Support Screening to Shape Propane Dehydrogenation SnPt-Based Catalysts

Propane dehydrogenation reaction (PDH) is an extremely attractive way to produce propylene; however, the catalysts often lead to byproduct formation and suffer from deactivation. This research focuses on the development of efficient Pt/Sn-based shaped catalysts by utilizing Mg-modified mesoporous silica, sepiolite (natural SiMgO mesoporous clay), and sepiolite/bentonite/alumina as supports with the aim of achieving superior stability and selectivity for industrial propylene production by PDH. The catalysts were prepared by sequential impregnation of the supports with the corresponding solutions of tin chloride and platinum chloride, by obtaining a nominal loading of 0.7 wt % of Sn and 0.5 wt % of Pt. A range of analytical techniques were used to characterize the catalysts, including X-ray diffraction, nitrogen physisorption isotherms, Hg intrusion porosimetry, thermogravimetric analyses, transmission electron microscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. The basicity of the catalysts was assessed using carbon dioxide temperature-programmed desorption (CO₂-TPD). The results confirm that the support material plays a critical role in catalyst performance; in particular, the presence of weak basic sites, due to magnesium addition, improved selectivity to propylene and reduced coke formation. Catalytic pellets of Sn-Pt supported on macroporous sepiolite or sepiolite and bentonite-modified mesoporous alumina performed comparably with propane conversion very close to thermodynamic equilibrium and selectivity to propylene above 95%. The latter support led to improved stability and was regenerated at milder temperatures, making it suitable for industrial applications.