Hydroconversion process employing catalyst with specified pore size distribution and no added silica

A process for hydrotreating a charge hydrocarbon feed containing components boiling about 1000.degree. F. and sulfur, metals, and carbon residue, said process comprises:

• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 2.2-6 wt % of a Group VIII metal oxide, 7-24 wt % of a Group VIB metal oxide and less than 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sub.2 /g, a Total Pore Volume of 0.82-0.98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., 46.5-56.5% of the pore volume of pores with diameters .ltoreq.200 .ANG. is present as micropores of diameter .+-.20 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG., 17-27% of the Total Pore Volume is present as pores with a diameter >600 .ANG. and 0.12-0.20 cc/g of the Total Pore Volume is present as pores having a diameter >1200 .ANG.,
• thereby forming hydroprocessed product containing a decreased content of components boiling above 1000.degree. F. a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue
• and recovering said hydroprocessed product, and
• recovering from said hydroprocessed product a portion having a boiling point above 650.degree. F., said portion containing a decreased content of sediment.

A process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals, and carbon residue, said process comprises:

• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.41 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 3.0-3.9 wt % of nickel oxide, 12.5-15.5 wt % of molybdenum oxide and .ltoreq.0.1 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 200-225 m.sup.2 /g, a Total Pore Volume of 0.82-0.98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG.,
• thereby forming hydroprocessed product containing a decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue,
• and recovering said hydroprocessed product and
• recovering from said hydroprocessed product a portion boiling above 650.degree. F., said portion containing decreased content of sediment.

A process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals, and carbon residue, said process comprises:

• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.41 wt % of silica, said porous alumina support bearing 3.0-3.9 wt % of nickel oxide, 12.5-15.5 wt % of molybdenum oxide and .ltoreq.0.1 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 200-225 m.sup.2 /g, a Total Pore Volume of 0.82-0.98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., 46.5-56.5% of the pore volume of pores with diameters .ltoreq.200 .ANG. is present as micropores of diameter .+-.20 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG., 17-27% of the Total Pore Volume is present as pores with a diameter >600 .ANG. and 0.12-0.20 cc/g of the Total Pore Volume is present as pores having a diameter >1200 .ANG.,
• thereby forming hydroprocessed product containing a decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue,
• and recovering said hydroprocessed product, and
• recovering from said hydroprocessed product a portion boiling above 650.degree. F. containing decreased content of sediment.

In a process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals and carbon residue to form hydroprocessed product, said product containing a decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue and recovering said hydroprocessed product,

• an improvement which allows operations at +10.degree. F., increases conversion of components boiling above 1000.degree. F. to product boiling below 1000.degree. F. by 5 wt %, and reduces Existent IP Sediment Test values in the portion of the hydroprocessed product boiling above 650.degree. F. which comprises
• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 2.2-6 wt % of a Group VIII metal oxide, 7-24 wt % of a Group VIB metal oxide and less than 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sup.2 /g, a Total Pore Volume of 0.82-0.98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG., about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG..

In a process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals and carbon residue to form hydroprocessed product, and hydroprocessed product containing a decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue and recovering said hydroprocessed product,

• an improvement which allows operations at +10.degree. F., increases conversion of components boiling above 1000.degree. F. to product boiling below 1000.degree. F. by 5 wt %, and reduces Existent IP Sediment Test values in the portion of the hydroprocessed product boiling above 650.degree. F. which comprises
• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 2.2-6 wt % of a Group VIII metal oxide, 7-24 wt % of a Group VIB metal oxide and less than 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sup.2 /g, a Total Pore Volume of 0.82-98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 100-130 .ANG., 46.5-56.5% of the pore volume of pores with diameters .ltoreq.200 .ANG. is present as micropores of diameter .+-.20 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG., 17-27% of the Total Pore Volume is present as pores with a diameter >600 .ANG. and 0.12-0.20 cc/g of the Total Pore Volume is present as pores having a diameter >1200 .ANG..

In a process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals and carbon residue to form hydroprocessed product, said hydroprocessed product containing a decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue and recovering said hydroprocessed product,

• an improvement which allows operations at +20.degree. F., increases conversion of components boiling above 1000.degree. F. to product boiling below 1000.degree. F. by 13.5 wt %, and reduces Accelerated IP Sediment Test values in the portion of the hydroprocessed product boiling above 650.degree. F. which comprises
• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 2.2-6 wt % of a Group VIII metal oxide, 7-24 wt % of a Group VIB metal oxide and less than 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sup.2 /g, a Total Pore Volume of 0.82-98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG..

In a process for hydrotreating a charge hydrocarbon feed containing components boiling above 1000.degree. F. and sulfur, metals and carbon residue to form hydroprocessed product, said hydroprocessed product containing decreased content of components boiling above 1000.degree. F. and a decreased content of sulfur, a decreased content of metals and a decreased content of carbon residue and recovering said hydroprocessed product,

• an improvement which allows operations at +20.degree. F., increases conversion of components boiling above 1000.degree. F. to product boiling below 1000.degree. F. by 13.5 wt %, and reduces Accelerated IP Sediment Test values in the portion of the hydroprocessed product boiling above 650.degree. F. which comprises
• contacting said hydrocarbon feed with hydrogen at isothermal hydroprocessing conditions in the presence of a catalyst, said catalyst including a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions, said porous alumina support bearing 2.2-6 wt % of a Group VIII metal oxide, 7-24 wt % of a Group VIB metal oxide and less than 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sup.2 /g, a Total Pore Volume of 0.82-98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., 46.5-56.5% of the pore volume of pores with diameters .ltoreq.200 .ANG. is present as micropores of diameter .+-.20 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG., 17-27% of the Total Pore Volume is present as pores with a diameter >600 .ANG. and 0.12-0.20 cc/g of the Total Pore Volume is present as pores having a diameter >1200 .ANG..

A hydrotreating catalyst characterized by stability at up to 10.degree. F. over normal hydrotreating process conditions consisting essentially of:

• a porous alumina support containing .ltoreq.0.5 wt % of silica, wherein no silicon containing components are intentionally added to the alumina, alumina support, impregnating solution or impregnating solutions,
• 2.2-6 wt % of a Group VIII metal oxide supported by said porous alumina support,
• 7-24 wt % of a Group VIB metal oxide supported by said porous alumina support and,
• less than about 0.3 wt % of a phosphorus oxide, with no phosphorous containing components intentionally added during the preparation of said catalyst,
• said catalyst having a Total Surface Area of 195-230 m.sup.2 /g, a Total Pore Volume of 0.82-98 cc/g, and a Pore Diameter Distribution wherein 27.0-34.0% of the Total Pore Volume is present as macropores of diameter greater than 250 .ANG., 66.0-73.0% of the Total Pore Volume is present as micropores of diameter less than 250 .ANG., 55-64.5% of the micropore volume is present as micropores of diameter .+-.25 .ANG. about a pore mode by volume of 110-130 .ANG., less than 0.05 cc/g of micropore volume is present as micropores with diameters less than 80 .ANG..