Hydrogenation catalyst with improved textural properties

Abstract

A method is provided for making a catalyst support, and includes the steps of providing an aqueous suspension of refractory inorganic oxide and refractory inorganic carbide; forming the suspension into droplets; exposing the droplets to a gelling agent whereby the droplets are at least partially solidified so as to provide substantially sphere-shaped portions of refractory inorganic oxide and refractory inorganic carbide; and drying and calcining the sphere-shaped portions so as to provide substantially spherical particles of catalyst support containing refractory inorganic oxide and refractory inorganic carbide. Catalytically active metal phases and hydrogenation processes using the catalyst are also described.

1 - 29 . (canceled)  
     
     
         30 . A catalyst support, comprising substantially spherical particles having siloxane bonds of a substantially homogenous mixture of refractory inorganic oxide and refractory inorganic carbide, the support having a solid surface area of at least about 65 m 2 /g, a particle size of at least about 0.1 mm, a pore volume of at least about 0.2 cc/g, and an average pore diameter of at least about 150 Å.  
     
     
         31 . The catalyst support of  claim 30 , wherein the spherical catalyst support has a particle size of between about 0.1 and about 3 mm.  
     
     
         32 . The catalyst support of  claim 30 , wherein the spherical catalyst support has a pore volume of at least about 0.4 cc/g.  
     
     
         33 . The catalyst support of  claim 30 , wherein the spherical catalyst support has a pore volume of between about 0.2 and about 0.7 cc/g.  
     
     
         34 . The catalyst support of  claim 30 , wherein the spherical catalyst support contains refractory inorganic carbide in an amount between about 10 and about 50% wt based upon total weight of the catalyst support.  
     
     
         35 . The catalyst support of  claim 30 , wherein the refractory inorganic oxide comprises silica, and the refractory inorganic carbide comprises silicon carbide.  
     
     
         36 . The catalyst support of  claim 30 , further comprising a catalytically active metal phase on the catalyst support, wherein the catalytically active metal phase comprises at least one first metal selected from Group 4 of the periodic table of elements, and at least one second metal selected from the group consisting of Groups 8, 9 and 10 of the periodic table of elements.  
     
     
         37 . The catalyst support of  claim 36 , wherein the at least one first metal is selected from the group consisting of Zr, Ti, Hf, and mixtures thereof, and wherein the at least one second metal is selected from the group consisting of Co, Fe, Ni, Ru and mixtures thereof.  
     
     
         38 . The catalyst support of  claim 36 , wherein the at least one first metal is Zr and the at least one second metal is Co.  
     
     
         39 . The catalyst support of  claim 36 , wherein the at least one first metal is present in an amount between about 0.1 and about 25% wt based upon combined weight of the catalyst support and the metal phase, and wherein the at least one second metal is present in an amount between about 1 and about 50% wt based upon combined weight of the catalyst support and the metal phase.  
     
     
         40 - 41 . (canceled)