Hydrocarbon conversion process using a Ni and/or CO substituted synthetic aluminosilicate catalyst

Claim 2

A process for the conversion of hydrocarbons in the presence of hydrogen which comprises contacting a mixture of hydrogen and said hydrocarbons under hydrocarbon conversion conditions with a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, said mineral corresponding to the following overall formula prior to drying and calcining: [(Al.sub.4.sub.-ew.sup.3.sup.+ Y.sub.3w.sup.2.sup.+).sup.VI (Q.sub.8 x.sub.-.sup.4.sup.+ Al.sub.x.sup.3.sup.+).sup.IV O.sub.20 (OH).sub.4.sub.-f F.sub.f ] .sup.. [dC.sup.y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattic unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 3

A process according to claim 1 wherein said Y consists essentially of nickel.

Claim 4

A process according to claim 1 wherein Q is silicon.

Claim 5

A process in accordance with claim 3 wherein said second bracket has the composition: [a M.sup.n + b Al(OH).sub.3.sub.-z.sup.z ] wherein an + bz = dy = x + 3(e-2)w and M is a cation selected from the group consisting of hydrogen, ammonium, multivalent metal cations other than aluminum, and partial hydroxides of multivalent metal cations, and n is the unsatisfied valence of M.

Claim 6

A process in accordance with claim 3 wherein said C is selected from the group consisting of hydrogen, alkaline earth metal, heavy metal, heavy-metal partial hydroxides, ammonium, substituted ammonium, and substituted phosphonium cations and mixtures thereof.

Claim 7

A process in accordance with claim 5 wherein C is primarily hydrogen.

Claim 8

A process in accordance with claim 6 wherein e has a value of about 2; w has a value from 0.2 to 1.66; x has a value from 0.5 to 2; and the value of f is from 0.5 to 3.75.

Claim 9

A process in accordance with claim 7 wherein x is about 1.5.

Claim 10

A process in accordance with claim 8 wherein Y is nickel.

Claim 11

A process in accordance with claim 8 wherein Y is cobalt.

Claim 12

A process in accordance with claim 2 wherein Q is silicon.

Claim 13

A hydrocarbon conversion process in accordance with claim 1 wherein said catalyst comprises said laminar 2:1 layer lattice aluminosilicate mineral having in addition a hydrogenation component deposited thereon.

Claim 14

A process in accordance with claim 12 wherein the hydrogenation component is at least one of the metals, metal oxides and metal sulfides from Groups VI and VIII.

Claim 15

A process according to claim 7 wherein said catalyst comprises said laminar 2:1 layer lattice aluminosilicate mineral having an addition a hydrogenation component deposited thereon, said deposited hydrogenation component comprising at least one of the metals, metal oxides and metal sulfides from Groups VI and VIII.

Claim 16

A process according to claim 8 wherein said catalyst comprises said laminar 2:1 layer lattice aluminosilicate mineral having in addition a hydrogenation component deposited thereon, said deposited hydrogenation component comprising at least one of the metals, metal oxides and metal sulfides from Groups VI and VIII.

Claim 17

A process according to claim 15 wherein the hydrogenation component is palladium.

Claim 18

A process in accordance with claim 12 wherein said hydrocarbon conversion process is hydrocracking a hydrocarbon charge stock under hydrocracking conditions.

Claim 19

A process according to claim 17, wherein the catalyst is the same as that defined in claim 13 and said catalyst is pre-reduced with hydrogen.

Claim 20

A process in accordance with claim 18 wherein said hydrocarbon conversion process is the hydrocracking of a hydrocarbon charge stock having a boiling range from 450° to 950° F. at atmospheric pressure.

Claim 21

A process in accordance with claim 19 wherein the hydrocarbon charge stock is a furnace oil boiling range material.

Claim 22

A process according to claim 18 wherein said hydrocarbon conversion process is the hydrocracking of a charge stock consisting of paraffinic hydrocarbons having from 4 to 8 carbon atoms.

Claim 23

A process according to claim 21 wherein the paraffinic hydrocarbon is a raffinate.

Claim 24

A process according to claim 19 wherein the catalyst is presulfided prior to use.

Claim 25

A process according to claim 23 wherein the hydrocracking conditions include a temperature from 300° to 750° F.

Claim 26

A process in accordance with claim 12 wherein said hydrocarbon conversion process is the hydroisomerization of at least one aliphatic hydrocarbon having from 4 to 7 carbon atoms per molecule under hydrosiomerization conditions.

Claim 27

A process according to claim 25 wherein the catalyst is the same as that defined in claim 13 and said catalyst is pre-reduced with hydrogen.

Claim 28

A process in accordance with claim 25 wherein the hydroisomerization conditions include a temperature from 300° F. to 750° F.

Claim 29

A process according to claim 26 wherein the hydrogenation component is selected from the group consisting of platinum and compounds thereof and palladium and compounds thereof.

Claim 30

A process according to claim 28 wherein Y is nickel.

