PROCESS FOR PREPARING HYDROTREATING CATALYSTS PREPARED FROM HYDROGELS AND CATALYSTS THUS PREPARED

Abstract: Process for preparing wide-pore catalysts prepared by incorporating a metals solution containing an element selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, into a phosphated alumina hydrogel support prepared in the presence of a methanol and/or ethanol containing solution. The final calcined catalysts have surface areas greater than 300 m²/g, crush strengths greater than 40.5 N and more than 20% of their pores greater than 15 nm.

Description: The present invention relates to a process for preparing wide-pore phosphated alumina hydrogel-derived catalysts having high surface areas, and to catalysts thus prepared. In the catalytic processing of petroleum feedstocks, it is often desirable to alter the pore structure of the catalyst in order to accommodate different types of feeds. For example, when processing feedstocks with no metals or with a low metals content, it may be technically and economically desirable to use narrow-pore catalysts. On the other hand, when processing feedstocks with high metals content, the metals tend to deposit rapidly on the catalyst surface and plug the pores of conventional hydroprocessing catalysts, resulting in a loss of catalytic activity for sulphur and nitrogen removal. In order to maintain hydrotreating activity, it is necessary that the catalyst be high in surface area. To facilitate the diffusion of large components into and out of the catalyst and to prevent surface deposits of coke and metals, large pore diameters are required. These criteria necessitate the use of wide-pore catalysts which have high surface areas and a significant fraction of large pores. The large pores allow enhanced diffusion of large molecules into the catalyst while the smaller pores, providing most of the surface area, allow for hydroprocessing of the feed. Methods for creating controlled pore sizes and aluminas are hence quite useful. The present invention relates to a process for preparing wide-pore catalysts having surface areas above 300 m²/g and at least 20% of the pore diameters greater than 15 nm, which process comprises: (a) precipitating an aqueous solution of one or more aluminium salt(s) in the presence of a phosphorus-containing compound in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, by adjusting the pH of said solution to a range between 5.5 and 10.0, thereby forming a precipitate, (b) ageing the precipitate at a temperature ranging from 20°C to 90°C for at least 15 minutes at a pH ranging from 9.0 to 12.0, (c) washing the precipitate, (d) mixing the precipitate with a solution containing solubilized salts of a heavy metal selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, at a pH in the range between 4.0 and 8.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having a catalytically effective amount of metals present, (e) extruding the product of step (d), and (f) drying and calcining the product of step (e) at a temperature ranging from 300°C to 900°C. It has been found that when methanol and/or ethanol is added as co-solvent during the precipitation step, the finished catalysts have a much broader pore size distribution than catalysts prepared using water as the solvent during precipitation. The catalysts prepared according to the invention have high surface areas, greater than 300 m²/g; high crush strengths, greater than 40.5 N, and substantial portions, greater than 20%, of their pores greater than 15 nm. These catalysts are quite useful for hydrotreating and hydrodemetallization applications. In the process according to the present invention, a high surface area, wide-pore phosphated alumina hydrogel-derived catalyst is prepared by incorporating a metal solution containing an element selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, into a phosphated alumina hydrog el support prepared by precipitating an aqueous solution of one or more aluminium salt(s) in the presence of a phosphorus-containing compound in a solution containing 15 to 50% by volume of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof. The process according to the present invention can suitably be carried out by (a) titrating an aqueous solution of an acid aluminium salt and an aqueous solution of a basic aluminium compound in the presence of a phosphorus-containing compound in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, thereby forming a precipitate, (b) ageing the precipitate at a temperature ranging from 20°C to 90°C for at least 15 minutes at a pH ranging from 9.0 to 12.0, (c) washing the precipitate, (d) mixing the precipitate with a solution containing solubilized salts of a heavy metal selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, at a pH in the range between 4.0 and 8.