Hydrocarbon-conversion catalyst and its method of preparation

Claim 2

A catalytic composition which comprises a crystalline borosilicate and a porous refractory inorganic oxide, said borosilicate and said inorganic oxide having been intimately admixed with one another, said borosilicate comprising a molecular sieve material providing an X-ray diffraction pattern comprising the following X-ray diffraction lines and assigned strengths: ______________________________________ d(A) Assigned Strength ______________________________________ 11.2 ± 0.2 W- VS 10.0 ± 0.2 W- MS 5.97 ± 0.07 W- M 3.82 ± 0.05 VS 3.70 ± 0.05 MS 3.62 ± 0.05 M- MS 2.97 ± 0.02 W- M 1.99 ± 0.02 VW- M ______________________________________ and having the following composition in terms of mole ratios of oxides: 0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :YSiO.sub.2 :ZH.sub.2 O, wherein M is at least one cation having a valence of n, Y is between 4 and about 600, and Z is between 0 and about 160.

Claim 3

The catalytic composition of claim 1, wherein said borosilicate and said inorganic oxide have been intimately admixed with one another after said borosilicate has been calcined.

Claim 4

The catalytic composition of claim 1, wherein said inorganic oxide is an alumina.

Claim 5

The catalytic composition of claim 1, wherein at least one catalytically-active metal comprising tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof has been placed onto said catalytic composition.

Claim 6

The catalytic composition of claim 1, wherein at least one catalytically-active metal comprising tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof has been placed onto said borosilicate before said borosilicate is mixed with said inorganic oxide.

Claim 7

The catalytic composition of claim 2, wherein at least one catalytically-active metal comprising tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof is placed onto said calcined borosilicate before said borosilicate is mixed with said inorganic oxide.

Claim 8

The catalytic composition of claim 2, wherein said inorganic oxide is an alumina.

Claim 9

The catalytic composition of claim 4, wherein at least one catalytically-active metal comprising tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof has been placed onto said catalytic composition.

Claim 10

The catalytic composition of claim 4, wherein said catalytically-active metal is placed onto said catalytic composition by impregnation techniques.

Claim 11

The catalytic composition of claim 4, wherein said catalytically-active metal is placed onto the borosilicate of said catalytic composition by ion-exchange.

Claim 12

The catalytic composition of claim 6, wherein said catalytically-active metal is placed onto said borosilicate by ion-exchange.

Claim 13

The catalytic composition of claim 6, wherein said catalytically-active metal is placed onto said borosilicate by impregnation techniques.

Claim 14

The catalytic composition of claim 11, wherein said catalytically-active metal is placed onto said catalytic composition by impregnation techniques.

Claim 15

The catalytic composition of claim 11, wherein said catalytically-active metal is place onto the borosilicate of said catalytic composition by ion-exchange.

Claim 16

The catalytic composition of claim 9, wherein said catalytically-active metal is molybdenum or nickel.

Claim 17

The catalytic composition of claim 10, wherein said catalytically-active metal is nickel.

Claim 18

The catalytic composition of claim 6, wherein said inorganic oxide is an alumina.

Claim 19

The catalytic composition of claim 11, wherein said catalytically-active metal is nickel.

Claim 20

The catalytic composition of claim 12, wherein said catalytically-active metal is molybdenum.

Claim 21

The catalytic composition of claim 13, wherein said catalytically-active metal is molybdenum or nickel.

Claim 22

The catalytic composition of claim 14, wherein said catalytically-active metal is nickel.

Claim 23

The catalytic composition of claim 18, wherein said inorganic oxide is an alumina.

Claim 24

The catalytic composition of claim 19, wherein said inorganic oxide is an alumina.

