Catalyst comprising zinc oxide,silica and alumina and processes employing same

Claim 2

A PROCESS FOR THE HYDRODESULFURIZATION OF A HYDROCARBON FEEDSTOCK, WHICH PROCESS COMPRISES CONTACTING IN A REACTION ZONE SAID FEEDSTOCK WITH A CATALYTIC COMPOSITION IN THE PRESENCE OF HYDROGEN AND UNDER HYDRODESULFURIZATION CONDITIONS, WHICH CATALYTIC COMPOSITION COMPRISES A HYDROGENATION COMPONENT COMPRISING A METAL OF GROUP VIA OF THE PERIODIC TABLE OF ELEMENTS AND A METAL OF GROUP VIII OF THE PERIODIC TABLE ON A SOLID CATALYTIC SUPPORT COMPRISING A COMPOSITE OF ZINC OXIDE, SILICA, AND A CATALYTICALLY ACTIVE ALUMINA, EACH METAL OF SAID HYDROGENATION COMPONENT BEING PRESENT IN THE ELEMENTAL FORM, AS THE OXIDE, AS THE SULFIDE, OR AS A COMBINATION THEREOF.

Claim 3

The process of claim 1 wherein said catalytic support of said catalytic composition has been prepared by: (1) adding an aqueous solution of a soluble zinc salt and a member selected from the group consisting of a suspension of an organic silicate in water and an aqueous alkali silicate solution to an alumina sol; (2) thoroughly blending said aqueous solution of a soluble zinc salt, said member selected from the group consisting of a suspension of an organic silicate in water and an aqueous alkali silicate solution, and the alumina sol to obtain a thoroughly blendeD mixture; (3) gelling said thoroughly blended mixture by adding a member selected from the group consisting of an aqueous solution of an alkali metal hydroxide and a solution of ammonium hydroxide to said thoroughly blended mixture to provide a pH of about 5.5 to about 10.0 and to obtain a gel; (4) filtering said gel to obtain a filtered material; (5) washing said filtered material with a member selected from the group consisting of water and ammonium carbonate solution to remove non-volatile soluble ions from the filtered material and to obtain a washed filtered material; (6) drying said washed filtered material to obtain a dried material; and (7) calcining said dried material in air at a temperature of at least 600*F. for a period of time of at least 0.5 hour.

Claim 4

The process of claim 2 wherein said feedstock is a member selected from the group consisting of petroleum hydrocarbon residua, shale oil, liquified coal, oil from tar sands, and combinations thereof.

Claim 5

The process of claim 3 wherein said hydrodesulfurization conditions comprise a temperature of about 600*F. to about 850*F., a hydrogen partial pressure of about 600 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 1,000 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 3.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 6

The process of claim 2 wherein said metal of Group VIA is molybdenum and said metal of Group VIII is cobalt, said molybdenum being present in an amount of about 2 weight percent to about 20 weight percent, calculated as MoO3, and based on the weight of said catalytic composition, and said cobalt being present in an amount of about 0.5 weight percent to about 5 weight percent, calculated as CoO and based on the weight of said catalytic composition, said silica is present in an amount of about 2 weight percent to about 10 weight percent, based on the weight of said catalytic support, and said catalytic support comprises a maximum amount of about 50 weight percent zinc oxide, based on the weight of said catalytic support.

Claim 7

The process of claim 5 wherein said feedstock is a member selected from the group consisting of petroleum hydrocarbon residua, shale oil, liquified coal, oil from tar sands, and combinations thereof.

Claim 8

The process of claim 6 wherein said hydrodesulfurization conditions comprise a temperature of about 600*F. to about 850*F., a hydrogen partial pressure of about 600 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 1,000 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 3.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 9

The process of claim 5 wherein said hydrodesulfurization conditions comprise a temperature of about 500*F. to about 850*F., a hydrogen partial pressure of about 100 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 200 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 10.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 10

The process of claim 2 wherein said hydrodesulfurization conditions comprise a temperature of about 500*F. to about 850*F., a hydrogen partial pressure of about 100 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 200 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 10.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 11

The process of claim 1 wherein said feedstock is a member selected from the group consisting of petroleum hydrocarbon residua, shale oil, liquified coal, oil from tar sands, and combinations thereof.

Claim 12

The process of claim 10 wherein said hydrodesulfurization conditions comprIse a temperature of about 600*F. to about 850*F., a hydrogen partial pressure of about 600 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 1,000 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 3.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 13

The process of claim 1 wherein said metal of Group VIA is molybdenum and said metal of Group VIII is cobalt, said molybdenum being present in an amount of about 2 weight percent to about 20 weight percent, calculated as Mo03 and based on the weight of said catalytic composition, and said cobalt being present in an amount of about 0.5 weight percent to about 5 weight percent, calculated as CoO and based on the weight of said catalytic composition, said silica is present in an amount of about 2 weight percent to about 10 weight percent, based on the weight of said catalytic support, and said catalytic support comprises a maximum amount of about 50 weight percent zinc oxide, based on the weight of said catalytic support.

Claim 14

The process of claim 12 wherein said feedstock is a member selected from the group consisting of petroleum hydrocarbon residua, shale oil, liquified coal, oil from tar sands, and combinations thereof.

Claim 15

The process of claim 13 wherein said hydrodesulfurization conditions comprise a temperature of about 600*F. to about 850*F., a hydrogen partial pressure of about 600 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 1,000 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 3.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 16

The process of claim 12 wherein said hydrodesulfurization conditions comprise a temperature of about 500*F. to about 850*F., a hydrogen partial pressure of about 100 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 200 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 10.0 volumes of hydrocarbon per hour per volume of catalyst.

Claim 17

The process of claim 1 wherein said hydrodesulfurization conditions comprise a temperature of about 500*F. to about 850*F., a hydrogen partial pressure of about 100 psig to about 2, 000 psig, a hydrogen-to-hydrocarbon ratio of about 200 SCFB to about 15,000 SCFB, and a LHSV of about 0.2 to about 10.0 volumes of hydrocarbon per hour per volume of catalyst.