hexane (HPLC
grade) a mobile phase, the mobile phase flow rate is 1 ml / min, and the HPLC retention time
for benzene is 1.2 min. The commercial gasoline product (4 % benzene) standard sample was
brought from Shell Global. Peak assignment in the sample spectrum is conducted by a careful
comparison with the standard gasoline spectrum. Research Octane Number (RON) of the
reformate sample is measured in duplication due to the ASTM D2700 procedure. The API
(density) test is performed on Mettler (METTLER TOLEDO DM45).
3. Results and discussion
3.1. Catalyst characterization
The results of catalyst composition analysis for metal elements Ga, Re, and Pt are
considered as a guide for ensuring accurate co-impregnation on alumina support during
catalyst preparation. The results of tri-metallic dispersion of the fresh catalyst prepared in our
laboratory (Catalyst x) are presented in Figure 1. The XRD pattern for Ga-Re-Pt /γ-Al2O3 has
detected the entire elements and ensures that these elements are imbedded on the support
structure in a good metal distribution pattern. It is obvious that Pt has the highest diffraction
and the other promoters (Ga and Re) are impregnated at less loading. This pattern also
ensures that a trimetalic structure is achieved after incipient wetness impregnation on alumina.

Figure 1. XRD patterns for fresh Ga-Re-Pt/Al2O3 laboratory prepared catalyst sample
Figure 2, shows the TPR traces of the tri-metallic catalyst. Pt/Al2O3 has a large hydrogen
consumption peak centered at 320oC. The total hydrogen consumption (TPR area) corresponds to
the total reduction of Pt(IV) to Pt(0) [12]. The TPR trace of Re is steeper and has a maximum
peak of 680oC, with a similar one for Ga at 840oC. This is an indication of an interaction
between Pt, Re, and Ga oxides and alumina. The three peaks are attributed to metals oxides
reduction at certain temperatures. Figure 3, presents a surface map obtained by SEM. This

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figure shows a good distribution of active metals (Pt, Re, and Ga) which represents while
particles of Pt, Re and Ga in different particle sizes, alumina support represents large particle,
furthermore. The agglomeration of active metals in some regions in the surface results in
decreasing activity of catalyst and may be a seed for early sintering.
200

34441
150
Signal ( mV )

100

50

-50
0 200 400 600 800 1000
Temperature / °C

Figure 2. TPR for fresh Ga-Re-Pt/Al2O3 laboratory prepared catalyst sample

Figure 3. SEM image for fresh Ga-Re-Pt/Al2O3 laboratory prepared catalyst sample
3.2. Effect of temperature
Several trade-offs could occur regarding the effect of temperature on the promotion of
desirable and undesirable reactions. Although the benefits of controlling temperature are
evident, this is a very challengeable task in light of the highly endothermic nature of the
dehydrogenation reactions [13]. Throughout this study the reactions were conducted at
temperature range of 480-540oC to verify the optimum temperature progression. The refor-

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ming experiment is performed 6 hours with 1 hour as a time increment, with no chlorine
addition throughout the experiments. Pt-Re-Ga catalyst is capable of operation over a wide
range of temperature with high improvement of Research Octane Number (RON) and this is
obvious in figure 4. This figure, Pt-Re-Ga exhibited a distinguished improving in RON with
increasing of temperature and a good stability of the prepared catalyst is achieved (there is
no RON decay throughout the time duration). In the lowest ratios of H 2/HC, the RON tends to
settle at certain values of 76 and 84 for 4 and 4.5 ratios respectively this inhibition may be
attributed to coke formation on the surface of the catalyst at low rate of hydrogen feeding. In
contrast, the higher temperatures resulted in progressive RON improvement at highest H2/HC
ratio (5 and 5.5). Generally the inhibition of coke formation does not result in lowering RON even
at low values of H2/HC ratios. As a result, the amount of hydrogen entering the reactor is an
effective parameter which determines the H2/HC ratio. H2/HC molar ratio is one of the main
parameters in the reforming units which should be controlled frequently and properly.
Low values accelerate the polymerization of the coke on the catalyst surface [14] hence,
Incipient Wetness Impregnation resulted in good catalyst stability at the operating tempe-
ratures, it can be also concluded that 5 ppm injection of chlorine is sufficient to retard further
coke deposition [15]. Figure 5, shows how benzene content progressively decreases with
increasing temperatures. The reforming at the highest temperature results in the lowest
benzene content of 1.88% at the highest H 2/HC ratio of 5.5. The other ratios also exhibit
reasonable benzene content of 2.81, 2.35, and 2.05 for H 2/HC 4.0, 4.5, and 5.0. In addition,
the temperature difference obviously accelerates catalyst deactivation at lower H 2/HC but
there is no evidence that sintering starts early at the tested temperatures; thereby, there are
no unexpected exothermic reactions that occur at these temperatures [16]. These finding are
in good agreement with [12,17-20]

Figure 4. Effect of operating temperature on Figure 5. Effect of operating temperature on benze-

research octane number of the treated gasoline ne content of the treated gasoline
3.3. Effect of LHSV
Figure 6, shows that the effect of space velocity (expressed as LHSV) is dramatically
significant on benzene content. Operating at 1, 1.25, and 1.5 hr-1 resulted in a significant de-
crease in benzene content and is proven via many researchers, that enhancement of naphtha
octane number in reformates is conventionally achieved by lowering LHSV or raising inlet
temperature [21]. Operating at a higher LHSV from 1.5 through 2.0 hr-1 played synergistic role
and resulted in an increase in benzene content, this can be attributed to the reduction of space
/ time of reactants (i.e. reducing the time required for reforming reaction with hydrogen over
the catalyst). Moreover, higher liquid flow rates give greater liquid hold up which evidently
decreases the contact of liquid and gas reactants on active site by increasing the film
thickness. While at low liquid flow rate, the liquid resides in the reactor for longer time, and
therefore undergoes more conversion and agrees with [22-23].

