High activity hydrotreating catalysts and processes using same

A method for preparing a catalyst for use in at least one process selected from the group consisting of:

• (I) hydroprocessing a petroleum feed;
• (II) hydrocracking (HCR) of a petroleum feedstock;
• (III) hydrodesulfurization of hydrocarbons;
• (IV) hydrodenitrification of hydrocarbons;
• (V) hydrodearomatization (HDA) of a petroleum feedstock;
• (VI) hydrodemetallation of hydrocarbons;
• and
• (VII) hydrotreating a charge hydrocarbon feed containing components boiling above 600° F. (315.6° C.), and at least one component selected from the group consisting of sulfur-containing compounds, nitrogen-containing compounds, metal-containing compounds, asphaltenes, carbon residue, sediment precursors, and mixtures thereof,
• the method comprising impregnating a porous inorganic oxide support with an aqueous solution comprising at least one catalytic agent or catalytic agent precursor selected from the group consisting of compounds of Group 6, alternatively referred to as Group VIB, of the Periodic Table of the Elements, and at least one catalytic agent or catalytic agent precursor selected from the group consisting of compounds of Groups 8, 9 or 10, alternatively referred to as Group VIII, of the Periodic Table of the Elements, and optionally comprising a phosphorous-containing compound and at least one organic chelating compound, the Group VIB and Group VIIIB and phosphorus compounds being thermally decomposable or oxidizable in the presence of an oxygen-containing atmosphere to their corresponding oxides and thereafter drying and calcining the resulting impregnated support, the support having been prepared by:
• mixing alumina-containing powder with water and optionally nitric acid to form a damp mix;
• shaping the damp mix so as to form support particles suitable for use in a hydroprocessing reactor;
• and
• the support comprising a porous inorganic oxide having a total pore volume (TPV) of about 0.8 cc/g to about 1.5 cc/g and, prior to incorporation of the metals and phosphorus when present having the following pore size distribution and pore content corresponding to values as measured using mercury porosimetry:
• equal to or greater than 25% to 45% of TPV in pores having a diameter of 100 Å (10 nm) to 200 Å (20 nm);
• greater than 15% to less than 30% of TPV in pores having a diameter of 200 Å (20 nm) to less than 1000 Å (100 nm);
• and
• equal to or greater than 10% to less than 30% of the pore volume in pores having a diameter of 1000 Å (100 nm) to 30,000 Å (3,000 nm).

A porous inorganic oxide carrier or support, having a total pore volume (TPV) of about 0.8 cc/g to about 1.5 cc/g and comprising:

• equal to or greater than about 25% to about 45% of TPV in pores having a diameter of 100 Angstroms (Å) (10 nm) to 200 Å (20 nm);
• greater than about 15% to less than about 30% of TPV in pores having a diameter of 200 Å (20 nm) to less than 1000 Å (100 nm);
• and
• equal to or greater than 10% to less than 30% of TPV in pores having a diameter of 1000 Å (100 nm) to 30,000 Å (3,000 nm).