Catalyst for simultaneous hydrotreating and hydrodewaxing of hydrocarbons

Claim 2

A catalyst composition comprising a Group VIB metal component and a Group VIII metal component on a support comprising an admixture of a porous refractory oxide and a silica polymorph consisting essentially of crystalline silica.

Claim 3

A catalyst composition useful for promoting the dewaxing of hydrocarbons by reaction with hydrogen, which catalyst comprises a Group VIB metal component and a Group VIII metal component on a support consisting essentially of a porous refractory oxide and a silica polymorph consisting essentially of crystalline silica.

Claim 4

A catalyst composition useful for promoting the dewaxing of hydrocarbons by reaction with hydrogen, which catalyst comprises a Group VIB metal component and a Group VIII metal component on a support consisting essentially of a porous refractory oxide and a silica polymorph consisting essentially of crystalline silica.

Claim 5

A catalyst composition useful for promoting the simultaneous dewaxing and denitrogenation of hydrocarbons by reaction with hydrogen, which catalyst comprises a Group VIB metal component and a Group VIII metal component on a support comprising an intimate admixture of a porous refractory oxide and a silica polymorph consisting essentially of a crystalline silica molecular sieve.

Claim 6

A catalyst composition useful for promoting the simultaneous dewaxing and denitrogenation of hydrocarbons by reaction with hydrogen, which catalyst comprises a Group VIB metal component and a Group VIII metal component on a support comprising an intimate admixture of a porous refractory oxide and a silica polymorph consisting essentially of a crystalline silica molecular sieve.

Claim 7

A catalyst composition as defined in claim 1 or 3 wherein said silica polymorph contains Group IIIA metals in a proportion no greater than 0.75 weight percent, calculated as the trioxides thereof.

Claim 8

A catalyst composition as defined in claim 2 or 3 wherein said silica polymorph comprises a crystalline molecular sieve having channels with openings defined by ten membered rings of oxygen atoms.

Claim 9

A catalyst composition as defined in claim 5 wherein the Group IIIA metal content of said silica polymorph is less than 0.75 weight percent, calculated as the trioxides.

Claim 10

A catalyst composition as defined in claim 1 or 2 wherein said silica polymorph contains channels whose maximum cross-sectional dimension is between about 5 and about 6 angstroms.

Claim 11

A catalyst composition as defined in claim 1, 2, or 3 wherein said silica polymorph is a form of silicalite.

Claim 12

A catalyst composition as defined in claim 2 wherein said silica polymorph is a silicalite having a specific gravity at 25° C. of 1.70±0.5 g./cc. and a mean refractive index of 1.39±0.01 when calcined in air for one hour at 600° C.

Claim 13

A catalyst composition as defined in claim 1, 2, or 3 wherein said silica polymorph has a specific gravity at 25° C. between about 1.65 and 1.80 g./cc.

Claim 14

A catalyst composition as defined in claim 1 or 3 wherein said silica polymorph has an X-ray diffraction pattern similar to ZSM-5.

Claim 15

A catalyst composition as defined in claim 5 wherein said silica polymorph has an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 16

A catalyst composition as defined in claim 1 or 2 wherein said silica polymorph has an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 17

A catalyst composition as defined in claim 7 wherein said silica polymorph has an X-ray diffraction pattern similar to ZSM-5.

Claim 18

A catalyst composition as defined in claim 5 wherein said silica polymorph contains less than 0.75 weight percent total metals, calculated as metals.

Claim 19

A catalyst composition as defined in claim 13 wherein said silica polymorph contains less than 0.75 weight percent total metals, calculated as metals.

Claim 20

A catalyst composition as defined in claim 11 wherein said silica polymorph contains less than 0.75 weight percent total metals, calculated as metals.

Claim 21

A catalyst composition as defined in claim 17 wherein said Group VIB metal component is selected from the group consisting of tungsten, molybdenum, the sulfides thereof, the oxides thereof, and mixtures thereof, and said Group VIII metal component is selected from the group consisting of nickel, cobalt, the sulfides thereof, the oxides thereof, and mixtures thereof.

