Hydrocracking catalyst of improved activity

Claim 2

A hydrocracking process which comprises contacting a hydrocarbon feedstock with a hydrogen-containing gas in the presence of a hydroconversion hydrocracking catalyst, wherein said catalyst comprises: (a) a crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above, said zeolite having been ion-exchanged with rare earth-containing cations and Group VIII noble metal-containing cations; (b) a porous, inorganic refractory oxide intimately mixed with said zeolite; and (c) between about 4.5 weight percent and about 6.5 weight percent water based on the total weight of said catalyst composition.

Claim 3

A process as defined by claim 1 wherein said zeolite has a sorptive capacity for water vapor at 25° C. and 4.6 mm mercury water vapor partial pressure of at least 20 percent by weight of said zeolite in its anhydrous form.

Claim 4

A process as defined by claim 1 wherein said zeolite is prepared by contacting an ammonium-exchanged Y zeolite with an aqueous solution of ammonium fluorosilicate, said Group VIII noble metal-containing cations comprise palladium and said porous, inorganic refractory oxide comprises alumina.

Claim 5

A process as defined by claim 1 wherein said crystalline aluminosilicate Y zeolite comprises between about 50 and about 90 weight percent or said hydrocracking catalyst.

Claim 6

A process as defined by claim 1 wherein said Group VIII noble metal-containing cations comprise palladium or platinum.

Claim 7

A process as defined by claim 1 wherein said porous, inorganic refractory oxide is selected from the group consisting of alumina, silica-alumina, silica-magnesia and silica-titania.

Claim 8

A process as defined by claim 1 wherein said crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above is prepared by contacting a Y zeolite with an aqueous solution of a fluorosilicate salt.

Claim 9

A process as defined by claim 1 wherein said Group VIII noble metal-containing cations comprise palladium and said porous, inorganic refractory oxide comprises alumina.

Claim 10

A process as defined by claim 8 wherein said crystalline aluninosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above comprises LZ-210 zeolite.

Claim 11

A process as defined by claim 8 wherein said crystalline aluminosilicate Y zeolite has a silica-to-alumina mole ratio between about 6.3 and about 7.0.

Claim 12

A process as defined by claim 1 wherein said hydrocracking catalyst contains between about 4.5 and about 6.0 weight percent water based on the total weight of said hydrocracking catalyst.

Claim 13

A process as defined by claim 3 wherein said zeolite prepared by contacting an ammonium-exchanged Y zeolite with an aqueous solution of ammonium fluorosilicate comprises LZ-210 zeolite.

Claim 14

A process as defined by claim 1 wherein said Group VIII noble metal-containing cations comprise palladium and said porous, inorganic refractory oxide component comprises alumina.

Claim 15

A process for refining a hydrocarbon feedstock containing organonitrogen components, organosulfur components or a mixture thereof comprising: (a) contacting said feedstock with a hydrogen-containing gas in a hydrotreating zone under hydrotreating conditions in the presence of a hydrotreating catalyst comprising a Group VIB metal component and a Group VIII metal component such that a substantial proportion of the organonitrogen components, organosulfur components or mixture thereof is converted to ammonia, hydrogen sulfide or a mixture thereof; (b) contacting substantially all of the effluent from said hydrotreating zone with molecular hydrogen in a first hydrocracking zone in the presence of a first hydrocracking catalyst comprising a zeolite and a hydrogenation component to produce a hydrocracking product of substantially lower boiling point; (c) separating said hydrocracking product into a higher boiling fraction and a lower boiling fraction; (d) contacting said higher boiling fraction with molecular hydrogen in a second hydrocracking zone under hydrocracking conditions in the presence of a second hydrocracking catalyst to convert said higher boiling fraction into lower boiling products, wherein said second hydrocracking catalyst comprises: (1) a crystalline aluminosilicate Y zeolite having a silica-to-alumina mode ratio of about 6.2 or above, said zeolite having been ion-exchanged with rare earth-containing cations and Group VIII noble metal-containing cations; (2) a porous, inorganic refractory oxide intimately mixed with said zeolite; and (3) between about 4.5 weight percent and about 6.0 weight percent water based on the total weight of said second hydrocracking catalyst.

