Catalyst and support, their methods of preparation, and processes employing same

Claim 3

The method of claim 1, wherein said composite is a mixture of alumina and about 1 wt% to about 20 wt% silica, a mixture of alumina, about 1 wt% to about 20 wt% silica, and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 1 wt% to about 10 wt% boria, a mixture of alumina, about 1 wt% to about 10 wt% boria, and about 5 wt% to about 20 wt% oxides of phosphorus, or a mixture of alumina, about 1 wt% to about 20 wt% magnesia, and about 5 wt% to about 20 wt% oxides of phosphorus, said oxides of phosphorus being calculated as P 2 O 5 and said quantities being based upon the weight of said composite.

Claim 4

The method of claim 1, wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 5

The method of claim 1, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 6

The method of claim 2 wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 7

The method of claim 2, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 8

The method of claim 2, wherein said composite is a mixture of alumina and about 1 wt% to about 20 wt% silica, based upon the weight of said composite.

Claim 9

The method of claim 3, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 10

The method of claim 5, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 11

The method of claim 7, wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 12

The method of claim 7, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 13

The method of claim 10, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 14

The method of claim 12, wherein said composite comprises a mixture of alumina and about 1 wt% to about 7 wt% silica, based upon the weight of said composite.

Claim 17

The method of claim 14, wherein said composite is a mixture of alumina and about 1 wt% to about 20 wt% silica, a mixture of alumina, about 1 wt% to about 20 wt% silica, and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 1 wt% to about 10 wt% boria, a mixture of alumina, about 1 wt% to about 10 wt% boria, and about 5 wt% to about 20 wt% oxides of phosphorus, or a mixture of alumina, about 1 wt% to about 20 wt% magnesia, and about 5 wt% to about 20 wt% oxides of phosphorus, said oxides of phosphorus being calculated as P 2 O 5 and said quantities being based upon the weight of said composite.

Claim 18

The method of claim 14, wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 19

The method of claim 14, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 20

The method of claim 14, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 21

The method of claim 15, wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 22

The method of claim 15, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 23

The method of claim 15, wherein said composite comprises a mixture of alumina and about 1 wt% to about 20 wt% silica, based upon the weight of said composite.

Claim 24

The method of claim 15, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 25

The method of claim 16, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 26

The method of claim 19, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 27

The method of claim 21, wherein said temperature is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 28

The method of claim 21, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 29

The method of claim 23, wherein said at least one hydrogenating metal is molybdenum and is present in an amount within the range of about 0.5 wt% to about 20 wt%, calculated as MoO 3 and based upon the weight of said catalytic composition.

Claim 30

The method of claim 24, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 31

The method of claim 25, wherein said steam is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 32

The method of claim 28, wherein said at least one hydrogenating metal is molybdenum and is present in an amount within the range of about 0.5 wt% to about 20 wt%, calculated as MoO 3 and based upon the weight of said catalytic composition.

Claim 33

The method of claim 29, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 34

The method of claim 31, wherein said composite comprises a mixture of alumina and about 1 wt% to about 7 wt% silica, based upon the weight of said composite.

Claim 35

A catalyst support which comprises two or more inorganic oxides and which is prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having a selected shape and at least 0.8 cc/gm of its pore volume in pores having diameters of 0 nm (0 A) to 120 nm (1,200 A) and at least 0.1 cc/gm of its pore volume in pores having diameters of 120 nm (1,200 A) to 5,000 nm (50,000 A) and heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a catalyst support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm.

Claim 36

A catalyst support which comprises two or more inorganic oxides and which is prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having a selected shape and at least 0.8 cc/gm of its pore volume in pores having diameters of 0 nm (0 A) to 120 nm (1,200 A) and at least 0.1 cc/gm of its pore volume in pores having diameters of 120 nm (1,200 A) to 5,000 nm (50,000 A) and heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a catalyst support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm.

Claim 37

The catalyst support of claim 33, wherein said composite is a mixture of alumina and about 1 wt% to about 20 wt% silica, a mixture of alumina, about 1 wt% to about 20 wt% silica, and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 1 wt% to about 10 wt% boria, a mixture of alumina, about 1 wt% to about 10 wt% boria, and about 5 wt% to about 20 wt% oxides of phosphorus, or a mixture of alumina, about 1 wt% to about 20 wt% magnesia, and about 5 wt% to about 20 wt% oxides of phosphorus, said oxides of phosphorus being calculated as P 2 O 5 and said quantities being based upon the weight of said composite.

Claim 38

The catalyst support of claim 34, wherein said steam that is used in its preparation is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 39

The catalyst support of claim 34, wherein said temperature that is used in its preparation is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 40

The catalyst support of claim 34, wherein said composite comprises a mixture of alumina and about 1 wt% to about 20 wt% silica, based upon the weight of said composite.