Claim 22

A catalyst composition as defined in claim 6 wherein said Group VIB metal component is selected from the group consisting of tungsten, molybdenum, the sulfides thereof, the oxides thereof, and mixtures thereof, and said Group VIII metal component is selected from the group consisting of nickel, cobalt, the sulfides thereof, the oxides thereof, and mixtures thereof.

Claim 23

A catalyst composition as defined in claim 8 wherein said Group VIB metal component is selected from the group consisting of tungsten, molybdenum, the sulfides thereof, the oxides thereof, and mixtures thereof, and said Group VIII metal component is selected from the group consisting of nickel, cobalt, the sulfides thereof, the oxides thereof, and mixtures thereof.

Claim 24

A catalyst composition comprising a Group VIB metal component and a Group VIII metal component on a support comprising a porous refractory oxide in intimate admixture with an essentially Group IIIA metal-free crystalline silica molecular sieve having channels with apertures defined by ten membered rings of oxygen atoms.

Claim 25

A catalyst composition comprising a Group VIB metal component and a Group VIII metal component on a support comprising a porous refractory oxide in intimate admixture with an essentially Group IIIA metal-free crystalline silica molecular sieve having channels with apertures defined by ten membered rings of oxygen atoms.

Claim 26

A catalyst composition comprising a Group VIB metal component and a Group VIII metal component on a support comprising a porous refractory oxide in intimate admixture with an essentially Group IIIA metal-free crystalline silica molecular sieve said molecular sieve comprising between about 2 and 90 percent by weight of said support.

Claim 27

A catalyst composition comprising a Group VIB metal component and a Group VIII metal component on a support comprising a porous refractory oxide in intimate admixture with an essentially Group IIIA metal-free crystalline silica molecular sieve said molecular sieve comprising between about 2 and 90 percent by weight of said support.

Claim 28

A catalyst composition as defined in claim 21 or 22 wherein said molecular sieve has an X-ray diffraction pattern similar to ZSM-5.

Claim 29

A catalyst composition as defined in claim 22 wherein said molecular sieve contains no more than 0.05 weight percent of organic materials, calculated as carbon.

Claim 30

A catalyst composition as defined in claim 21 wherein the specific gravity of said molecular sieve is between about 1.65 and 1.80 cc./gm at 25° C.

Claim 31

A catalyst composition as defined in claim 21 or 22 wherein said molecular sieve is a form of silicalite.

Claim 32

A catalyst composition as defined in claim 26 wherein said silicalite has a mean refractive index of 1.39±0.01.

Claim 33

A catalyst composition as defined in claim 26 wherein said silicalite is essentially organic-free.

Claim 34

A hydroprocessing catalyst composition consisting essentially of a Group VIB metal component and a Group VIII metal component on a support consisting essentially of an intimate admixture of a porous refractory oxide and a silica polymorph consisting essentially of crystalline silica having a Group IIIA metal content less than 0.75 percent by weight, calculated as the trioxides, and an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 35

A hydroprocessing catalyst composition consisting essentially of a Group VIB metal component and a Group VIII metal component on a support consisting essentially of an intimate admixture of a porous refractory oxide and a silica polymorph consisting essentially of crystalline silica having a Group IIIA metal content less than 0.75 percent by weight, calculated as the trioxides, and an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 36

A catalyst composition as defined in claim 29 wherein said Group VIB metal component is a tungsten component and said Group VIII metal component is a nickel component.

Claim 37

A catalyst composition as defined in claim 30 wherein said porous refractory oxide is alumina.

Claim 38

A catalyst composition as defined in claim 1, 3, 9, 21, 24, or 29 wherein said Group VIB metal component is selected from the group consisting of tungsten, molybdenum, the sulfides thereof, the oxides thereof, and mixtures thereof, and said Group VIII metal component is selected from the group consisting of nickel, cobalt, the sulfides thereof, the oxides thereof, and mixtures thereof.

Claim 39

A catalyst composition comprising between about 5 and 40 percent by weight of one or more Group VIB metal components, calculated as the metal trioxides, and between about 0.5 and 15 percent by weight of one or more Group VIII metal components, calculated as the metal monoxides, on a support consisting essentially of a porous refractory oxide and a silica polymorph consisting essentially of a crystalline silica having channels with apertures whose maximum cross-sectional dimension is between about 5 and 6 angstroms, said crystalline silica being essentially free of Group IIIA metals.

