Catalyst carrier and catalyst composition, processes for their preparation and their use

Abstract

The invention provides a shaped catalyst carrier which is an inorganic refractory oxide having a monomodal mercury pore volume distribution wherein at least 50% of the total pore volume is present in pores having a pore diameter in the range of from 4 to 50 nm, a catalyst incorporating said carrier and having a high metals content. The catalyst finds use in hydrocracking refinery feedstocks.

1 . A shaped catalyst carrier which comprises at least one inorganic refractory oxide, which carrier has a monomodal pore size distribution wherein at least 50% of the total pore volume is present in pores having a diameter in the range of from 4 to 50 nm and wherein the pore volume present in said pores is at least 0.4 ml/g, all as measured by mercury intrusion porosimetry.  
     
     
         2 . A catalyst carrier as claimed in  claim 1 , wherein the pore volume present in pores of diameter from 4 to 50 nm is at least 0.5 ml/g.  
     
     
         3 . A catalyst carrier as claimed in  claim 2 , wherein at least 60% of the total pore volume is present in pores having a diameter in the range of from 4 to 50 nm.  
     
     
         4 . A catalyst carrier as claimed in  claim 3 , which comprises an amorphous silica-alumina material or a crystalline aluminosilicate faujasite material.  
     
     
         5 . A catalyst carrier as claimed in  claim 4 , wherein the compacted bulk density is in the range of from 0.35 to 0.50 g/ml.  
     
     
         6 . A process for the preparation of a catalyst carrier, said process comprises shaping a mix comprising said at least one refractory oxide wherein the mix has an LOI in the range of from 55 to 75%.  
     
     
         7 . A process as claimed in  claim 6 , wherein the shaping is by extrusion.  
     
     
         8 . A process as claimed in  claim 7 , wherein the mix is an extrusion mix which has a pH in the range of from 3.5 to 7.0.  
     
     
         9 . A process as claimed in  claim 8 , wherein the LOI is in the range of from 58% to 75% and the pH is in the range of from 3.5 to 5.0.  
     
     
         10 . A process as claimed in  claim 9 , wherein acid is added to the extrusion mix to adjust the pH, which acid is selected from the group consisting of acetic acid and nitric acid.  
     
     
         11 . A carrier obtainable by a process as claimed in  claim 10 .  
     
     
         12 . A catalyst composition which comprises a carrier as claimed in  claim 1 , and at least one hydrogenation metal component selected from Group VIb and Group VIII metals.  
     
     
         13 . A catalyst composition as claimed in  claim 12 , wherein the Group VIb metal is tungsten present in an amount in the range of from 20 to 27 wt %, calculated as the trioxide and based on total weight of catalyst, and the Group VIII metal is nickel present in an amount in the range of from 4 to 6 wt %, calculated as the oxide and based on total weight of catalyst.  
     
     
         14 . A process for the preparation of a catalyst composition which said process comprises calcining a carrier as claimed in  claim 1;  and depositing at least one hydrogenation metal selected from the group consisting of Group VIb and Group VIII in the appropriate amount, wherein the deposition is effected by an impregnation solution containing an organic compound having at least two moieties selected from carboxyl, carbonyl, and hydroxyl.  
     
     
         15 . A process as claimed in  claim 14 , wherein the organic compound is an organic acid selected from the group consisting of citric acid, tartaric acid, oxalic acid, malonic acid and malic acid.  
     
     
         16 . A catalyst composition obtainable by the process as claimed in  claim 15 .  
     
     
         17 . A hydrocracking process which comprises contacting a hydrocarbonaceous feed with a catalyst composition as claimed in  claim 12  at elevated temperature and pressure.  
     
     
         18 . A catalyst composition as claimed in  claim 12 , wherein the carrier is essentially free of aluminosilicate zeolite and wherein the carrier further comprises at least one promoter element selected from the group consisting of silicon and boron.