Claim 41

The catalyst support of claim 36, wherein said steam that is used in its preparation is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 42

The catalyst support of claim 37, wherein said temperature that is used in its preparation is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 43

The catalyst support of claim 37, wherein said steam that is used in its preparation is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 44

The catalyst support of claim 40, wherein said temperature that is used in its preparation is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.).

Claim 45

The catalyst support of claim 41, wherein said composite is a mixture of alumina and about 1 wt% to about 7 wt% silica, based upon the weight of said composite.

Claim 46

A catalyst which comprises a hydrogenating component comprising at least one hydrogenating metal and a large-pore, high-surface area support comprising two or more inorganic oxides, said at least one hydrogenating metal being present in the elemental form, as the oxide, as the sulfide, or mixtures thereof, said catalyst having been prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having a selected shape and at least 0.8 cc/gm of its pore volume in pores having diameters of 0 nm (0 A) to 120 nm (1,200 A) and at least 0.1 cc/gm of its pore volume in pores having diameters of 120 nm (1,200 A) to 5,000 nm (50,000 A), heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a steam-treated support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm, and subsequently impregnating said steam-treated support material with said at least one hydrogenating metal.

Claim 47

A catalyst which comprises a hydrogenating component comprising at least one hydrogenating metal and a large-pore, high-surface area support comprising two or more inorganic oxides, said at least one hydrogenating metal being present in the elemental form, as the oxide, as the sulfide, or mixtures thereof, said catalyst having been prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having a selected shape and at least 0.8 cc/gm of its pore volume in pores having diameters of 0 nm (0 A) to 120 nm (1,200 A) and at least 0.1 cc/gm of its pore volume in pores having diameters of 120 nm (1,200 A) to 5,000 nm (50,000 A), heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a steam-treated support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm, and subsequently impregnating said steam-treated support material with said at least one hydrogenating metal.

Claim 48

The catalyst of claim 43, wherein said composite is a mixture of alumina and about 1 wt% to about 20 wt% silica, a mixture of alumina, about 1 wt% to about 20 wt% silica, and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 5 wt% to about 20 wt% oxides of phosphorus, a mixture of alumina and about 1 wt% to about 10 wt% boria, a mixture of alumina, about 1 wt% to about 10 wt% boria, and about 5 wt% to about 20 wt% oxides of phosphorus, or a mixture of alumina, about 1 wt% to about 20 wt% magnesia, and about 5 wt% to about 20 wt% oxides of phosphorus, said oxides of phosphorus being calculated as P 2 O 5 and said quantities being based upon the weight of said composite.

Claim 49

The catalyst of claim 43, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 50

The catalyst of claim 44, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 51

The catalyst of claim 44, wherein said composite comprises a mixture of alumina and about 1 wt% to about 20 wt% silica, based upon the weight of said composite.

Claim 52

The catalyst of claim 47, wherein said at least one hydrogenating metal is selected from the group consisting of vanadium, metals of Group VIB of the Periodic Table of Elements, and metals of Group VIII of the Periodic Table of Elements.

Claim 53

The catalyst of claim 48, wherein the temperature that is used in its preparation is within the range of about 704° C. (1,300° F.) to about 927° C. (1,700° F.) and the steam that is used in its preparation is employed at a pressure within the range of about 30 kPa (4.4 psia) to about 274 kPa (25 psig).

Claim 54

The catalyst of claim 49, wherein said at least one hydrogenating metal is molybdenum and is present within the range of about 0.5 wt% to about 20 wt%, calculated as MoO 3 and based upon the weight of the catalyst.

Claim 57

A catalyst support comprising two or more inorganic oxides and having a selected shape, a total pore volume that is at least 0.8 cc/gm, and a bimodal distribution of pore sizes, said catalyst support having been prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having said selected shape, said total pore volume, and said bimodal distribution of pore sizes and heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a catalyst support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm.

Claim 58

A catalyst support comprising two or more inorganic oxides and having a selected shape, a total pore volume that is at least 0.8 cc/gm, and a bimodal distribution of pore sizes, said catalyst support having been prepared by forming a composite comprising said two or more inorganic oxides into a shaped catalyst support material having said selected shape, said total pore volume, and said bimodal distribution of pore sizes and heating said shaped catalyst support material in the presence of steam at sufficient elevated temperature, steam pressure, and time period to increase the average pore diameter of said shaped catalyst support material in the absence of any appreciable reduction in pore volume so as to provide a catalyst support material having an average pore diameter of at least 18 nm (180 A) and a surface area below 200 m 2 /gm.