Catalysts made from a new aluminum trihydroxide phase and method of making

A process for making a catalyst composition comprising:

• (a) forming a starting material comprising silica coated amorphous alumina comprising between about 4 wt. % and about 8 wt. % silica, wherein at least about 20 wt. % of said alumina is amorphous, into a shape;
• (b) wetting the starting material by contact with a chelating agent and an amount of metal compound in a carrier liquid;
• (c) aging the so-wetted starting material while wet;
• (d) drying the so-aged starting material at a temperature between about 100° C. and about 230° C. and under conditions to substantially volatilize the carrier liquid;
• and
• (e) calcining the so-dried material.

A process for improving the catalytic activity of a silica-alumina supported catalyst comprising between about 4 wt. % and about 8 wt. % silica, wherein at least about 20 wt. % of said alumina is amorphous, and a metal or metal compound, comprising:

• (a) wetting said catalyst by contact with a chelating agent in a carrier liquid;
• (b) aging the so-wetted catalyst while wet;
• (c) drying the so-aged catalyst at a temperature between about 100° C. and about 230° C. and under conditions to substantially volatilize the carrier liquid;
• and
• (d) calcining the so-dried catalyst.

A process for regenerating a previously used silica-alumina supported catalyst comprising between about 4 wt. % and about 8 wt. % silica, wherein at least about 20 wt. % of said alumina is amorphous, and a metal or metal compound, comprising:

• (a) removing material deposited on said catalyst during its previous use;
• (b) wetting said catalyst by contact with a chelating agent in a carrier liquid;
• (c) aging the so-wetted catalyst while wet;
• (d) drying the so-aged catalyst at a temperature between about 100° C. and about 230° C. and under conditions to substantially volatilize the carrier liquid;
• and
• (e) calcining the so-dried catalyst.

A process for making a catalyst composition tailored to the treatment of a hydrocarbonaceous material, comprising:

• (a) determining the concentration of nitrogen-containing compounds in the hydrocarbonaceous material;
• (b) choosing a starting material comprising silica coated amorphous alumina comprising between about 4 wt. % and about 8 wt. % silica, wherein at least about 20 wt. % of said alumina is amorphous, wherein said alumina has an appropriate concentration of silica so that, when wet-aged at an appropriate wet-aging temperature for an appropriate length of time forms a catalyst precursor, said catalyst precursor comprising a sufficient concentration of a composition comprising an aluminum trihydroxide phase having measurable X-ray diffraction peaks between about 2θ=18.15° and about 2θ=18.50°, between about 2θ=36.1° and about 2θ=36.85°, between about 2θ=39.45° and about 2θ=40.30°, and between about 2θ=51.48° and about 2θ=52.59°, that a catalyst made from said catalyst precursor will be effective in treating said hydrocarbonaceous material;
• wherein said appropriate concentration of silica, appropriate wet-aging temperature and appropriate length of time are chosen to be in proportion to the concentration of said nitrogen-containing compounds;
• (c) forming said starting material into a shape;
• (d) wetting said starting material by contact with a chelating agent and an amount of metal compound in a carrier liquid;
• (e) aging the so-wetted starting material while wet at the temperature chosen in (b) for the length of time chosen in (b);
• (f) drying the so-aged starting material at a temperature between about 100° C. and about 230° C. and under conditions to substantially volatilize the carrier liquid;
• and
• (g) calcining the so-dried material.