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having a catalytically effective amount of metals present, (e) extruding the product of step (d), and (f) drying and calcining the product of step (e) at a temperature ranging from 300°C to 900°C. The phosphated alumina hydrogel can be prepared by titrating an aqueous solution of one or more aluminium salt(s) with an appropriate acidic or basic material or solution in the presence of a phosphorus-containing compound to cause precipitation of the phosphated alumina gel. Alcohols suitable for use during the precipitation step are methanol, ethanol and mixtures thereof, with ethanol being preferred. The amount of alcohol present during the precipitation step ranges from 15%v to 50%v, preferably 20%v to 40%v. While the alcohol is present during precipitation of the hydrogel, the phosphated alumina supports themselves are not affected by the presence of the alcohol. However, after a reslurry treatment with the metal solutions, the finished catalysts have much broader pore-size distributions than their counterparts prepared using only water. The temperature and pH of the precipitation are important variables in the preparation of the according to the present invention aluminas needed to produce desirable physical qualities in the catalysts. Changes in precipitation temperatures and pHs result in changes in porosities. According to the present invention, a precipitation temperature typically ranges from 20°C to 90°C, and preferably from 50°C to 85°C, and a precipitation pH typically ranges from 5.5 and 10.0, preferably from 5.5 and 8.0, and more preferably between 6.0 and 7.5. The length of time required for the precipitation step is not critical. However, the maximum rate of addition of the appropriate aluminium species is fixed by the rate at which the two streams can be mixed and the pH and temperature of the system can be effectively controlled. In the process according to the present invention the alumina gel can be prepared by titrating an acidic aluminium salt such as, for example, aluminium sulphate, aluminium nitrate or aluminium chloride, in aqueous solution with a basic precipitating medium such as, for example, sodium hydroxide or ammonium hydroxide, in the presence of a phosphorus-containing compound, or, by titrating an alkali metal aluminate such as, for example, sodium aluminate or potassium aluminate, in aqueous solution with an acidic precipitating medium such as, for example, hydrochloric acid or nitric acid, in the presence of a phosphorus-containing compound. The adjustment of the pH of an aluminium-containing solution to between 5.5 and 10.0 will result in prec ipitation of the aluminium as aluminium hydroxide or hydrated aluminium oxide. In a preferred embodiment, the phosphated alumina hydrogel is prepared by titrating in a solution containing 15%v to 50%v, preferably 20%v to 40%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, an aqueous solution of an alkali metal aluminate and an aqueous solution of a acid aluminium salt in the presence of a phosphorus-containing compound to cause precipitation of the phosphated alumina gel. The precipitation can be carried out by adding an aqueous solution of the basic aluminium species to an aqueous solution of the acidic aluminium species present in the alcohol solution, or the procedure can be reversed by adding the solution of the acidic aluminium species to the solution of the basic aluminium species present in the alcohol solution (referred to as "sequential precipitation"). Preferably, the precipitation according to the present invention is carried out by simultaneously adding the acid aluminium species and the basic aluminium species, at least one of which has a phosphorus-containing compound dissolved therein, to the alcohol solution, thus creating a well-defined and constant environment for the precipitation of the hydrogel (referred to as "simultaneous precipitation"). As used herein, the term "a phosphorus-containing compound" is generic and refers to one phosphorus-containing compound as well as more than one phosphorus-containing compound. The phosphorus-containing compound suitably comprises phosphoric acid, a phosphate salt or a mixture thereof. Suitable phosphate salts include alkali metal phosphates, alkali metal hydrogen phosphates, ammonium phosphate and ammonium hydrogen phosphate. The phosphorus-containing