Claim 25

A catalytic composition that is suitable for the conversion of hydrocarbon streams, which composition comprises at least one catalytically-active metal comprising tungsten, vanadium, molybdenium, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof and a catalytic support comprising a crystalline borosilicate suspended in and distributed throughout a matrix of a refractory inorganic oxide, which composition has been prepared by the method which comprises: (1) admixing said borosilicate in a finely-divided state with a hydrosol, sol, or hydrogel of said inorganic oxide in order to uniformly disperse said borosilicate in said hydrosol, sol, or hydrogel of said inorganic oxide to form an admixture, said borosilicate comprising a molecular sieve material providing an X-ray diffraction pattern comprising the following X-ray diffraction lines and assigned strengths: ______________________________________ d(A) Assigned Strength ______________________________________ 11.2 ± 0.2 W- VS 10.0 ± 0.2 W- MS 5.97 ± 0.07 W- M 3.82 ± 0.05 VS 3.70 ± 0.05 MS 3.62 ± 0.05 M- MS 2.97 ± 0.02 W- M 1.99 ± 0.02 VW- M ______________________________________ and having the following composition in terms of mole ratios of oxides: 0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :YSiO.sub.2 :ZH.sub.2 O, wherein M is at least one cation, n is the valence of the cation, Y is a value within the range of 4 to about 600, and Z is a value within the range of 0 to about 160; (2) while continually stirring the admixture, adding a gelling medium to promote gellation and to form a gel; (3) drying said gel at a temperature of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 100 hours in the presence of air to form a dried mixture; (4) calcining said dried mixture by heating said dried mixture in air at a maximum rate of 200° F. per hour (111° C. per hour) to a calcination temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) and maintaining said dried material at said calcination temperature for a period of about 30 minutes to about 20 hours to provide a calcined catalytic support material; (5) impregnating said calcined catalytic support material with a solution of a heat-decomposable compound of said catalytically-active metal to provide an impregnated material; (6) drying said impregnated material at a temperature of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 100 hours in air to obtain a dried impregnated material; and (7) calcining said dried impregnated material by heating said dried impregnated material in air at a maximum rate of 200° F. per hour (111° C. per hour) to a calcination temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) and maintaining said dried impregnated material at said calcination temperature for a period of about 30 minutes to about 20 hours to provide said catalytic composition.

Claim 26

A catalytic composition that is suitable for the conversion of hydrocarbon streams, which composition comprises at least one catalytically-active metal comprising tungsten, vanadium, molybdenium, rhenium, nickel, cobalt, chromium, manganese, platinum, palladium, a rare earth metal, or mixtures thereof and a catalytic support comprising a crystalline borosilicate suspended in and distributed throughout a matrix of a refractory inorganic oxide, which composition has been prepared by the method which comprises: (1) admixing said borosilicate in a finely-divided state with a hydrosol, sol, or hydrogel of said inorganic oxide in order to uniformly disperse said borosilicate in said hydrosol, sol, or hydrogel of said inorganic oxide to form an admixture, said borosilicate comprising a molecular sieve material providing an X-ray diffraction pattern comprising the following X-ray diffraction lines and assigned strengths: ______________________________________ d(A) Assigned Strength ______________________________________ 11.2 ± 0.2 W- VS 10.0 ± 0.2 W- MS 5.97 ± 0.07 W- M 3.82 ± 0.05 VS 3.70 ± 0.05 MS 3.62 ± 0.05 M- MS 2.97 ± 0.02 W- M 1.99 ± 0.02 VW- M ______________________________________ and having the following composition in terms of mole ratios of oxides: 0.9±0.2M.sub.2/n O:B.sub.2 O.sub.3 :YSiO.sub.2 :ZH.sub.2 O, wherein M is at least one cation, n is the valence of the cation, Y is a value within the range of 4 to about 600, and Z is a value within the range of 0 to about 160; (2) while continually stirring the admixture, adding a gelling medium to promote gellation and to form a gel; (3) drying said gel at a temperature of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 100 hours in the presence of air to form a dried mixture; (4) calcining said dried mixture by heating said dried mixture in air at a maximum rate of 200° F. per hour (111° C. per hour) to a calcination temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) and maintaining said dried material at said calcination temperature for a period of about 30 minutes to about 20 hours to provide a calcined catalytic support material; (5) impregnating said calcined catalytic support material with a solution of a heat-decomposable compound of said catalytically-active metal to provide an impregnated material; (6) drying said impregnated material at a temperature of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 100 hours in air to obtain a dried impregnated material; and (7) calcining said dried impregnated material by heating said dried impregnated material in air at a maximum rate of 200° F. per hour (111° C. per hour) to a calcination temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) and maintaining said dried impregnated material at said calcination temperature for a period of about 30 minutes to about 20 hours to provide said catalytic composition.

Claim 27

The catalytic composition of claim 24, wherein said borosilicate is a borosilicate that has been exchanged at the cationic sites with at least one of the materials selected from the group consisting of hydrogen, a rare earth metal, aluminum, a metal of Group IB, a metal of Group IIB, a metal of Group VIB, a metal of Group VIII, manganese, vanadium, rhenium, and mixtures thereof.

