Process for preparing a heavy crude conversion catalyst

Claim 2

A process for the synthesis and preparation of a catalyst support having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water; aluminum halide or alcohol:aluminum halide ranging from about 15:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 1.5:1 to about 2.0:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying to gel to a solids content ranging from about 12 to about 40 weight percent, extruding the gel through a die to form an extrudate, drying said extrudate as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, and then recovering a product.

Claim 3

The process of claim 1 wherein a Group VIB or Group VIII metal hydrogenation component, or both, is incorporated with the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component is incorporated within the support by impregnation from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst includes, when the catalyst is of size ranging from about 1/50 inch up to 1/25 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 150A to about 250A; when the catalyst is of size ranging from about 1/25 inch to about 1/8 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 175A to about 275A; a surface area ranging at least about 200 m 2 /g to about 600 m 2 /g and a pore volume ranging from about 0.8 cc/g to about 3.0 cc/g.

Claim 4

The process of claim 2 wherein the recovered catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <10 % 150-250A >15 % 350A+ <35 % Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 320-475 1/25 up to 1/8" 0-50A <5 % 175-275A >15 % 350A <40 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 5

The process of claim 1 wherein one or more Group VIII noble metal, lanthanum or lanthanum series metal compounds which is thermally decomposable to form an oxide, are added to the solution in molar ratio metal: aluminum halide ranging from about 0.001:1 to about 0.06:1 during the synthesis, a Group VIB or Group VIII metal hydrogenation component, or or both, is incorporated with the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component is incorporated within the support by impregnation from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <5 % 150-250A >20 % 350A+ <30 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-575 1/25 up to 1/8" 0-50A <4 % 175-275A >20 % 350A+ <35 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 350-600 ______________________________________

Claim 6

The process of claim 4 wherein the molar ratio metal:aluminum halide ranges from about 0.01:1 to about 0.03:1 and the catalyst recovered is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <1 % 150-250A >45 % 350A+ <7 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 1/25 up to 1/8" 0-50A <3 % 175-275A >30 % 350A+ <25 % Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 /g 370-650 ______________________________________

Claim 7

The process of claim 1 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide is added to the solution during the synthesis to form a cogel, and the calcined catalyst thereby formed includes when the catalyst is of size ranging from about 1/50 inch up to 1/25 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 150A to about 250A; when the catalyst is of size ranging from about 1/25 inch to about 1/8 inch average particle size diameter, at least about 15 percent ot its total pore volume of absolute diameter within the range of about 175A to about 275A; a surface area ranging at least about 200 m 2 /g to about 600 m 2 /g and a pore volume ranging from about 0.8 cc/g to about 3.0 cc/g.

Claim 8

The process of claim 6 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 9

The process of claim 1 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 10

The process of claim 1 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <5 % 150-250A >20 % 350A+ <30 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-575 1/25 up to 1/8" 0-50A <4 % 175-275A >20 % 350A+ <35 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 350-600 ______________________________________

Claim 11

The process of claim 9 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 12

The process of claim 4 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 13

The process of claim 1 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.01:1 to about 0.03:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <1 % 150-250A >45 % 350A+ <7 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 1/25 up to 1/8" 0-50A <3 % 175-275A >30 % 350A+ <25 % Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 /g 370-650 ______________________________________

Claim 14

The process of claim 12 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 15

A process for the synthesis and preparation of a catalyst support having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, and then recovering a product.

Claim 16

A process for the synthesis and preparation of a catalyst support having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, and then recovering a product.

Claim 17

The process of claim 14 wherein a Group VIB or Group VIII metal hydrogenation component, or both, is incorporated with the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component is incorporated within the support by impregnation from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst comprises at least about 55 percent of its total pore volume of absolute diameter within the range of about 100A to about 200A, less than 10 percent of its pore volume in pores of diameters 50A-, less than about 25 percent of its total pore volume in diameters ranging 300A+, surface areas range from about 200 m 2 /g to about 600 m 2 /g, and pore volumes ranges from about 0.6 to about 1.5 cc/g.

Claim 18

The process of claim 14 wherein one or more Group VIII noble metals, lanthanum or lanthanum series metals, of compounds thereof which is thermally decomposable to form an oxide, are added to the solution in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1 during the synthesis.

Claim 19

The process of claim 16 wherein the molar ratio metal:aluminum halide ranges from about 0.01:1 to about 0.03:1, a Group VIB or Group VIII metal hydrogenation component, or both, is incorporated with the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component is incorporated within the support by impregnation from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <1 % 100-200A >70 % 300A+ <1 % Surface Area: 250 m.sup.2 /g-350 m.sup.2 /g Pore Volume: 0.9 cc/g-1.3 cc/g ______________________________________

Claim 20

The process of claim 14 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer,

Claim 21

The process of claim 14 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum lanthanum series metal, or compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % (2) Surface area: 200 m.sup.2 /g-600 m.sup.2 /g (3) Pore volume: 0.6 cc/g-1.5 cc/g ______________________________________

Claim 22

The process of claim 19 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 23

The process of claim 16 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 24

The process of claim 14 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more of Group VIII noble metal, lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <1 % 100-200A >70 % 300A+ <1 % Surface Area: 250 m.sup.2 /g-350 m.sup.2 /g Pore Volume: 0.9 cc/g-1.3 cc/g ______________________________________

Claim 25

The process of claim 22 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 26

The process of claim 17 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 27

A process for the synthesis and preparation of a catalyst support having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum halide or alcohol:aluminum halide ranging from about 15:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 1.5:1 to about 2.0:1 while maintaining a pH in the range of about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, again drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, and then recovering a product.