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Figure 6. Effect of space velocity on benzene content of reformate

3.4. Effect of time on stream
PONA test is a detailed analysis of reformate hydrocarbon and it is considered in this study to
assess the liquid products. C5+% is the main parameter in this test. Table 1 shows a sample
of PONA test for heavy naphtha and reformate which are based on ASTM D6293-98. The
impregnation with Ga and Re increase the activity of the catalyst. With this catalyst at the
operating temperature range of 480-540oC the selectivity is higher than with the commercial
catalyst according to routine test in the Baiji Refinery (Iraq) as shown in table 1. The product
distribution varies obviously with temperature. Table 1, shows that 540 oC has the optimum
liquid product distribution and the highest percentage of liquid products. This finding agrees
with [16], they concluded that the gas producing selectivity of the commercial catalyst is sen-
sitive towards the reaction temperature, while on the modified catalysts the liquid product
yield is nearly constant. The laboratory prepared catalyst shows an average C5+ yield at
71.8%. Full analysis of the hydrocarbon composition of the reformate at different temperature
shows that every 20oC increase in temperature results in about 0.5 wt% less aromatics and
0.21–0.34 wt.% higher isoparaffins. This yield can be attributed to the inhibition of hydro-
cracking and/or hydrogenolysis side reactions and agrees with [10,17].
Table 1. PONA test for heavy naphta and reformate by commercial and laboratory prepared catalysts
Reformate Reformate
Com. Heavy naphtha (commercial (laboratory prepared 1.5 LHSV, 5.5 H2/HC
name A+O= 7.0% catalyst) catalyst) wt.% ratio
A+O= 51.0% A+O= 49.61%
Conc. RT Conc. RT Conc. RT 480oC 500oC 520oC 540oC
PC3 0.139 2.908 0.015 0.373 0.023 0.436 0.0858 0.0428 0.036 0.023
PC4 0.930 3.547 0.95 1.173 1.114 1.381 0.9502 0.972 1.086 1.114
NC5 3.348 6.29 0.116 2.62 0.102 3.162 1.759 1.286 0.926 0.102
PC5 14.492 7.467 6.69 3.17 7.127 3.329 11.709 9.709 8.302 7.127
NC6 8.059 11.222 0.585 5.817 0.431 4.724 4.151 2.693 1.421 0.431
PC6 21.231 12.688 14.48 6.840 15.78 7.536 15.603 17.603 18.682 21.78
NC7 6.257 16.763 0.587 10.25 0.525 10.681 2.905 1.841 0.737 0.525
PC7 18.986 18.342 16.232 11.707 15.392 12.261 17.019 16.206 16.87 15.392
NC8 3.921 22.117 0.047 15.693 0.0528 16.032 2.032 2.289 1.043 0.0528
PC8 12.224 23.583 7.729 17.067 6.495 16.806 9.257 9.625 7.937 6.495
NC9 0.595 28.258 0.074 20.433 0.096 21.419 0.308 0.274 0.117 0.096
PC9 2.819 29.58 1.494 22.53 1.257 20.63 1.783 1.716 1.646 1.257
Total 93.00 49.00 50.394 67.562 64.3 58.803 50.394
RT- retention time, conc. in wt%

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4. Conclusions
It can be concluded that gallium and rhenium interacted with platinum on alumina support
successfully and can be used as a tri-metallic catalyst in reforming reactions. The charac-
terization test proved that co-impregnation method works with this kind of catalyst. High
reformate yield may be caused by a reduction in hydrocracking and/or hydrogenolysis side
reactions. There is no significant early sintering at the early life of this catalyst due to ope-
rating at 480-540oC. This catalyst results in 1.88 % benzene and 1.6% higher reformate yield
at the optimum operating conditions of 540oC, liquid hourly space velocity of 1.5 h-1 and 5.5
hydrogen/hydrocarbon ratio according to PONA test which compared the performance with
the refinery yield. It is realized that Ga and Re addition greatly improves the selectivity,
activity and stability of the catalyst. The addition of Ga and Re to the Pt/Al 2O3 catalyst reducing
the benzene/i-C7 ratio yielding environmentally friendly gasoline.
Acknowledgements
The author is grateful to Missouri University of Science and Technology for catalyst charac-
terization and evaluation. This work is supported with Grant of ISFP 2012 by US DOS.
Conflict of Interest
The authors declare no conflict of interest.
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*Correspondence: [email protected] ; Tel.: 573-239-7199

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