Claim 16

A process for refining a hydrocarbon feedstock containing organonitrogen components, organosulfur components or a mixture thereof comprising: (a) contacting said feedstock with a hydrogen-containing gas in a hydrotreating zone under hydrotreating conditions in the presence of a hydrotreating catalyst comprising a Group VIB metal component and a Group VIII metal component such that a substantial proportion of the organonitrogen components, organosulfur components or mixture thereof is converted to ammonia, hydrogen sulfide or a mixture thereof; (b) contacting substantially all of the effluent from said hydrotreating zone with molecular hydrogen in a first hydrocracking zone in the presence of a first hydrocracking catalyst comprising a zeolite and a hydrogenation component to produce a hydrocracking product of substantially lower boiling point; (c) separating said hydrocracking product into a higher boiling fraction and a lower boiling fraction; (d) contacting said higher boiling fraction with molecular hydrogen in a second hydrocracking zone under hydrocracking conditions in the presence of a second hydrocracking catalyst to convert said higher boiling fraction into lower boiling products, wherein said second hydrocracking catalyst comprises: (1) a crystalline aluminosilicate Y zeolite having a silica-to-alumina mode ratio of about 6.2 or above, said zeolite having been ion-exchanged with rare earth-containing cations and Group VIII noble metal-containing cations; (2) a porous, inorganic refractory oxide intimately mixed with said zeolite; and (3) between about 4.5 weight percent and about 6.0 weight percent water based on the total weight of said second hydrocracking catalyst.

Claim 17

A process as defined by claim 14 wherein said first hydrocracking catalyst in said first hydrocracking zone is the same as said second hydrocracking catalyst in said second hydrocracking zone.

Claim 18

A process as defined by claim 14 wherein said crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above has a sorptive capacity for water vapor at 25° C. and 4.6 mm mercury water vapor partial pressure of at least about 20 weight percent of said zeolite in its anhydrous form.

Claim 19

A porcess as defined by claim 14 wherein said crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above is prepared by contacting an ammonium-exchanged Y zeolite with an aqueous solution of ammonium fluorosilicate, said Group VIII noble metal-containing cations comprise palladium and said porous, inorganic refractory oxide comprises alumina.

Claim 20

A process as defined by claim 17 wherein said crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio greater than about 6.2 or above prepared by contacting an ammonium-exchanged Y zeolite with an aqueous solution of ammonium fluorosilicate comprises LZ-210 zeolite.

Claim 21

A hydrocracking process which comprises contacting a hydrocarbon feedstock with a hydrogen-containing gas in the presence of a hydrocracking catalyst under hydrocracking conditions wherein said catalyst comprises: (a) a crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above, said zeolite having been ion-exchanged with rate earth-containing cations and Group VIII noble metal-containing cations; (b) a porous, inorganic refractory oxide component; and (c) between about 4.0 weight percent and about 7.0 weight percent water based on the total weight of said hydrocracking catalyst.

Claim 22

A hydrocracking process which comprises contacting a hydrocarbon feedstock with a hydrogen-containing gas in the presence of a hydrocracking catalyst under hydrocracking conditions wherein said catalyst comprises: (a) a crystalline aluminosilicate Y zeolite having a silica-to-alumina mole ratio of about 6.2 or above, said zeolite having been ion-exchanged with rate earth-containing cations and Group VIII noble metal-containing cations; (b) a porous, inorganic refractory oxide component; and (c) between about 4.0 weight percent and about 7.0 weight percent water based on the total weight of said hydrocracking catalyst.

Claim 23

A process as defined by claim 18 wherein said Group VIII noble metal-containing cations comprise palladium or platinum.

Claim 24

A process as defined by claim 19 wherein said crystalline aluminosilicate Y zeolite is prepared by contacting a Y zeolite with an aqueous solution of ammonium fluorosilicate.

Claim 25

A process as defined by claim 21 wherein said crystalline aluminosilicate Y zeolite prepared by contacting a Y zeolite with an aqueous solution of ammonium fluorosilicate comprises LZ-210 zeolite.

Claim 26

A process as defined by claim 22 wherein said crystalline aluminosilicate Y zeolite has a silica-to-alumina mole ratio between about 6.3 and about 7.0.

Claim 27

A process as defined by claim 19 wherein said Group VIII noble metal-containing cations comprises palladium, said porous, inorganic refractory oxide component comprises alumina and said crystalline aluminosilicate Y zeolite comprises LZ-210 zeolite.