Catalysts and method of their preparation

Claim 1

A hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide under said oxidizing conditions between a component metal of Group VIII and a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof, comprising a Group VIII metal or mixture thereof supported on a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof which Group IIA metal oxide is supported on an acidic refractory oxide wherein the Group IIA metal oxide is present in sufficient quantity to neutralize the acid sites of the acidic refractory oxide support and to supply an excess at a level of from about 0.5 to 50 moles Group IIA metal oxide per mole of said Group VIII metal or mixtures thereof, the Group VIII metal or mixtures thereof on Group IIA metal oxide or mixtures thereof on neutralized acidic refractory oxide combination being supported on an acidic refractory oxide.

Claim 21

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide under said oxidizing conditions between a Group VIII component and a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof, which comprise the steps of (a) impregnating a high surface area Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof with a precursor of a Group VIII metal or mixtures thereof dissolved in a solvent; (b) drying the composite resulting from step (a) to remove said solvent; (c) admixing said dried composite of step (b) with an acidic refractory oxide; (d) contacting the composite of (c) with a reducing agent at conditions whereby the Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in (i) sufficient quantity to neutralize the acid sites of the acidic refractory oxide and to (ii) provide an excess at a level of from about 0.5 to 50 moles per mole of said Group VIII metal or mixture thereof, and (e) depositing the composite resulting from (d) onto an acidic refractory oxide support.

Claim 22

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide under said oxidizing conditions between a Group VIII component and a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof, which comprise the steps of (a) impregnating a high surface area Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof with a precursor of a Group VIII metal or mixtures thereof dissolved in a solvent; (b) drying the composite resulting from step (a) to remove said solvent; (c) admixing said dried composite of step (b) with an acidic refractory oxide; (d) contacting the composite of (c) with a reducing agent at conditions whereby the Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in (i) sufficient quantity to neutralize the acid sites of the acidic refractory oxide and to (ii) provide an excess at a level of from about 0.5 to 50 moles per mole of said Group VIII metal or mixture thereof, and (e) depositing the composite resulting from (d) onto an acidic refractory oxide support.

Claim 28

A method for activating supported Group VIII noble metal catalysts which have become deactivated due to noble metal agglomeration, which comprises impregnating said agglomerated catalysts with a solution comprising a Group IIA metal oxide precursor, wherein the Group IIA metal oxide resulting from said precursor is selected from the group consisting of calcium oxide, barium oxide strontium oxide and mixtures thereof, wherein the Group IIA metal oxide is present in sufficient quantity to neutralize the acidity of the support of the Group VIII catalyst and to provide an excess at a level of from about 0.5 to 50 moles/mole of said Group VIII metal, calcining said impregnated catalyst in the presence of oxygen for a time sufficient to convert said Group VIII noble metal and said excess Group IIA metal oxide into a mixed metal oxide complex and reducing said complex oxide to convert said mixed metal oxide into the noble metal metallic state and the Group IIA metal oxide state.

Claim 29

A method for activating supported Group VIII noble metal catalysts which have become deactivated due to noble metal agglomeration, which comprises impregnating said agglomerated catalysts with a solution comprising a Group IIA metal oxide precursor, wherein the Group IIA metal oxide resulting from said precursor is selected from the group consisting of calcium oxide, barium oxide strontium oxide and mixtures thereof, wherein the Group IIA metal oxide is present in sufficient quantity to neutralize the acidity of the support of the Group VIII catalyst and to provide an excess at a level of from about 0.5 to 50 moles/mole of said Group VIII metal, calcining said impregnated catalyst in the presence of oxygen for a time sufficient to convert said Group VIII noble metal and said excess Group IIA metal oxide into a mixed metal oxide complex and reducing said complex oxide to convert said mixed metal oxide into the noble metal metallic state and the Group IIA metal oxide state.

Claim 33

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide, under said oxidizing conditions, between a Group VIII metal component and a Group IIA metal oxide selected from the group consisting of calcium, barium and strontium oxides and mixtures thereof comprising the steps of (a) impregnating a high surface area, nonacidic refractory oxide selected from the group consisting of silica, silica-alumina and alumina with (i) a Group VIII metal precursor, and (ii) Group IIA metal oxide precursor, the Group IIA metal oxide resulting from said precursor being capable of combining with the Group VIII metal resulting from a precursor in the form of a complex oxide, both (i) and (ii) being dissolved in a solvent; (b) drying the composite of step (a) to remove said solvent; (c) calcining the composite of step (b) in the presence of oxygen at a temperature sufficient to convert the Group IIA metal oxide precursor to an oxide; (d) admixing the composite of step (c) with an acidic refractory oxide; and (e) contacting the Group VIII metal precursor containing composite of step (d) with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in an amount of from about 0.5 to 50 moles/mole of Group VIII metal.

