Alumina having bimodal pore structure, catalysts made therefrom and processes using same
Alumina having a pore structure characterized by the absence of macropores, no more than 5% of the total pore volume in pores greater than 350 Å, a high pore volume (greater than 0.8 cc/g measured by mercury intrusion) and a bi-modal pore volume distribution character, where the two modes are separated by 10 to 200 Å, and the primary pore mode is larger than the median pore diameter (MPD), calculated either by volume or by surface area, the MPD by volume being itself larger than the MPD by surface area. Also provided are catalysts made from and processes using such alumina.
1. A catalyst support comprising an alumina extrudate characterized by having:
no more than 5% of its total pore volume in pores having a diameter greater than 350 Å;
a total pore volume greater than 0.8 cc/g measured by mercury intrusion; and
a bi-modal pore volume distribution having a primary and a secondary mode, wherein
the primary mode exhibits a higher maximum than the secondary mode;
the primary and secondary modes are separated by at least about 10 Å and by as much as about 200 Å;
the primary pore mode occurs at a pore diameter greater than the median pore diameter (“MPD”), calculated either by volume (“MPD V ”) or by surface area (“MPD SA ”); and
the MPD V is larger than the MPD SA .
2. The catalyst support of claim 1 wherein the percentage of total pore volume in pores having a diameter greater than 350 Å is no more than 2.5%.
3. The catalyst support of claim 1 wherein the primary mode occurs between about 100 Å and about 200 Å.
4. The catalyst support of claim 1 wherein the primary and secondary modes are separated by between about 20 Å and about 80 Å.
5. The catalyst support of claim 1 wherein the primary and secondary modes are separated by between about 10 Å and about 20 Å.
6. A catalyst composition comprising at least one catalytically active metal selected from the group consisting of metals, metallic oxides, metallic sulfides, and mixtures thereof and a catalyst support comprising an alumina extrudate characterized by having:
no more than 5% of its total pore volume in pores having a diameter greater than 350 Å; and
a bi-modal pore volume distribution having a primary and a secondary mode, wherein
the primary mode exhibits a higher maximum than the secondary mode;
the primary and secondary modes are separated by at least about 10 Å and by as much as about 200 Å;
the primary pore mode occurs at a pore diameter greater than the median pore diameter (“MPD”), calculated either by volume (“MPD V ”) or by surface area (“MPD SA ”); and
the MPD V is larger than the MPD SA .
7. The catalyst composition of claim 6 wherein the percentage of total pore volume in pores having a diameter greater than 350 Å is no more than 2.5%.
8. The catalyst composition of claim 6 wherein the primary mode occurs between about 100 Å and about 200 Å.
9. The catalyst composition of claim 6 wherein the primary and secondary modes are separated by between about 20 Å and about 80 Å.
10. The catalyst composition of claim 6 wherein the primary and secondary modes are separated by between about 10 Å and about 20 Å.
11. The catalyst composition of claim 6 further comprising a promoter.
12. The catalyst composition of claim 11 wherein the promoter is P 2 O 5 .
13. The catalyst composition of claim 11 wherein the metals are catalytically active transition metals selected from the group consisting of Group VIB and Group VIII metals and the promoter is P 2 O 5 .
14. The catalyst composition of claim 6 wherein the metals are catalytically active transition metals selected from the group consisting of Group VIB and Group VIII metals.
15. The catalyst composition of claim 6 wherein the metals are nickel, cobalt, molybdenum and tungsten.
16. The catalyst composition of claim 6 wherein the metals are nickel, cobalt, molybdenum and tungsten, wherein the catalyst further comprises P 2 O 5 .
17. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 35 wt. % calculated as MoO 3 and cobalt in an amount up to 9 wt. % calculated as CoO, wherein wt. % is based on the total catalyst composition weight.
18. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 35 wt. % calculated as MoO 3 , cobalt in an amount up to 9 wt. % calculated as CoO, said composition further comprising up to 10 wt. % P 2 O 5 , wherein wt. % is based on the total catalyst composition weight.
19. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 35 wt. % calculated as MoO 3 and nickel in an amount up to 7 wt. % calculated as NiO, wherein wt. % is based on the total catalyst composition weight.
20. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 35 wt. % calculated as MoO 3 , nickel in an amount up to 7 wt. % calculated as NiO, said composition further comprising up to 10 wt. % P 2 O 5 , wherein wt. % is based on the total catalyst composition weight.
21. The catalyst composition of claim 6 wherein the metal is molybdenum in an amount up to 20 wt. % calculated as MoO 3 , wherein wt. % is based on the total catalyst composition weight.
22. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 20 wt. % calculated as MoO 3 and one selected from nickel, cobalt and mixtures thereof in an amount up to 5 wt. % calculated as the oxide, wherein wt. % is based on the total catalyst composition weight.
23. The catalyst composition of claim 6 wherein the metals are molybdenum in an amount up to 20 wt. % calculated as MoO 3 and one selected from nickel, cobalt and mixtures thereof in an amount up to 5 wt. % calculated as the oxide, said composition further comprising up to 10 wt. % P 2 O 5 , wherein wt. % is based on the total catalyst composition weight.
24. The catalyst composition of claim 6 wherein the metals are noble metals in an amount up to 2 wt. % calculated on an elemental basis, wherein wt. % is based on the total catalyst composition weight.
25. The catalyst composition of claim 24 wherein the noble metal is platinum.
26. A process for the catalytic hydrodesulfurization of a hydrocarbon-containing feed comprising contacting the feed under hydrodesulfurization conditions with the catalyst composition as set forth in any one of claims 6 – 23 .
27. A process for the catalytic hydrodenitrogenation of a hydrocarbon-containing feed comprising contacting the feed under hydrodenitrogenation conditions with the catalyst composition as set forth in any one of claims 6 – 23 .
28. A process for the catalytic hydroconversion of a hydrocarbon-containing feed comprising contacting the feed under hydroconversion conditions with the catalyst composition as set forth in any one of claims 6 – 23 .
29. A process for the catalytic hydrodemetallation of a hydrocarbon-containing feed comprising contacting the feed under hydrodemetallation conditions with the catalyst composition as set forth in any one of claims 6 – 23 .
30. A process for the catalytic hydrocracking of a hydrocarbon-containing feed comprising contacting the feed under hydrocracking conditions with the catalyst composition as set forth in any one of claims 6 – 23 .
31. A process for the catalytic reforming of a hydrocarbon-containing feed comprising contacting the feed under reforming conditions with the catalyst composition as set forth in any one of claims 6 – 14 , 24 and 25 .
32. A process for the catalytic hydrogenation-dehydrogenation of a hydrocarbon-containing feed comprising contacting the feed under hydrogenation-dehydrogenation conditions with the catalyst composition as set forth in any one of claims 6 – 14 , 24 and 25 .
33. A process for the catalytic isomerization of a hydrocarbon-containing feed comprising contacting the feed under isomerization conditions with the catalyst composition as set forth in any one of claims 6 – 14 , 24 and 25 .