compound is preferably phosphoric acid and is preferably mixed with the acid aluminium species prior to precipitation. Alternatively, the phosphorus-containing compound can be sodium or ammonium phosphate and mixed with the basic aluminium species prior to precipitation. The phosphorus-containing compound can also be added as a separate solution or added to both the acid aluminium species and the basic aluminium species without significantly affecting the results. In a preferred embodiment, the phosphorus-containing compound is prepared using commercially available 85% phosphoric acid although other phosphorus-containing materials may be utilized. The amount of phosphorus-containing compound added to the acid aluminium species and/or the basic aluminium species is suitably from 0.06 to 0.30 moles of phosphorus per mole of aluminium. After the precipitation step is completed, the pH of the slurry is adjusted by the addition of a basic aluminate solution to fall in the range from 9.0 to 12.0, preferably 10.0 to 11.5, and aged at a temperature in the range from 20°C to 90°C, preferably 50°C to 85°C for at least 15 minutes. An upper limit on the length of time for ageing is not critical and is normally determined by economical considerations. Ageing times will typically range from 0.1 to 10 hours, preferably from 0.25 to 5 hours, and more preferably from 0.25 to 1 hour. In general, aluminas with acceptable properties are produced by holding the ageing temperature substantially equal to the precipitation temperature. After ageing, the slurry is washed and filtered in routine fashion to remove substantially all the salts formed during the precipitation of the hydrogel which can be removed by washing. The preferred solvent for washing is water although other solvents such as lower alkanols may be utilized. After washing, the hydrogel is reslurried with a solution containing solubilized salts of a heavy metal selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, sufficient to deposit on the final catalyst from 1%w to 5%w nickel and/or cobalt and from 8%w to 18%w molybden um or 10%w to 32%w tungsten. When mixtures of molybdenum and tungsten are utilized, the final catalyst contains 8%w to 32%w molybdenum and/or tungsten. Alternatively, the solution may contain amounts of nickel and/or cobalt and molybdenum and/or tungsten in excess of that required to deposit the aforesaid amounts of metals, which excess may be removed by washing following the reslurry step. A typical solution can be prepared by combining a molybdenum solution with a nickel and/or cobalt solution. In a preferred embodiment, the solution contains a stabilizing amount of phosphorus. Typically, the metals solution contains a phosphorus-containing compound having an amount of phosphorus in the range from 0.2 to 1.5 moles of phosphorus per mole of molybdenum and/or tungsten. The phosphorus-containing compound is suitably phosphoric acid, a phosphate salt or a mixture thereof. The molybdenum solution contains a water-soluble source of molybdenum such as ammonium heptamolybdate or ammonium dimolybdate dissolved in water. The tungsten solution typically contains ammonium metatungstate dissolved in water. A preferred method for preparing the molybdenum and the tungsten solutions comprises adding hydrogen peroxide to the solution in the range of 0.1 to 1.0 mole of hydrogen peroxide per mole of molybdenum or tungsten, respectively. In addition, a suitable soluble amine compound such as monoethanolamine, propanolamine or ethylenediamine may be added to the solutions in order to aid in stabilization of the solution. The nickel solution contains one or more nickel salts dissolved in water and optionally, a phosphorus-containing compound. A wide range of nickel compounds are suitable, such as nickel nitrate, nickel acetate, nickel formate, nickel sulphate, nickel oxide, nickel phosphate, nickel carbonate, nickel chloride, and nickel hydroxide. Two compounds that are especially useful are nickel nitrate and nickel carbonate. The cobalt solution contains one or more cobalt salts dissolved in water and optionally, a phosphorus-containing compound. A wide range of cobalt compounds are suitable, such as cobalt nitrate, cobalt hydroxide, cobalt acetate, cobalt oxalate, or cobalt oxide. The preferred cobalt compound is cobalt nitrate. The reslurry of the hydrogel support with the metals solution is carried out at a pH in the range between 4.0 and 8.0, preferably between 4.0 and 6.0, adjusting to these pH ranges by adding, if necessary, acid or base to the hydrogel, the metals solution and/or the mixture