Conversion of hydrocarbons with a catalyst comprising an alumina-zeolite, a group VI-B metallic component and a group VIII metallic component

Claim 2

A process for the conversion of a hydrocarbon at hydrocarbon conversion conditions which comprises contacting said hydrocarbon with a catalyst prepared by a method comprising: (a) extruding alumina and a sodium form zeolite; (b) calcining the resulting extrudate; (c) contacting the resulting calcined extrudate with a sodium ion exchange solution to reduce the sodium concentration of said extrudate; (d) contacting the resulting extrudate from step c) with a rare earth salt solution; (e) calcining the resulting extrudate from step d); (f) contacting the resulting calcined extrudate from step e) with a sodium ion exchange solution to further reduce the sodium concentration of extrudate to less than about 0.5 wt. %; and (g) incorporating at least one metal component selected from Group VI-B and at least one metal component selected from Group VIII on the resulting extrudate from step f).

Claim 3

The process of claim 1 wherein said alumina is Ziegler alumina.

Claim 4

The process of claim 1 wherein said zeolite is faujasite.

Claim 5

The process of claim 1 wherein said calcining occurs at a temperature from about 700° F. to about 1300° F.

Claim 6

The process of claim 1 wherein said sodium concentration of the extrudate is less than about 0.1 wt. %.

Claim 7

The process of claim 1 wherein said Group VI-B metal component is tungsten.

Claim 8

The process of claim 1 wherein said Group VI-B metal component comprises from about 1 to about 20 wt. % of the finished catalyst based on the elemental metal.

Claim 9

The process of claim 1 wherein said Group VIII metal comprises from about 0.1 to about 5 wt. % of the finished catalyst based on the elemental metal.

Claim 10

The process of claim 1 wherein said Group VIII metal component is nickel.

Claim 11

The process of claim 1 wherein said hydrocarbon conversion conditions include a pressure of about 400 psig to about 3000 psig.

Claim 12

The process of claim 1 wherein said hydrocarbon conversion conditions include a temperature of about 400° F. to about 900° F.

Claim 13

The process of claim 1 wherein said hydrocarbon conversion conditions include a liquid hourly space velocity of about 0.1 hr. -1 to about 10 hr. -1 .

Claim 14

The process of claim 1 wherein said hydrocarbon conversion conditions include a hydrogen circulation rate of about 1000 to about 15,000 SCFB of charge stock.

Claim 15

A process for the hydrocracking of a hydrocarbon oil comprising contacting the hydrocarbon oil under hydrocracking conditions at an elevated temperature and pressure with a hydrocracking catalyst prepared by a method comprising: (a) extruding alumina and a sodium form zeolite; (b) calcining the resulting extrudate; (c) contacting the resulting calcined extrudate with a sodium ion exchange solution to reduce the sodium concentration of said extrudate; (d) contacting the resulting extrudate from step (c) with a rare earth salt solution; (e) calcining the resulting extrudate from step (d); (f) contacting the resulting extrudate from step (e) with a sodium ion exchange solution to further reduce the sodium concentration of the extrudate to less than about 0.5 wt. %; and (g) incorporating at least one metal component selected from Group VI-B and at least one metal component selected from Group VIII on the resulting extrudate from step (f).

Claim 16

A process for the hydrocracking of a hydrocarbon oil comprising contacting the hydrocarbon oil under hydrocracking conditions at an elevated temperature and pressure with a hydrocracking catalyst prepared by a method comprising: (a) extruding alumina and a sodium form zeolite; (b) calcining the resulting extrudate; (c) contacting the resulting calcined extrudate with a sodium ion exchange solution to reduce the sodium concentration of said extrudate; (d) contacting the resulting extrudate from step (c) with a rare earth salt solution; (e) calcining the resulting extrudate from step (d); (f) contacting the resulting extrudate from step (e) with a sodium ion exchange solution to further reduce the sodium concentration of the extrudate to less than about 0.5 wt. %; and (g) incorporating at least one metal component selected from Group VI-B and at least one metal component selected from Group VIII on the resulting extrudate from step (f).