Hydrotreating catalyst comprising an interstratified crystalline clay-type aluminosilicate component and a crystalline zeolitic molecular sieve component and process using said catalyst

Claim 2

A hydrocarbon conversion catalyst comprising an interstratified smectite-illite crystalline clay-type aluminosilicate component, a crystalline zeolitic molecular sieve component, a hydrogenating component selected from platinum and compounds thereof and palladium and compounds thereof, and a component selected from the metals cerium, manganese, zinc, and compounds of said metals.

Claim 3

A catalyst as in claim 1, wherein one of said crystalline components is substantially in the ammonium or hydrogen form, and further is substantially free of any catalytic loading metal or metals.

Claim 4

A catalyst as in claim 1, wherein said interstratified crystalline component contains 0-0.5 weight percent sodium and 0.0-3.0 weight percent fluorine, all on an anhydrous interstratified crystalline component basis.

Claim 5

A catalyst as in claim 1, which further comprises a component selected from the metals Ag, Cu, Sn, Ti, Zr, Th, Hf, V, alkaline earth metals Mg, Ca, Sr and Ba, rare earth metals having atomic numbers 57 and 59-71, and compounds of said metals.

Claim 6

A catalyst as in claim 1, wherein said interstratified crystalline aluminosilicate component and said crystalline molecular sieve component are in particulate form and are dispersed in a matrix comprising a siliceous gel and said hydrogenating component.

Claim 7

A catalyst as in claim 5, wherein at least one of said crystalline components is substantially in the ammonium or hydrogen form, and further is substantially free of any catalytic loading metal or metals.

Claim 8

A catalyst as in claim 5, which further comprises tin or a compound thereof.

Claim 9

A hydrocarbon conversion catalyst comprising: a. a gel matrix comprising a silica-alumina gel, b. a hydrogenating component selected from platinum and compounds thereof and palladium and compounds thereof, c. a component selected from the metals cerium, manganese, zinc, and compounds of said metals, d. an interstratified smectite-illite crystalline clay-type aluminosilicate component in particulate form, and e. a crystalline zeolitic molecular sieve component in particulate form; said interstratified aluminosilicate component and said molecular sieve component being dispersed through said gel matrix.

Claim 10

A hydrocarbon conversion catalyst comprising: a. a gel matrix comprising a silica-alumina gel, b. a hydrogenating component selected from platinum and compounds thereof and palladium and compounds thereof, c. a component selected from the metals cerium, manganese, zinc, and compounds of said metals, d. an interstratified smectite-illite crystalline clay-type aluminosilicate component in particulate form, and e. a crystalline zeolitic molecular sieve component in particulate form; said interstratified aluminosilicate component and said molecular sieve component being dispersed through said gel matrix.

Claim 11

A catalyst as in claim 8, wherein said matrix further comprises combined fluorine, in an amount of 0.0 to 5.0 weight percent.

Claim 12

A catalyst composite comprising: A. A gel matrix comprising: a. 5-85 weight percent silica, b. 10-94 weight percent alumina, c. a platinum or palladium component, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 0.01 to 3 weight percent of said matrix, calculated as metal, d. a component selected from cerium, manganese and zinc, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 0.1 to 25 weight percent of said matrix, calculated as metal; B. An interstratified smectite-illite crystalline clay-type aluminosilicate in particulate form, dispersed through said matrix; C. A crystalline zeolitic molecular sieve, in particulate form, dispersed through said matrix.

Claim 13

A catalyst composite comprising: A. A gel matrix comprising: a. 5-85 weight percent silica, b. 10-94 weight percent alumina, c. a platinum or palladium component, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 0.01 to 3 weight percent of said matrix, calculated as metal, d. a component selected from cerium, manganese and zinc, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 0.1 to 25 weight percent of said matrix, calculated as metal; B. An interstratified smectite-illite crystalline clay-type aluminosilicate in particulate form, dispersed through said matrix; C. A crystalline zeolitic molecular sieve, in particulate form, dispersed through said matrix.