Claim 40

A catalyst composition comprising between about 5 and 40 percent by weight of one or more Group VIB metal components, calculated as the metal trioxides, and between about 0.5 and 15 percent by weight of one or more Group VIII metal components, calculated as the metal monoxides, on a support consisting essentially of a porous refractory oxide and a silica polymorph consisting essentially of a crystalline silica having channels with apertures whose maximum cross-sectional dimension is between about 5 and 6 angstroms, said crystalline silica being essentially free of Group IIIA metals.

Claim 41

A catalyst composition as defined in claim 33 wherein said silica polymorph has an X-ray diffraction pattern similar to ZSM-5.

Claim 42

A catalyst composition as defined in claim 34 wherein said crystalline silica is essentially free of organic components and said crystalline silica contains less than 0.75 percent by weight of total metals.

Claim 43

A catalyst composition as defined in claim 33 or 35 wherein said crystalline silica is a form of silicalite.

Claim 44

A catalyst composition as defined in claim 36 wherein said Group VIB metal components are selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, and said Group VIII metal components are selected from the group consisting of nickel, cobalt, the oxides thereof, the sulfides thereof, and mixtures thereof.

Claim 45

A catalyst composition as defined in claim 24 or 34 wherein said Group VIB metal components are selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, and said Group VIII metal components are selected from the group consisting of nickel, cobalt, the oxides thereof, the sulfides thereof, and mixtures thereof.

Claim 46

A catalyst composition useful for promoting the simultaneous dewaxing and denitrogenation of hydrocarbons by reaction with hydrogen, which catalyst comprises at least 1.0 weight percent of a Group VIII metal component selected from the group consisting of cobalt, nickel, the oxides thereof, the sulfides thereof, and mixtures thereof, and at least 10 weight percent of a Group VIB metal component selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, and a support comprising a porous refractory oxide and between about 15 and 45 weight percent of a silica polymorph consisting essentially of crystalline silica.

Claim 47

A catalyst composition useful for promoting the simultaneous dewaxing and denitrogenation of hydrocarbons by reaction with hydrogen, which catalyst comprises at least 1.0 weight percent of a Group VIII metal component selected from the group consisting of cobalt, nickel, the oxides thereof, the sulfides thereof, and mixtures thereof, and at least 10 weight percent of a Group VIB metal component selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, and a support comprising a porous refractory oxide and between about 15 and 45 weight percent of a silica polymorph consisting essentially of crystalline silica.

Claim 48

A catalyst composition as defined in claim 39 wherein said crystalline silica contains less than 0.75 weight percent of Group IIIA elements and said refractory oxide comprises alumina.

Claim 49

A catalyst composition as defined in claim 40 wherein said silica polymorph has, when calcined in air at 600° C. for one hour, a mean refractive index of 1.39±0.01 and a specific gravity at 25° C. between 1.65 and 1.80 grams per cubic centimeter.

Claim 50

A catalyst composition useful for hydrodewaxing consisting essentially of between about 1 and about 5 percent by weight of one or more Group VIII metal components selected from the group consisting of cobalt, nickel, the oxides thereof, the sulfides thereof, and mixtures thereof, calculated as the metal monoxides, and between about 15 and 30 percent by weight of one or more Group VIB metal components selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, calculated as the metal trioxides, on a support consisting essentially of a porous refractory oxide in admixture with between about 15 and 45 percent by weight of the support of a silicalite having an X-ray diffraction pattern similar to ZSM-5 and a specific gravity at 25° C. between about 1.65 and 1.80 g./cc.

Claim 51

A catalyst composition useful for hydrodewaxing consisting essentially of between about 1 and about 5 percent by weight of one or more Group VIII metal components selected from the group consisting of cobalt, nickel, the oxides thereof, the sulfides thereof, and mixtures thereof, calculated as the metal monoxides, and between about 15 and 30 percent by weight of one or more Group VIB metal components selected from the group consisting of molybdenum, tungsten, the oxides thereof, the sulfides thereof, and mixtures thereof, calculated as the metal trioxides, on a support consisting essentially of a porous refractory oxide in admixture with between about 15 and 45 percent by weight of the support of a silicalite having an X-ray diffraction pattern similar to ZSM-5 and a specific gravity at 25° C. between about 1.65 and 1.80 g./cc.