Claim 31

A process for the preparation of 2,2-dimethylbutane which comprises contacting a charge stock consisting essentially of a mixture of hydrogen and normal hexane under hydroisomerization conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component, said mineral corresponding to the following overall formula prior to drying and calcining: [(Al.sub.4.sub.-ew.sup.3.sup.+Y.sub.3w.sup.2.sup.+).sup.VI (Q.sub.8.sub.-x.sup.4.sup.+ Al.sub.x.sup.3.sup.+).sup.IV O.sub.20 (OH).sub.4.sub.-f F.sub.f ].sup.. [dC.sup.y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 32

A process for the preparation of 2,2-dimethylbutane which comprises contacting a charge stock consisting essentially of a mixture of hydrogen and normal hexane under hydroisomerization conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component, said mineral corresponding to the following overall formula prior to drying and calcining: [(Al.sub.4.sub.-ew.sup.3.sup.+Y.sub.3w.sup.2.sup.+).sup.VI (Q.sub.8.sub.-x.sup.4.sup.+ Al.sub.x.sup.3.sup.+).sup.IV O.sub.20 (OH).sub.4.sub.-f F.sub.f ].sup.. [dC.sup.y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 33

A process in accordance with claim 30 wherein the catalyst is presulfided before use.

Claim 34

A process in accordance with claim 31 where a sulfur compound is continuously added to the n-hexane charge stock.

Claim 35

A process in accordance with claim 30 wherein the hydroisomerization conditions include a temperature from 300° to 750° F.

Claim 36

A process for the production of liquid petroleum gas which comprises contacting a mixture of hydrogen and a raffinate boiling from 100° to 400° F. under hydrocracking conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component, said mineral corresponding to the following overall formula prior to drying and calcining: [(Al 4 -ew 3 + Y 3w 2 + ) VI (Q 8 -x 4 + Al x 3 + ) IV O 20 (OH) 4 +f F f ] .sup.. [dC y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 37

A process for the production of liquid petroleum gas which comprises contacting a mixture of hydrogen and a raffinate boiling from 100° to 400° F. under hydrocracking conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component, said mineral corresponding to the following overall formula prior to drying and calcining: [(Al 4 -ew 3 + Y 3w 2 + ) VI (Q 8 -x 4 + Al x 3 + ) IV O 20 (OH) 4 +f F f ] .sup.. [dC y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 38

A process in accordance with claim 34 wherein the catalyst is presulfided prior to use.

Claim 39

A process for the preparation of isobutane, which comprises contacting a charge stock consisting essentially of hydrogen and normal hexane under hydrocracking conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component; said mineral corresponding to the following overall formula prior to drying and calcining: [(Al 4 -ew 3 + Y 3w 2 + ) VI (Q 8 -x 4 + Al x 3 + ) IV O 20 (PH) 4 +f F f ] .sup.. [dC y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 40

A process for the preparation of isobutane, which comprises contacting a charge stock consisting essentially of hydrogen and normal hexane under hydrocracking conditions in the presence of a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component; said mineral corresponding to the following overall formula prior to drying and calcining: [(Al 4 -ew 3 + Y 3w 2 + ) VI (Q 8 -x 4 + Al x 3 + ) IV O 20 (PH) 4 +f F f ] .sup.. [dC y ] where Al is aluminum; Y is selected from the class consisting of nickel, cobalt and mixtures thereof; Q is at least 0.95 mol fraction silicon ions, the remainder consisting of tetravalent ions having an ionic radius not to exceed 0.65 A; and F is fluorine; C is at least one charge-balancing cation; and where e has a numerical value from 2 to 3 inclusive; w has a numerical value from 0.01 to 2 inclusive, with the proviso that the quantity ew have a numerical value from 0.02 to 4 inclusive; f has a value of 4 or less; x has a numerical value from 0.05 to 2.0 inclusive; y is the valence of the cation C; d is the number of cations C where the product dy = x + 3(e-2)w; and wherein said first bracket represents said layer-lattice unit cell formulation and said second bracket represents said charge-balancing cations.

Claim 41

A process according to claim 36 wherein the catalyst is presulfided.

Claim 42

A process according to claim 36 wherein the catalyst is continually sulfided by having a sulfur compound present in the feedstock.

Claim 43

A process according to claim 36 wherein the hydrocracking conditions include a temperature from 350° to 1000° F., an LHSV of feedstock from 0.1 to 10.0, pressure from 400 to 3000 psig, and an H 2 -to-feed mol ratio of 0.5 to 20.00.

Claim 44

A process for the desulfurization of a sulfur containing charge stock in the presence of hydrogen which comprises contacting a mixture of hydrogen and said sulfur containing charge stock under hydrodesulfurization conditions with a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component comprising at least one of the metals, metal oxides or metal sulfides selected from the metals of Groups VI and VIII of the Periodic Table.

Claim 45

A process for the desulfurization of a sulfur containing charge stock in the presence of hydrogen which comprises contacting a mixture of hydrogen and said sulfur containing charge stock under hydrodesulfurization conditions with a catalyst comprising: a laminar 2:1 layer-lattice aluminosilicate mineral possessing layer-lattice unit cells, each cell having an inherent negative charge balanced by cations exterior to said unit cell, and a hydrogenation component comprising at least one of the metals, metal oxides or metal sulfides selected from the metals of Groups VI and VIII of the Periodic Table.

Claim 46

A process according to claim 40 wherein Q is silicon, Y is nickel, and the charge stock is a residual petroleum.