Claim 14

A catalyst composite as in claim 10, wherein said interstratified crystalline aluminosilicate is present in an amount of 5 to 99 weight percent, and said molecular sieve is present in an amount of 1 to 70 weight percent, based on said composite.

Claim 15

A catalyst composite as in claim 10, wherein at least one of said crystalline components is substantially in the ammonium or hydrogen form, and is substantially free of any catalytic loading metal or metals.

Claim 16

A catalyst composite as in claim 8, further comprising a component selected from the metals Ag, Cu, Sn, Ti, Zr, Th, Hf, V, alkaline earth metals Mg, Ca, Sr and Ba, rare earth metals having atomic numbers 57 and 59-71, and compounds of said metals.

Claim 17

A catalyst composite as in claim 13, comprising titanium in the form of titania.

Claim 18

A catalyst composite as in claim 10, characterized by an average pore diameter below 100 Angstroms and a surface area above 200 square meters per gram.

Claim 19

A catalyst consisting essentially of: A. A porous xerogel comprising: a. 5 to 85 weight percent silica, b. 10 to 94 weight percent alumina, c. palladium, in the form of metal, oxide, sulfide, or any combination thereof, in an amount of 0.01 to 3 weight percent of said xerogel, calculated as metal, d. a component selected from cerium manganese and zinc, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 5 to 25 weight percent of said xerogel, calculated as metal, e. titanium oxide, in an amount of 0.1 to 10 weight percent of said xerogel, calculated as metal; B. A clay-type, interstratified smectite-illite crystalline aluminosilicate, in an amount of 5 to 99 weight percent of said catalyst, said crystalline alumunosilicate being in the form of particles, said particles being dispersed through said xerogel; C. A crystalline zeolitic molecular sieve, in an amount of 1 to 70 weight percent of said catalyst, said molecular sieve being in the form Of particles, said particles being dispersed through said xerogel; said catalyst having an average pore diameter below 100 Angstroms and a surface area above 200 square meters per gram.

Claim 20

A catalyst consisting essentially of: A. A porous xerogel comprising: a. 5 to 85 weight percent silica, b. 10 to 94 weight percent alumina, c. palladium, in the form of metal, oxide, sulfide, or any combination thereof, in an amount of 0.01 to 3 weight percent of said xerogel, calculated as metal, d. a component selected from cerium manganese and zinc, in the form of metal, oxide, sulfide or any combination thereof, in an amount of 5 to 25 weight percent of said xerogel, calculated as metal, e. titanium oxide, in an amount of 0.1 to 10 weight percent of said xerogel, calculated as metal; B. A clay-type, interstratified smectite-illite crystalline aluminosilicate, in an amount of 5 to 99 weight percent of said catalyst, said crystalline alumunosilicate being in the form of particles, said particles being dispersed through said xerogel; C. A crystalline zeolitic molecular sieve, in an amount of 1 to 70 weight percent of said catalyst, said molecular sieve being in the form Of particles, said particles being dispersed through said xerogel; said catalyst having an average pore diameter below 100 Angstroms and a surface area above 200 square meters per gram.

Claim 21

A hydrotreating process which comprises contacting a hydrocarbon feed containing substantial amounts of materials boiling above 200*F. and selected from the group consisting of petroleum distillates, solvent-deasphalted petroleum residua, shale oils and coal tar distillates, in a reaction zone with hydrogen and the catalyst of claim 1, at hydrotreating conditions including a temperature in the range 400* to 950*F., a pressure in the range 800 to 3,500 psig, a liquid hourly space velocity in the range 0.1 to 5.0, and a total hydrogen supply rate of 200 to 20,000 SCF of hydrogen per barrel of feedstock, and recovering hydrotreated products from said reaction zone.

Claim 22

A process as in claim 17, wherein said hydrocarbon feed contains a substantial amount of organic nitrogen, and wherein ammonia is removed from the effluent from said reaction zone.

Claim 23

A process as in claim 17, wherein a gasoline product and a jet fuel product are recovered from the effluent from said reaction zone.