Claim 52

A catalyst composition as defined in claim 42 wherein said silicalite is essentially organic-free and contains metals in a proportion no greater than 0.75 percent by weight.

Claim 53

A catalyst as defined in claim 43 wherein said silicalite is present in a proportion between about 20 and 40 percent by weight.

Claim 54

A catalyst as defined in claim 42 or 44 wherein said Group VIB metal component is selected from the group consisting of tungsten, tungsten oxides, and tungsten sulfides, and said Group VIII metal is selected from the group consisting of nickel, nickel oxides, and nickel sulfides.

Claim 55

A catalyst composition useful for simultaneous dewaxing, denitrogenation and desulfurization of hydrocarbons by reaction with hydrogen consisting essentially of between about 1 and about 5 percent by weight of nickel components, calculated as NiO, and between about 15 and 30 percent by weight of tungsten components, calculated as WO 3 , on a support consisting essentially of a porous refractory oxide in admixture with between about 20 and 40 percent by weight of the support of an organic-free silicalite having a specific gravity at 25° C. of 1.70±0.5 g./cc., a mean refractive index of 1.39±0.01, and an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 56

A catalyst composition useful for simultaneous dewaxing, denitrogenation and desulfurization of hydrocarbons by reaction with hydrogen consisting essentially of between about 1 and about 5 percent by weight of nickel components, calculated as NiO, and between about 15 and 30 percent by weight of tungsten components, calculated as WO 3 , on a support consisting essentially of a porous refractory oxide in admixture with between about 20 and 40 percent by weight of the support of an organic-free silicalite having a specific gravity at 25° C. of 1.70±0.5 g./cc., a mean refractive index of 1.39±0.01, and an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 57

A catalyst composition as defined in claim 22, 33, 42, or 46 wherein said catalyst is in a sulfided form.

Claim 58

A catalyst composition as defined in claim 35 or 46 wherein said porous refractory oxide is selected from the group consisting of alumina, silica, beryllia, zirconia, titania, magnesia, thoria, silica-alumina, silica-titania, silica-zirconia, silica-zirconia-titania, zirconia-titania, a dispersion of silica-alumina in alumina, and mixtures thereof.

Claim 59

A catalyst composition as defined in claim 42 or 46 wherein said porous refractory oxide is alumina.

Claim 60

A catalyst composition as defined in claim 42 or 46 wherein said porous refractory oxide is alumina having a surface area above about 100 m 2 /gm.

Claim 61

A catalyst composition as defined in claim 3, 21, or 22 wherein said porous refractory oxide comprises a member selected from the group consisting of alumina, silica, beryllia, chromia, zirconia, titania, magnesia, thoria, silica-alumina, silica-titania, silica-zirconia, silica-zirconia-titania, and zirconia-titania and said crystalline molecular sieve has an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 62

A catalyst composition as defined in claim 1 or 39 wherein said porous refractory oxide comprises a member selected from the group consisting of alumina, silica, beryllia, chromia, zirconia, titania, magnesia, thoria, silica-alumina, silica-titania, silica-zirconia, silica-zirconia-titania, and zirconia-titania and said silica polymorph has an X-ray diffraction pattern whose six strongest lines are as set forth in the following table, wherein S refers to strong lines and VS to very strong lines: ______________________________________ d-A Relative Intensity ______________________________________ 11.1 ± 0.2 VS 10.0 ± 0.2 VS 3.85 ± 0.07 VS 3.82 ± 0.07 S 3.76 ± 0.05 S 3.72 ± 0.05 S ______________________________________

Claim 63

A catalyst composition as defined in claim 51 wherein said crystalline molecular sieve has a refractive index of 1.39+0.01.

Claim 64

A catalyst composition as defined in claim 52 wherein said silica polymorph has a refractive index of 1.39±0.01.