Hydrotreating catalyst containing phosphorus and boron
A catalyst having at least one Group VIB metal component, at least one Group VIII metal component, a phosphorus component, and a boron-containing carrier component. The amount of the phosphorus component is at least 1 wt %, expressed as an oxide (P 2 O 5 ) and based on the total weight of the catalyst, and the amount of boron content is in the range of about 1 to about 13 wt %, expressed as an oxide (B 2 O 3 ) and based on the total weight of the catalyst. In one embodiment of the invention, the boron-containing carrier component is a product of a co-extrusion of at least a carrier and a boron source. A method for producing the catalyst and its use for hydrotreating a hydrocarbon feed are also described.
1. A catalyst comprising
at least one Group VIB metal component,
at least one Group VIII metal component comprising nickel and/or cobalt,
a phosphorus component, and
a boron-containing carrier component,
wherein the amount of the phosphorus component is at least about 1 wt %, expressed as an oxide (P 2 O 5 ) and based on the total weight of the catalyst, and the boron content is in the range of about 1 to about 13 wt %, expressed as an oxide (B 2 O 3 ) and based on the total weight of the catalyst; and wherein the formation of the catalyst involves at least co-extruding a boron compound with a carrier to form a boron-containing carrier extrudate, drying and calcining the extrudate, and impregnating the calcined extrudate with a solution comprised of a phosphorus source, at least one Group VIB metal source and/or at least one Group VIII metal source.
2. The catalyst according to claim 1 wherein the Group VIB metal component comprises molybdenum.
3. The catalyst according to claim 2 wherein the Group VIII metal component comprises nickel.
4. The catalyst according to claim 2 wherein the Group VIII metal component comprises cobalt.
5. The catalyst according to claim 1 wherein the Group VIII metal component comprises nickel.
6. The catalyst according claim 1 wherein the carrier comprises alumina.
7. The catalyst according to claim 1 wherein the boron compound is selected from the group consisting of meta-boric acid, ortho-boric acid, ammonium borate tetra-hydrate, sodium tetra borate, ammonium borate, ammonium tetra borate, boric oxide, mono-, di- and tri-alkyl amine borate, ammonium tetra phenyl borate, and a mixture of any two or more of the foregoing.
8. The catalyst according to claim 1 , further comprising an organic additive.
9. The catalyst according to claim 8 , wherein the organic additive is
(i) an organic compound selected from the group consisting of (a) organic compounds comprising at least two oxygen atoms and 2-10 carbon atoms, and (b) the ethers, esters, acetals, acid chlorides, acid amides, oligomers and polymers of the organic compounds of (a), and/or
(ii) an organic compound comprising at least one covalently bonded nitrogen atom and at least one carbonyl moiety.
10. A method which comprises contacting a hydrocarbon feed with a catalyst according to claim 9 under hydrotreating conditions so as to hydrotreat the hydrocarbon feed.
11. The catalyst according to claim 9 wherein the organic additive is selected from an organic compound selected from the group consisting of organic compounds comprising at least two oxygen atoms and 2-10 carbon atoms, and the ethers, esters, acetals, acid chlorides, acid amides, oligomers or polymers thereof.
12. A method which comprises contacting a hydrocarbon feed with a catalyst according to claim 1 under hydrotreating conditions so as to hydrotreat the hydrocarbon feed.
13. The catalyst according to claim 1 wherein the components consist of at least one Group VIB metal component, at least one Group VIII metal component comprising nickel and/or cobalt, a phosphorus component, a boron-containing carrier component, and optionally an organic additive.
14. The catalyst according to claim 13 wherein the organic additive is
(i) an organic compound selected from the group consisting of (a) organic compounds comprising at least two oxygen atoms and 2-10 carbon atoms, and (b) the ethers, esters, acetals, acid chlorides, acid amides, oligomers and polymers of the organic compounds of (a), and/or
(ii) an organic compound comprising at least one covalently bonded nitrogen atom and at least one carbonyl moiety.
15. A method of producing a catalyst, the method comprising
co-extruding a boron compound with a carrier to form a boron-containing carrier extrudate,
drying and calcining the extrudate, and
impregnating the calcined extrudate with a solution comprised of a phosphorus source, at least one Group VIB metal source and/or at least one Group VIII metal source comprising nickel and/or cobalt,
the amount of the boron compound and the amount of the phosphorus source being sufficient so as to form a catalyst composition at least having a boron content in the range of about 1 wt % to about 13 wt %, expressed as an oxide (B 2 O 3 ) and based on the total weight of the catalyst, and a phosphorus content of at least about 1 wt %, expressed as an oxide (P 2 O 5 ) and based on the total weight of the catalyst.
16. The method according to claim 15 , further comprising calcining an impregnated calcined extrudate formed in the impregnating step.
17. The method according to claim 15 , further comprising drying an impregnated calcined extrudate formed in the impregnation step so as to form a dried impregnated calcined extrudate so as to form the catalyst.
18. The method according to claim 17 wherein the solution further comprises an organic additive.
19. The method of claim 15 , further comprising drying an impregnated calcined extrudate formed in the impregnation step so as to form a dried impregnated calcined extrudate, and further calcining the dried impregnated calcined extrudate so as to form the catalyst.
20. The method according to claim 15 wherein the solution further comprises an organic additive.
21. The method according to claim 20 wherein the organic additive is
(i) an organic compound selected from the group consisting of (a) organic compounds comprising at least two oxygen atoms and 2-10 carbon atoms, and (b) the ethers, esters, acetals, acid chlorides, acid amides, oligomers and polymers of the organic compounds of (a), and/or
(ii) an organic compound comprising at least one covalently bonded nitrogen atom and at least one carbonyl moiety.
22. A catalyst formed by the process of claim 15 .
23. The method according to claim 15 wherein the components consist of a boron compound, a carrier, and a solution comprised of a phosphorus source, at least one Group VIB metal source, at least one Group VIII metal source comprising nickel and/or cobalt, and optionally an organic additive.
24. The method according to claim 23 wherein the organic additive is
(i) an organic compound selected from the group consisting of organic compounds comprising at least two oxygen atoms and 2-10 carbon atoms, and the ethers, esters, acetals, acid chlorides, acid amides, oligomers or polymers thereof, and/or
(ii) an organic compound comprising at least one covalently bonded nitrogen atom and at least one carbonyl moiety.