of the slurry and the metals solution, and a temperature in the range between 20°C and 90°C until adsorption of the metals salts onto the gel is sufficient to yield a final calcined catalyst having a catalytically effective amount of metals present. Typically, the times for reslurry will range from 0.5 to 2 hours. Optionally, the resulting material can be washed to remove unadsorbed metals and filtered in routine fashion. Following the reslurry step, the material may be extruded and then dried and calcined; dried, mulled with addition of water, extruded or pelleted and calcined; or partially dried, extruded or pelleted, dried more completely and calcined. Drying is accomplished by conventional means. It may be carried out by forced draft drying, vacuum drying, air drying or similar means. Drying temperatures are not critical and depend upon the particular means utilized for drying. Drying temperatures will typically range from 50°C to 150°C. In a preferred embodiment, the material is extruded and then dried. Alternatively, the material may be extruded after drying to the proper loss on ignition (LOI). However, to facilitate extrusion, organic binders and/or lubricants may be added prior to extrusion. After drying, the material is calcined to produce the finished catalyst. The material may be calcined in any atmosphere, reducing, oxidizing or neutral, although air is preferred. However, if binders and/or lubri cants are used in the process according to the present invention the material is preferably heated in an oxygen-containing atmosphere, preferably air, in order to burn out the binders and lubricants. Calcining temperatures will typically range from 300°C to 900°C. Drying, calcining and burn-out may be combined in one or two steps. Most frequently the calcining and/or burn-out steps are combined using an oxygen-containing atmosphere. Certain other processing steps may be incorporated into the above-described procedure without deviating from the scope and intent of the present invention. For example, prior to the complete drying of the catalyst it may be extruded and then dried more completely, followed by calcination. The final catalysts are found to have surface areas greater than 300 m²/g, pore volumes ranging from 0.6 to 1.2 cm³/g and with at least 20% of its pore volume having diameters above 15 nm. Pore diameters are also measured by mercury intrusion. Crush strengths are greater than 40.5 N. In general, the metals contents of the final catalysts range from 1%w to 5%w nickel and/or cobalt, preferably from 2.5%w to 4%w nickel and/or cobalt, from 8%w to 18%w molybdenum or 10%w to 32%w tungsten, and from 1%w to 6%w phosphorus. The catalysts prepared according to the present invention can be suitably applied to hydrocarbon conversion processes such as catalytic cracking, hydrocracking, hydrotreating, isomerization, hydrogenation, dehydrogenation, oligomerization, alkylation, dealkylation and the like. The catalysts are particularly suitable for demetallization involving crude feedstocks. The larger pores of the catalysts prepared according to the present invention are not quickly plugged up and hence provide a longer life. Typical hydroconversion processes utilizing the catalysts of the present invention will be carried out at a temperature ranging from 150°C to 450°C, a pressure ranging from 14 bar to 175 bar and a liquid hourly space velocity of 0.1 to 10.0 reciprocal hour. The invention will now be illustrated by the following Examples. Example 1 Seven hundred and forty grams of reagent grade sodium aluminate were added to 1000 grams of water which was then heated to 60°C in order to effect dissolution of the materials. Five hundred and forty-four grams of aluminium chloride hexahydrate were added to 760 grams of water. One hundred and twelve grams of 85% phosphoric acid along with 112 grams of water were added to the aluminium chloride solution which was then heated to 60°C. Both solutions were cooled to slightly less than 60°C and placed in dropping funnels. Five litres of a 40% by volume ethanol solution was added to a 10 litre stainless steel bucket equipped with a pH meter, thermometer and stirrer. After the pH was adjusted to 7.0 using the sodium aluminate solution, the two solutions in the dropping funnels were added simultaneously to the well-stirred bucket, maintaining a precipitation pH of 7. A total of 1370 grams of sodium aluminate solution and 761 grams of aluminium chloride solution were used to effect the titration. After these quantities of reagents had been used, the final aging pH of the solution rose to between 10.0 and 11.0. The solution was aged for one hour at 60°C. The resulting material was filtered and washed in two large Buchner funnels with about 50 litres of water. The excess water from the wet filter cake was removed by vacuum. The hydrogel was then divided into three equal portions. The following solutions were then prepared. 