Hydroconversion catalyst and method for making the catalyst

Abstract

A high-activity hydrotreating catalyst, having a low density, suitable for deep removal of sulfur, nitrogen, micro-carbon residue and organometallic contaminants from hydrocarbon feedstocks is disclosed. Further disclosed is a method of preparation of this catalyst, which may contain 0.3-10 wt % of a Group IVB metal promoter, 5-25 wt % of a Group VIB metal component, and 1-8 wt % of a Group VIII metal, along with a method of hydrotreating employing this catalyst.

What is claimed is:  
     
         1 . A method of making a hydrotreating catalyst which comprises the following steps: 
 (a) mixing a refractory inorganic oxide carrier with an aqueous acidic solution comprising at least one component from Group VIII and at least one component from Group VIB to form particles of the catalyst; and    (b) shaping, drying and calcining the particles of the catalyst.    
     
     
         2 . The method of  claim 1 , further comprising the following steps: 
 (c) post-impregnating the particles of the catalyst with additional hydrogenation components including at least one component from Group VIII and at least one component from Group VIB; and    (d) shaping, drying and calcining the particles of the catalyst.    
     
     
         3 . The method of  claim 1 , wherein the refractory inorganic oxide carrier of step (a) is mixed with at least one Group IVB component before the aqueous acidic solution is added.  
     
     
         4 . The method of  claim 1 , where in the mixture of step (a) is further treated with an acid selected from the group consisting of acetic acid, sulfuric acid, oxalic acid, hydrochloric acid, formic acid; nitric acid, phosphoric acid and citric acid.  
     
     
         5 . The method of  claim 1 , wherein the refractory inorganic oxide carrier is alumina.  
     
     
         6 . The method of  claim 3 , wherein the Group IVB component is selected from the group consisting of the metals and compounds of titanium, zirconium and hafnium.  
     
     
         7 . The method of  claim 1 , wherein the Group VIII metals are selected from the group consisting of the metals and compounds of nickel and cobalt.  
     
     
         8 . The method of  claim 1 , wherein the Group VIB metals are selected from the group consisting of the metals and compounds of molybdenum and tungsten.  
     
     
         9 . The method of  claim 3 , wherein the Group IVB metal is present in amounts ranging from 0.3 through 10 wt % of the catalyst.  
     
     
         10 . The method of  claim 9 , wherein the Group IVB metal is present in amounts ranging from 3 through 6 wt % of the catalyst.  
     
     
         11 . The method of  claim 2 , wherein the Group VIB component is present in amounts ranging from 5 through 25 wt % of the catalyst and Group VIII component is present in amounts ranging from 1 through 8 wt % of the catalyst.  
     
     
         12 . The method of  claim 11 , wherein the Group VIB component is present in amounts ranging from 10 through 20 wt % of the catalyst and Group VIII component is present in amounts ranging from 2 through 4 wt % of the catalyst.  
     
     
         13 . A catalyst prepared according to the method of  claim 1 ,  2 ,  3  or  4 .  
     
     
         14 . A catalyst composition comprising: 
 (a) a refractory organic oxide carrier;    (b) at least one component from Group VIII;    (c) at least one component from Group VIB; and    (d) at least one component from Group IVB.    
     
     
         15 . A method for the hydrotreating of a hydrocarbon feed containing a substantial amount of heteroatoms and other contaminants, which method comprises contacting said feed in a reaction zone under hydrotreating conditions comprising a temperature within the range of about 500° F. to about 850° F., a total pressure within the range of about 450 to about 3500 pounds per square inch gauge, a liquid hourly space velocity ranging from about 0.05 to about 5.0 hr. −1 , and a hydrogen partial pressure ranging from about 350 to about 3200 pounds per square inch gauge, in the presence of hydrogen and with a catalyst prepared by the method comprising: 
 (a) mixing a refractory inorganic oxide carrier with an aqueous acidic solution comprising at least one component from Group VIII and at least one component from Group VIB to form particles of the catalyst; and  
 (b) shaping, drying and calcining the particles of the catalyst.  
 
     
     
         16 . A method for the hydrotreating of a hydrocarbon feed containing a substantial amount of heteroatoms and other contaminants, which method comprises contacting said feed in a reaction zone under hydrotreating conditions comprising a temperature within the range of about 500° F. to about 850° F., a total pressure within the range of about 450 to about 3500 pounds per square inch gauge, a liquid hourly space velocity ranging from about 0.05 to about 5.0 hr. −1 , and a hydrogen partial pressure ranging from about 350 to about 3200 pounds per square inch gauge, in the presence of hydrogen and with a catalyst composition comprising: 
 (a) a refractory organic oxide carrier;  
 (b) at least one component from Group VIII;  
 (c) at least one component from Group VIB; and  
 (d) at least one component from Group IVB.  
 
     
     
         17 . The method of  claim 15 , wherein the refractory inorganic oxide carrier of step (a) is mixed with at least Group IVB component before the aqueous acidic solution is added.  
     
     
         18 . The method of  claim 15 , wherein the catalyst preparation further comprises: 
 (c) post-impregnating the particles of the catalyst with additional hydrogenation components including at least one component from Group VIII and at least one component from Group VIB; and    (d) shaping, drying and calcining the particles of the catalyst.    
     
     
         19 . The method of  claim 15 , wherein the mixture of step (a) is further treated with an acid selected from the group consisting of acetic acid, sulfuric acid, oxalic acid, hydrochloric acid, formic acid; nitric acid, phosphoric acid and citric acid.  
     
     
         20 . The method of  claim 1 , wherein the refractory inorganic oxide carrier has a pore volume falling within a range of 0.40-0.70 cc/g, a pore size distribution peak falling within a range of 50-110 angstroms, and less than 5% of said pore volume in pores having a pore diameter above 1000 angstroms.