More specifically, the present invention relates to a bi-functional catalyst with a hydro-dehydrogenating activ- ity and a process for the contemporaneous production of middle distillates and lubricating bases, with a balanced yield, starting from feedstocks mainly consisting of n- paraffin mixtures, comprising at least one hydrocracking step in the presence of said bi-functional catalyst.

Mixtures of mainly paraffinic hydrocarbons, including a significant fraction with a high boiling point, are nor- mally obtained as distillation residues in refining proc- esses of fuels of petroleum origin. Other mainly paraffinic products are, for example, so-called"slack waxes"which are obtained as by-product of the production of lubricating

bases through the solvent extraction process.

These products are normally under solid or semi-solid form (waxes) at room temperature, particularly when preva- lently linear, and do not allow direct use as fuel in the transport field. In order to upgrade these hydrocarbon mix- tures, it is therefore necessary to subject them to degra- dation and/or upgrading processes to obtain products of greater interest, such as fuels, lubricants, solvents and other derivatives having improved characteristics. The im- provement of the above-mentioned aspects has so far been obtained by subjecting the waxes to more or less complex processes of chain length reduction, in the presence of hy- drogen (normally known by the English term hydrocracking) and hydro-isomerization.

At the same time, other hydrocracking and/or isomeri- zation catalysts have been developed for the production of lubricating oils, having optimum performances in terms of composition and the isomerization degree of the lubricating bases obtained, starting from n-paraffin feedstocks. These hydrocracking processes are carried out in the presence of a bi-functional catalyst, containing a metal with a hydro- dehydrogenating activity supported on an inorganic solid normally consisting of an oxide or silicate with acidic characteristics.

Typically, hydrocracking catalysts include metals of

groups 6 to 10 of the periodic table of elements (in the form approved by IUPAC and published by CRC Press Inc. in 1989, to which reference will be made hereinafter), espe- cially nickel, cobalt, molybdenum, tungsten or noble metals such as palladium or platinum. Whereas the former are more suitable for processing hydrocarbon mixtures having rela- tively high sulphur contents, noble metals are more active but are poisoned by sulphur and require a feedstock which is essentially without this.

Supports which can be used for the purpose are various type of zeolites ( (3, Y), X-Al203 (where X can be Cl or F), silico-aluminas, the latter being amorphous or with various crystallinity degrees, or mixtures of crystalline zeolites and amorphous oxides. A very wide examination of the dif- ferent catalysts, the specific characteristics and differ- ent hydrocracking processes based on the same, can be found, among the many available in literature, in the pub- lication of J. Scherzer and A. J. Gruia"Hydrocracking Sci- ence and Technology", Marcel Dekker, Inc. Editor (1996).

It is also well known that the above-mentioned iso- merization and hydrocracking processes are carried out un- der conditions wherein the conversion per passage of the high boiling fraction is rarely over 90% and is normally maintained at below 80%, especially to reduce the produc- tion of low value light fractions. The non-converted frac-

tion can be recycled to the hydrocracking, or is separated and used for the production of lubricating bases. In this case it is necessary for the high-boiling residue to be subjected to further treatment (isomerization and/or dewax- ing) whose purpose is to transform or separate the waxy fraction contained therein.

One of the most relevant problems in the hydrocracking process of linear paraffin mixtures, consists in the diffi- culty of contemporaneously obtaining, from the same proc- ess, middle distillates with good characteristics at low temperatures and a 360+ °C fraction with suitable charac- teristics in terms of average molecular weight and isomeri- zation degree, for the production of bases for lubricant oils. If a 150+ °C cut is subjected to hydrocracking using the catalytic systems currently in use and the reaction is carried out so as to obtain middle distillates having good characteristics at low temperatures, then one can see that the 360+ °C residue has too low a molecular weight and, consequently, the obtained lubricating base exhibit a low viscosity. When, on the contrary, the reaction is carried out so as to obtain a 360+ cut with a sufficiently high mo- lecular weight, the yields of lubricating base are low, due to the presence of a still high quantity of linear paraf- fins, which makes a subsequent dewaxing step necessary and, in addition, the cold properties of the middle distillates

are not satisfactory.

No solution seems to have been found as yet for the above overall problems with respect to the processes and catalysts of the known art. Even though the use, as cata- lyst support, of certain particular amorphous micro-meso- porous silico-aluminas, as described in European patent ap- plication EP-A 1,101, 813, is capable of providing an excel- lent equilibrium between gas oil and kerosene in the middle distillate fraction, it apparently does not also allow a fraction of lubricating base to be produced with optimal characteristics which enable it to be adopted without any further specific treatment.

It has now been surprisingly found that certain amor- phous silico-aluminas with a low aluminum content, contain- ing certain quantities of phosphorus, bonded to the oxide matrix, are advantageously suitable as active support in combination with one or more metals with a hydro- dehydrogenating function, for the preparation of a catalyst for refining processes such as the hydro-treatment of hy- drocarbons for the production of fuels and bases for lubri- cating oils.