30.57 grams of nickel nitrate as hexahydrate was mixed with 21.53 grams of 85% phosphoric acid and diluted to 500 millilitres with water. An additional solution of 45.39 grams of ammonium heptamolybdate and 7.07 grams of 30% hydrogen peroxide were diluted to 500 millilitres with water. The two solutions were combined slowly with stirring and one portion of the hydrogel was added and reslurried with the solution at 80°C for two hours at a pH of 5.0. At the end of two hours, the slurry was filtered and washed with two litres of water. The excess water from the slurry was again removed by vacuum. The wet gel was then extruded using a small, hand-held extruder using a 4 mm cylindrical die, dried overnight at 120°C and calcined in air at 510°C. The properties of the catalyst (1) are listed in Tables I and II. Example 2 A catalyst (2) was prepared according to Example 1 except that the molybdenum solution contained additionally 4 g of monoethanolamine and the pH of the reslurry was 5.5. The properties of the final catalyst are listed in Tables I and II. Comparative Experiment A A carrier A was prepared according to Example 1, except that five hundred and forty-three grams of aluminium chloride hexahydrate were added to 760 grams of water and that five thousand grams of water were substituted for the ethanol solution. The hydrogel thus obtained was directly extruded (without the incorporation of any metal compound(s)) using a small, hand-held extruder using a 4 mm cylindrical die, dried overnight at 120°C and calcined in air at 510°C. The properties of the carrier are listed in Tables I and II. Comparative Experiment B A catalyst B was prepared according to Example 1, except that five hundred and forty-two grams of aluminium chloride hexahydrate were added to 760 grams of water, that five thousand grams of water were substituted for the ethanol solution, and that the pH of the reslurry was 4.5. The properties of the catalyst are listed in Tables I and II. Comparative Experiment C A carrier C was prepared according to Example 1, except that the hydrogel was directly extruded (without the incorporation of any metal compound(s)) using a small, hand-held extruder using a 4 mm cylindrical die, dried overnight at 120°C and calcined in air at 510°C. The properties of the carrier are listed in Tables I and 11. Comparative Experiment D Five hundred and eighty-two grams of reagent grade sodium aluminate were added to 787 grams of water which was then heated to 60°C in order to effect solution of the materials. Two hundred and seventy-one grams of aluminium chloride hexahydrate were added to 380 grams of water. Fifty-six grams of 85% phosphoric acid along with 56 grams of water were added to the aluminium chloride solution which was then heated to 60°C. Both solutions were cooled to slightly less than 60°C and placed in dropping funnels. Five litres of a 40% by volume isopropanol solution was added to a 10 litre stainless steel bucket equipped with a pH meter, thermometer and stirrer. After the pH was adjusted to 7.0 using the sodium aluminate solution, the two solutions in the dropping funnels were added simultaneously to the well-stirred bucket, maintaining a precipitation pH of 7. A total of 1370 grams of sodium aluminate solution and 761 grams of aluminium chloride solution were used to effect titration. After these quantities of reagents had been used, the final ageing pH of the solution rose to between 10.0 and 11.0. The solution was aged for one hour at 60°C. The resulting material was filtered and washed in two large Buchner funnels with about 50 litres of water. The excess water from the wet filter cake was removed by vacuum. The hydrogel was then divided into three equal portions. The following solutions were prepared. 21.54 grams of nickel nitrate as hexahydrate was mixed with 15.12 grams of 85% phosphoric acid and diluted to 500 millilitres with water. An additional solution of 32.01 grams of ammonium heptamolybdate and 4.5 grams of 30% hydrogen peroxide were diluted to 500 millilitres with water. The two solutions were combined slowly with stirring and one portion of the hydrogel was added and reslurried with the solution at 80°C for two hours at a pH of 5. 