Claim 34

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide, under said oxidizing conditions, between a Group VIII metal component and a Group IIA metal oxide selected from the group consisting of calcium, barium and strontium oxides and mixtures thereof comprising the steps of (a) impregnating a high surface area, nonacidic refractory oxide selected from the group consisting of silica, silica-alumina and alumina with (i) a Group VIII metal precursor, and (ii) Group IIA metal oxide precursor, the Group IIA metal oxide resulting from said precursor being capable of combining with the Group VIII metal resulting from a precursor in the form of a complex oxide, both (i) and (ii) being dissolved in a solvent; (b) drying the composite of step (a) to remove said solvent; (c) calcining the composite of step (b) in the presence of oxygen at a temperature sufficient to convert the Group IIA metal oxide precursor to an oxide; (d) admixing the composite of step (c) with an acidic refractory oxide; and (e) contacting the Group VIII metal precursor containing composite of step (d) with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in an amount of from about 0.5 to 50 moles/mole of Group VIII metal.

Claim 43

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide under said oxidizing conditions between a Group VIII metal component and a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof which comprises: (a) contacting a high surface area acidic refractory inorganic oxide with (i) a Group VIII metal precursor, and (ii) Group IIA metal oxide precursor, the Group IIA metal oxide resulting from said precursor being capable of combining with the Group VIII metal resulting from said precursor in a complex oxide, both (i) and (ii) being dissolved in a solvent; (b) drying said impregnated inorganic acidic refractory oxide of step (a) to remove said solvent; (c) calcining the composite of step (b) in the presence of oxygen at a temperature sufficient to convert the Group IIA metal oxide precursor to an oxide; (d) admixing the composite of step (c) with an acidic refractory oxide, and (e) contacting the composite of step (d) containing the Group VIII metal precursor with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in (i) sufficient quantity to neutralize the acid sites of the acidic refractory inorganic oxide of step (a) plus (ii) provide an excess at a level of from about 0.5 to 50 moles per mole of said Group VIII metal.

Claim 44

A method of making a hydrocarbon conversion catalyst resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide under said oxidizing conditions between a Group VIII metal component and a Group IIA metal oxide selected from the group consisting of calcium oxide, barium oxide, strontium oxide and mixtures thereof which comprises: (a) contacting a high surface area acidic refractory inorganic oxide with (i) a Group VIII metal precursor, and (ii) Group IIA metal oxide precursor, the Group IIA metal oxide resulting from said precursor being capable of combining with the Group VIII metal resulting from said precursor in a complex oxide, both (i) and (ii) being dissolved in a solvent; (b) drying said impregnated inorganic acidic refractory oxide of step (a) to remove said solvent; (c) calcining the composite of step (b) in the presence of oxygen at a temperature sufficient to convert the Group IIA metal oxide precursor to an oxide; (d) admixing the composite of step (c) with an acidic refractory oxide, and (e) contacting the composite of step (d) containing the Group VIII metal precursor with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in (i) sufficient quantity to neutralize the acid sites of the acidic refractory inorganic oxide of step (a) plus (ii) provide an excess at a level of from about 0.5 to 50 moles per mole of said Group VIII metal.

Claim 61

A method of making a hydrocarbon conversion catalyst which is resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide, under said oxidizing condition, between a Group VII metal component and a Group IIA metal oxide selected from the group consisting of calcium, barium and strontium oxides and mixtures thereof comprising the steps of (a) impregenating a high surface area, Group IIA metal oxide with a Group VIII metal precursor, the Group IIA metal oxide being capable of combining with the Group VIII metal resulting from its precursor in the form of a complex oxide, the Group VIII metal precursor being dissolved in a solvent, (b) drying the composite of step (a) to remove said solvent, (c) contacting the Group VIII metal precursor containing composite of step (b) with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in an amount of from about 0.5 to 50 moles/mole of Group VIII metal, and (d) depositing the composite resulting from step (c) onto an acidic refractory inorganic oxide support.

Claim 62

A method of making a hydrocarbon conversion catalyst which is resistant to metal agglomeration upon regeneration under oxidizing conditions due to the formation of a complex oxide, under said oxidizing condition, between a Group VII metal component and a Group IIA metal oxide selected from the group consisting of calcium, barium and strontium oxides and mixtures thereof comprising the steps of (a) impregenating a high surface area, Group IIA metal oxide with a Group VIII metal precursor, the Group IIA metal oxide being capable of combining with the Group VIII metal resulting from its precursor in the form of a complex oxide, the Group VIII metal precursor being dissolved in a solvent, (b) drying the composite of step (a) to remove said solvent, (c) contacting the Group VIII metal precursor containing composite of step (b) with a reducing agent at conditions whereby said Group VIII metal precursor is converted to the metal, wherein the Group IIA metal oxide is present in an amount of from about 0.5 to 50 moles/mole of Group VIII metal, and (d) depositing the composite resulting from step (c) onto an acidic refractory inorganic oxide support.