Claim 28

A process for the synthesis and preparation of a catalyst support having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum halide or alcohol:aluminum halide ranging from about 15:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 1.5:1 to about 2.0:1 while maintaining a pH in the range of about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, again drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, and then recovering a product.

Claim 29

The process of claim 25 wherein a Group VIB or Group VIII metal hydrogenation component, or both, is incorporated within the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component being incorporated within the support by impregnation of the support from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst includes, when the catalyst is of size ranging from about 1/50 inch up to 1/25 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 150A to about 250A; when the catalyst is of size ranging from about 1/25 inch to about 1/8 inch average particle size diameter at least about 15 percent of its total pore volume of absolute diameter within the range of about 175A to about 275A, a surface area ranging at least about 200 m 2 /g to about 600 m 2 /g, and a pore volume ranging from about 0.8 cc/g to about 3.0 cc/g.

Claim 30

The process of claim 25 wherein one or more Group VIII noble metal, lanthanum or lanthanum series metal compounds which is thermally decomposable to form an oxide, are added to the solution in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1 during the synthesis, a Group VIB or Group VIII metal hydrogenation component, or both, it incorporated with the calcined support to form a catalyst, said Group VIB or Group VIII metal hydrogenation component is incorporated within the support by impregnation from solution with a compound, or compounds, thermally decomposable to form an oxide of said metal, or metals, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <5 % 150-250 A >20 % 350A+ <30 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-575 1/25 up to 1/8" 0-50A <4 % 175-275A >20 % 350A+ <35 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 350-600 ______________________________________

Claim 31

The process of claim 27 wherein the molar ratio metal:aluminum halide ranges from about 0.01:1 to about 0.03:1 and the catalyst recovered is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <1 % 150-250A >45 % 350A+ <7 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 1/25 up to 1/8" 0-50A <3 % 175-275A >30 % 350A+ <25 % Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 g 370-650 ______________________________________

Claim 32

The process of claim 25 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <1 % 150-250A >45 % 350A+ <7 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 1/25 up to 1/8" 0-50A <3 % 175-275A >30 % 350A+ <25 % Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 /g 370-650 ______________________________________

Claim 33

The process of claim 29 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 34

The process of claim 25 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 35

The process of claim 25 wherein the compound of Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterizied as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <10 % 150-250A >15 % 350A+ <35 % Pore Volume, cc/g 1.1-1.7 Surface Area. m.sup.2 /g 320-475 1/25 up to 1/8" 0-50A <5 % 175-275A >15 % 350A+ <40 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 36

The process of claim 32 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 37

The process of claim 27 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 38

process process of claim 25 wherein the compound of a Group VIB or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <10 % 150-250A >15 % 350A+ <35 % Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 320-475 1/25 up to 1/8" 0-50A <5 % 175-275A >15 % 350A+ <40 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 39

The process of claim 35 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 40

The process of claim 28 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 41

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said Group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % (2) Surface area: 200 m.sup.2 g-600 m.sup.2 /g (3) Pore volume 0.6 cc/g-1.5 cc/g ______________________________________

Claim 42

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in an aqueous or alcohol medium in molar ratio of water:aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to substantially ambient temperature or higher to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, separating the gel from the syneresis liquid, drying the gel to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes in contact with syneresis liquid for a period sufficient to increase the strength of the gel without significant adverse shrinkage of the size of the pores developed in the gel, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said Group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % (2) Surface area: 200 m.sup.2 g-600 m.sup.2 /g (3) Pore volume 0.6 cc/g-1.5 cc/g ______________________________________

Claim 43

The process of claim 38 wherein one or more of the Group VIII noble metals, lanthanum or lanthanum series metals, or compounds or salts thereof, are added to the solution in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1 during the synthesis.

Claim 44

The process of claim 39 wherein the molar ratio metal:aluminum halide ranges from about 0.01:1 to about 0.03:1 and the product recovered is characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <1 % 100-200A >70 % 300A+ <1 % (2) Surface area: 250 m.sup.2 /g-350 m.sup.2 /g (3) Pore volume: 0.9 cc/g-1.3 cc/g ______________________________________

Claim 45

The process of claim 38 wherein the compound of a Group VIB metal or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst, and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % Surface Area: 200 m.sup.2 /g-600 m.sup.2 /g Pore Volume: 0.6 cc/g-1.5 cc/g ______________________________________

Claim 46

The process of claim 41 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 47

The process of claim 38 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 48

The process of claim 38 wherein the compound of a Group VIB metal or Group VIII metal, or both, thermally decomposable to form an oxide of said metal, or metals, and one or more Group VIII noble metal, lanthanum or lanthanum series metal, compounds which are thermally decomposable to form an oxide added in molar ratio metal:aluminum halide ranging from about 0.001:1 to about 0.06:1, are added to the solution during the synthesis to form a catalyst and the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <1 % 100-200A >70 % 300A+ <1 % Surface Area: 250 m.sup.2 /g-350 m.sup.2 /g Pore Volume: 0.9 cc/g-1.3 cc/g ______________________________________

Claim 49

The process of claim 44 wherein the Group VIB metal is molybdenum and the Group VIII metal is nickel or cobalt.