0. At the end of two hours, the slurry was filtered and washed with two litres of water. The excess water from the slurry was again removed by vacuum. The wet gel was then extruded using a small, hand-held extruder using a 4 mm cylindrical die, dried overnight at 120°C and calcined in air at 510°C. The properties of the catalyst (D) are listed in Tables I and II. Comparative Experiment E A catalyst (E) was prepared according to Comparative Experiment D, except that a 10% by volume ethanol solution was used. The properties of the catalyst are listed in Tables I and II. As can be seen in Tables I and II, the catalysts prepared in Examples 1 and 2 show an increase in the number of macropores while maintaining high surface areas. As evidenced by Comparative Experiment B, however, this increase in the number of macropores cannot be attributed to the amount of phosphorus present in the catalysts. Comparative Experiments A and C show that the presence of alcohol in the support has no effect on the pore size distribution of the support materials. It is only when the metals solutions are added that an increase in macropores is seen. Comparative Experiments D and E are included to show that the type and amount of alcohol utilized are critical to the formation of products having more than 20% of their pores greater than 15 nm. a) 209 cm³ volume fully settled in a graduated cup and weighed. b) BET, by nitrogen adsorption/desorption, Micromeritics Digisorb 2500 Instrument. c) By nitrogen adsorption, Micromeritics Digisorb 2500 Instrument. d) Flat plate, single pellet, extrudate approximately 5 mm in length. e) Weight percent determined by neutron activation analysis or atomic absorption spectroscopy. f) Weight percent determined by neutron activation analysis or atomic absorption spectroscopy. g) Weight percent determined by neutron activation analysis or atomic absorption spectroscopy. h) Determined by mercury intrusion, to 4136 bar using a Micromeritics Autopore 9210, using a 130° contact angle and 0.473 N/m surface tension of mercury. Numbers listed are percent pore volume.

Claims: 1. A process for preparing wide-pore catalysts having surface areas above 300 m²/g and at least 20% of the pore diameters greater than 15 nm, which process comprises: (a) precipitating an aqueous solution of one or more aluminium salt(s) in the presence of a phosphorus-containing compound in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, by adjusting the pH of said solution to a range between 5.5 and 10.0, thereby forming a precipitate, (b) ageing the precipitate at a temperature ranging from 20°C to 90°C for at least 15 minutes at a pH ranging from 9.0 to 12.0, (c) washing the precipitate, (d) mixing the precipitate with a solution containing solubilized salts of a heavy metal selected from the group consisting of molybdenum, tungsten and mixtures thereof, and an element selected from the group consisting of nickel, cobalt and mixtures thereof, at a pH in the range between 4.0 and 8.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having a catalytically effective amount of metals present, (e) extruding the product of step (d), and (f) drying and calcining the product of step (e) at a temperature ranging from 300°C to 900°C. 2. A process according to claim 1, wherein step (a) comprises forming a precipitate by titrating an aqueous solution of an acid aluminium salt and an aqueous solution of a basic aluminium comp ound in the presence of a phosphorus-containing compound in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof. 3. A process according to claim 2, wherein step (a) comprises forming a precipitate by titrating an aqueous solution of an acid aluminium salt and phosphoric acid with an aqueous solution of a basic aluminium compound in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof. 4. A process according to claim 2, wherein step (a) comprises forming a precipitate by titrating an aqueous solution of an acid aluminium salt with an aqueous solution of a basic aluminium compound and sodium phosphate in a solution containing 15%v to 50%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof. 5. A process according to any one of claims 1-4, wherein the solution in step (a) contains 20%v to 40%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof. 6. A process according to any one of claims 1-5, wherein the precipitation is carried out at a pH in the range between 5.5 and 8.0. 7. A process according to any one of claims 1-6, wherein the precipitation is carried out at a temperature between 20°C and 90°C. 8. A process according to any one of claims 1-7, wherein the amount of phosphorus-containing compound in step (a) is from 0.06 to 0.30 moles of phosphorus per mole of aluminium. 