Hydrocarbon-conversion catalyst and its method of preparation

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.degree. F. (25.degree. C.) to about 392.degree. F. (200.degree. 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.degree. F. per hour (111.degree. C. per hour) to a calcination temperature within the range of about 752.degree. F. (400.degree. C.) to about 1,112.degree. F. (600.degree. 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.degree. F. (25.degree. C.) to about 392.degree. F. (200.degree. 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.degree. F. per hour (111.degree. C. per hour) to a calcination temperature within the range of about 752.degree. F. (400.degree. C.) to about 1,112.degree. F. (600.degree. 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.

A method for the preparation of a catalytic composition that is suitable for the conversion of hydrocarbon streams, which method comprises:

• (1) admixing a crystalline borosilicate in a finely-divided state with a refractory inorganic oxide to form a catalytic support material, said catalytic support material having said borosilicate suspended in and distributed throughout a matrix of said inorganic oxide, 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) impregnating said catalytic support material with a solution of a heat-decomposable compound of a catalytically-active metal to provide an impregnated material;
• (3) drying said impregnated material at a temperature of about 77.degree. F. (25.degree. C.) to about 392.degree. F. (200.degree. C.) for a period of about 10 minutes to about 100 hours in air to obtain a dried impregnated material;
• and (4) calcining said dried impregnated material at a temperature within the range of about 752.degree. F. (400.degree. C.) to about 1,112.degree. F. (600.degree. C.) for a period of about 30 minutes to about 20 hours to provide said catalytic composition.