Claim 50

The process of claim 39 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 51

The process of claim 40 wherein the gel is aged for a period ranging from about 6 hours to about 30 days, and longer.

Claim 52

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in the aqueous or alcohol medium in molar ratio of water: aluminum halide or alcohol:aluminum halide ranging from about 15:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 1.5:1 to about 2.0:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to a temperature sufficient to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. 1 day to about 3 days at substantially ambient temperatures; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for periods ranging from about 10 hours to about 24 hours; drying said gel as required to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. for a period ranging from about 6 hours to about 30 days, or longer, at ambient conditions; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for a period ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said Group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterizsed as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <10 % 150-250A >15 % 350A+ <35 % Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 320-475 1/25 up to 1/8" 0-50A <5 % 175-275A >15 % 350A+ <40 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 53

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in the aqueous or alcohol medium in molar ratio of water: aluminum halide or alcohol:aluminum halide ranging from about 15:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 1.5:1 to about 2.0:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to a temperature sufficient to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. 1 day to about 3 days at substantially ambient temperatures; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for periods ranging from about 10 hours to about 24 hours; drying said gel as required to a solids content ranging from about 12 to about 40 weight percent, forming gel shapes, drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. for a period ranging from about 6 hours to about 30 days, or longer, at ambient conditions; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for a period ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said Group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterizsed as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <10 % 150-250A >15 % 350A+ <35 % Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 320-475 1/25 up to 1/8" 0-50A <5 % 175-275A >15 % 350A+ <40 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 54

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in the aqueous or alcohol medium in molar ratio of water: aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to a temperature sufficient to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. 1 day to about 3 days at substantially ambient temperatures; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for periods ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. for a period ranging from about 6 hours to about 30 days, or longer, at ambient conditions; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for a period ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % (2) Surface area: 200 m.sup.2 /g-600 m.sup.2 /g (3) Pore volume: 0.6 cc/g-1.5 cc/g ______________________________________

Claim 55

A process for the synthesis and preparation of a catalyst having a relatively high concentration of pores of uniformly large diameter, high surface area and pore volume comprising dispersing an aluminum halide salt in the aqueous or alcohol medium in molar ratio of water: aluminum halide or alcohol:aluminum halide ranging from about 22:1 to about 30:1 and, while maintaining the temperature within a range of from about 30° F. to about 100° F., adding olefin oxide in molar ratio of olefin oxide:halide of from about 0.3:1 to about 1.5:1 while maintaining a pH in the range of from about 5-8 to effect removal of the halide from solution and form a sol, raising the solution to a temperature sufficient to form a gel which separates from its syneresis liquid, aging the gel while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. 1 day to about 3 days at substantially ambient temperatures; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for periods ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, aging said gel shapes while in contact with syneresis liquid in accordance with one of the following schedules of conditions: i. for a period ranging from about 6 hours to about 30 days, or longer, at ambient conditions; ii. at elevated temperatures ranging from about 80° F. to about 180° F. for a period ranging from about 10 hours to about 24 hours; drying said gel shapes as required to a solids content ranging above about 25 weight percent, washing, drying, calcining, impregnating said calcined support with a solution containing a compound of a Group VIB or Group VIII metal hydrogenation component, or both, said group VIB or Group VIII metal compound being thermally decomposable to form an oxide of said metal hydrogenation component, or components, and then recovering a product characterized as follows: ______________________________________ (1) Distribution of Pore Diameters ______________________________________ 0-50A <10 % 100-200A >55 % 300A+ <25 % (2) Surface area: 200 m.sup.2 /g-600 m.sup.2 /g (3) Pore volume: 0.6 cc/g-1.5 cc/g ______________________________________

Claim 56

The process of claim 48 wherein the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <5 % 150-250A >20 % 350A+ <30 % Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-575 1/25 up to 1/8" 0-50A <4 % 175-275A >20 % 350A+ <35 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 350-600 ______________________________________

Claim 57

The process of claim 48 wherein the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters by Average Particle Size Diameter in Inches ______________________________________ 1/50 up to 1/25" 0-50A <1 % 150-250A >45 % 350A+ <7 % Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 1/25 up to 1/8" 0-50A <3 % 175-275A >30 % 350A+ <25 % Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 /g 370-650 ______________________________________

Claim 58

The process of claim 49 wherein the catalyst is characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <1 % 100-200A >70 % 300A+ <1 % Surface Area: 250 m.sup.2 /g-350 m.sup.2 /g Pore Volume: 0.9 cc/g-1.3 cc/g ______________________________________