9. A process according to any one of claims 1-8, wherein the ageing pH is in the range between 10.0 and 11.5. 10. A process according to any one of claims 1-9, wherein the final catalyst contains from 1%w to 5%w nickel and/or cobalt and from 8%w to 18%w molybdenum. 11. A process according to any one of claims 1-10, wherein the solution used in step (d) additionally contains an amount of from 0.2 to 1.5 moles of phosphorus per mole of molybdenum. 12. A process according to claim 2, wherein step (a) comprises forming a precipitate by titrating an aqueous solution of an acid aluminium salt selected from the group consisting of aluminium sulphate, aluminium nitrate and aluminium chloride, and an aqueous solution of a basic aluminium compound selected from the group consisting of sodium aluminate and potassium aluminate, in the presence of a phosphorus-containing compound in a solution containing 20%v to 40%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof,wherein step (b) comprisesageing the precipitate at a temperature ranging from 20°C to 90°C for at least 15 minutes at a pH ranging from 10.0 to 11.5,and wherein step (d) comprisesmixing the precipitate with a solution containing solubilized molybdate or dimolybdate salts and nickel or cobalt salts, and phosphoric acid in an amount of from 0.2 to 1.5 moles of phosphorus per mole of molybdenum, at a pH in the range between 4.0 and 6.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having from 2.5%w to 4%w nickel or cobalt and from 10%w to 14%w molybdenum. 13. A process according to claim 1, wherein step (a) comprises precipitating an aqeuous solution of an acid aluminium salt selected from the group consisting of aluminium sulphate, aluminium nitrate and aluminium chloride, with an aqueous solution of a base in the presence of a phosphorus-containing compound in a solution containing 20%v to 40%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, thereby forming a precipitate,wherein step (b) comprisesageing the precipitate at a temperature ranging from 20°C to 90°C for at least 15 minutes at a pH ranging from 10.0 to 11.5,and wherein step (d) comprisesmixing the precipitate with a solution containing solubilized molybdate or dimolybdate salts and nickel and/or cobalt salts, and phosphoric acid in an amount of from 0.2 to 1.5 moles of phosphorus per mole of molybdenum, at a pH in the range between 4.0 and 6.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having from 2.5%w to 4%w nickel and/or cobalt and from 10%w to 14%w molybdenum. 14. A process according to claim 1, wherein step (a) comprises precipitating an aqueous solution of an acid with an aqueous solution of a basic aluminium compound selected from the group consisting of sodium aluminate and potassium aluminate, in the presence of a phosphorus-containing compound in a solution containing 20%v to 40%v of an alcohol selected from the group consisting of methanol, ethanol and mixtures thereof, thereby forming a precipitate,wherein step b) comprisesageing the precipitate at a temperature ranging from 20 to 90°C for at least 15 minutes at a pH ranging from 10.0 to 11.5,and wherein step (d) comprisesmixing the precipitate with a solution containing solubilized molybdate or dimolybdate salts and nickel and/or cobalt salts, and phosphoric acid in an amount of from 0.2 to 1.5 moles of phosphorus per mole of molybdenum, at a pH in the range between 4.0 and 6.0 and a temperature in the range between 20°C and 90°C until adsorption of said salts onto the gel is sufficient to yield a final catalyst having from 2.5%w to 4%w nickel and/or cobalt and from 10%w to 14%w molybdenum. 15. A catalyst for hydrotreating metals-containing crude oil feedstocks which comprises a catalytically effective amount of an element selected from the group consisting of nickel, cobalt and mixtures thereof, and a catalytically effective amount of a heavy metal selected from the group consisting of molybdenum, tungsten and mixtures thereof, said catalyst having a surface area greater than 300 m²/g and at least 20% of its pore volume in pores having diameters greater than 15 nm, wherein said catalyst is prepared by a process according to any one of claims 1-14. 16. A process for the hydrotreating, in particular demetallization, of hydrocarbon feeds, wherein use is made of a catalyst as claimed in claim 15.

Inventors: KEMP, RICHARD ALAN
Applicants: SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1987
Main classification: B01J27
IPC codes: B01J37, C10G11, C10G47, C10G45, B01J35, C01F7, B01J27