Claim 28

The catalytic composition of claim 24, wherein said inorganic oxide is an alumina.

Claim 29

The catalytic composition of claim 24, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 30

The catalytic composition of claim 25, wherein said inorganic oxide is an alumina.

Claim 31

The catalytic composition of claim 25, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 32

The cataytic composition of claim 28, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 33

The catalytic composition of claim 30, wherein said catalytically-active metal is molybdenum when said catalytically-active metal is a metal of Group VIB and wherein said catalytically-active metal is nickel when said catalytically-active metal is a metal of Group VIII.

Claim 36

The method of preparation of claim 32, wherein said inorganic oxide is an alumina and said catalytic support material is prepared by: (1) admixing said borosilicate in a finely-divided state with said alumina by mulling spray-dried alumina with 5 to 20 wt.% gamma-alumina hydrosol or beta-alumina trihydrate and with said borosilicate to form a mixture that is suitable for extruding; (2) adding water in an amount that will yield an extrudate having about 20 wt.% to about 50 wt.% water; (3) adding, if needed, an extrusion aid and a pore-diameter modifier; (4) extruding said resulting admixture to form an extruded admixture; (5) drying said extruded admixture in air at a temperature of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 20 hours to obtain a dried extrudate; and (6) calcining said dried extrudate at a temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) for a period of about 30 minutes to about 20 hours to provide a calcined cataytic support material.

Claim 37

The method of preparation of claim 32, wherein said catalytic support material is prepared by: (1) admixing said borosilicate in a finely-divided state with a hydrosol, sol, or hydrogel of said inorganic oxide in order to uniformly disperse said borosilicate in said hydrosol, sol, or hydrogel of said inorganic oxide to form an admixture; (2) while continually stirring the admixture, adding a gelling medium to promote gellation and to form a gel; (3) drying said gel at a temperature within the range of about 77° F. (25° C.) to about 392° F. (200° C.) for a period of about 10 minutes to about 100 hours in air to form a dried mixture; and (4) calcining said dried mixture at a temperature within the range of about 752° F. (400° C.) to about 1,112° F. (600° C.) for a period of about 20 minutes to about 20 hours to provide a calcined catalytic support material.

Claim 38

The method of claim 32, wherein said borosilicate has been cation-exchanged with a suitable cation selected from the group consisting of hydrogen, a rare earth metal, aluminum, a metal of Group IB, a metal of Group IIB, a metal of Group VIB, a metal of Group VIII, manganese, vandium, rhenium, and mixtures thereof.

Claim 39

The method of claim 32, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 40

The method of claim 33, wherein said borosilicate has been cation-exchanged with a suitable cation selected from the group consisting of hydrogen, a rare earth metal, aluminum, a metal of Group IB, a metal of Group IIB, a metal of Group VIB, a metal of Group VIII, manganese, vanadium, rhenium, and mixtures thereof.

Claim 41

The method of claim 33, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 42

The method of claim 34, wherein sid borosilicate has been cation-exchanged with a suitable cation selected from the group consisting of hydrogen, a rare earth metal, aluminum, a metal of Group IB, a metal of Group IIB, a metal of Group VIB, a metal of Group VIII, manganese, vanadium, rhenium, and mixtures thereof.

Claim 43

The method of claim 34, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 44

The method of claim 35, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 45

The method of claim 37, wherein said cataytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 46

The method of claim 38, wherein, if a metal of Group VIB is employed as the catalytically-active metal, molybdenum is that metal of Group VIB and, if a metal of Group VIII is employed as the cataytically-active metal, nickel is that metal of Group VIII.

Claim 47

The method of claim 39, wherein said catalytically-active metal is a metal of Group VIB of the Periodic Table of Elements or a metal of Group VIII of the Periodic Table of Elements.

Claim 48

The method of claim 42, wherein, if a metal of Group VIB is employed as the catalytically-active metal, molybdenum is that metal of Group VIB and, if a metal of Group VIII is employed as the catalytically-active metal, nickel is that metal of Group VIII.

Claim 49

The method of claim 44, wherein, if a metal of Group VIB is employed as the catalytically-active metal, molybdenum is that metal of Group VIB and, if a metal of Group VIII is employed as the catalytically-active metal, nickel is that metal of Group VIII.