A first object of the present invention therefore re- lates to a solid catalyst, which can be used in hydrotreat- ing processes of hydrocarbons, comprising: (A) a support of an acidic nature consisting of a catalyti-

cally active porous solid, including silicon, aluminum, phosphorus and oxygen bonded to one another in such a way as to form a mixed amorphous solid forming a single phase, characterized by an Si/Al atomic ratio of between 15 and 250, a P/A1 ratio of at least 0.1, but lower than 5, pref- erably of between 0.3 and 3.5, a total pore volume ranging from 0.5 to 2.0 ml/g, an average pore diameter ranging from 3 nm to 40 nm, and a specific surface area ranging from 200 to 1000 m2/g, preferably between 300 and 900 m2/g ; (B) at least one metal with a hydro-dehydrogenating activ- ity selected from groups 6 to 10 of the periodic table of elements, dispersed on said support (A) in an amount of be- tween 0.05 and 5% by weight with respect to the total weight of the catalyst.

A second object of the present invention relates to a hydrotreating process of hydrocarbons, particularly hy- drocracking of mainly paraffin mixtures, for the production of fuels and/or lubricating bases.

Other objects of the present invention will appear evident from the following description and claims.

The meaning of some of the terms used herein is de- fined hereunder, for the purpose of clarifying the descrip- tion and claims of the present patent application and de- fining its scope: the term amorphous as used herein with reference to

the porous support of the catalyst of the present invention and its compositions and uses, indicates a substantial ab- sence of low angle X-ray scattering signals, according to the usual measuring technique described further on; -"distillation temperature"referring to a hydrocarbon mix, indicates, when not otherwise specified, the head tem- l perature or temperature range of a typical distillation column wherein said mixture is collected, at normal pres- sure (0.1009 MPa); the range definitions always include the extremes, when not otherwise specified, nevertheless, the term"range included"within two extremes, refers to any range between said extremes; the term"hydrocracking"is used herein with the gen- eral meaning of catalytic treatment at a high temperature of a hydrocarbon mix, preferably including a fraction with a boiling point higher than 350°C, in the presence of hy- drogen, obtaining a mixture with a lower boiling point; the hydrocracking treatment normally also includes so-called hydro-isomerization treatment, in so far as an isomerised product is obtained, having a boiling temperature lower than that of the feed mixture; the terms"kerosene"and"gas oil"as hereinafter used, refer to the two hydrocarbon fractions forming the so-called middle distillate, with a distillation tempera-

ture of between 140 and 280°C and between 240 and 380°C, respectively.

In its most general form, the acidic support (A) of the catalyst, according to the present invention, essen- tially comprises an amorphous homogeneous phase of mixed silicon, aluminum and phosphorus oxide, wherein the phos- phorus is in the maximum oxidation state (+5) and is com- monly bonded to the matrix of the other oxides by means of P-O-AI bonds, as determined by means of 27Al-NMR and 31P-NMR spectroscopic analysis. It has an extremely high surface area (determined by the BET method), preferably ranging from 300 to 900 m2/g, more preferably from 400 to 800 m2/g, and a pore size within the range of mesopores, preferably with an average diameter (determined by means of the DFT method) ranging from 5 to 30 nm, more preferably from 6 to 25 nm. The porosity (total pore volume as ml/g) is ex- tremely high and can be regulated, within certain limits, through the times, temperatures and other operating parame- ters during the gel formation in the preparation process of said support. The porosity of the amorphous support pref- erably ranges from 0.7 to 1.7 ml/g.

From a morphological point of view, the catalytically active amorphous solid of the present invention comprises a non-ordered network of pores with an essentially monomodal size distribution within a relatively wide range. The dif-

ference between 10% and 90% of the pore dimensions in the distribution curve is preferably within a range of diame- ters from 2 to 40 nm, preferably from 5 to 30 nm. The ox- ides forming the matrix are in turn arranged disorderly in a three-dimensional polymeric lattice, without forming crystalline structures detectable with X-rays.

Said acidic amorphous support prevalently consists of silicon oxide and is characterized by the presence of cer- tain quantities of Al and P homogeneously bonded and dis- tributed in the oxide matrix, so that the P/Al ratio is lower than 5 and at least equal to 0.1. For P/Al ratio val- ues of 5 or higher, a substantial collapse of the porous structure is observed, with a considerable decrease in the catalytic and support properties; for P/A1 values lower than 0.1, no substantial progress was observed with respect to a traditional amorphous silica and alumina matrix having an analogous composition. More advantageous results were obtained when the P/Al ratio ranges from 0.3 to 3.5, and particularly within the range of 0.5 to 2.5.

One of the essential characteristics of the catalyst of the present invention is the selection in the support (A) of the aluminum content within a narrow and quantita- tively limited range, which in turn determines the phospho- rus content range. The Si/Al atomic ratio preferably ranges from 20 to 200, more preferably from 25 to 150.

Said amorphous support can also comprise, when neces- sary, smaller quantities of other components, in a mix or dispersed in the oxide matrix, in particular other metal compounds, especially oxides, different from those forming the component (B), suitable for giving particular charac- teristics or catalytic functions. Said additional compo- nents do not normally form more then 20% by weight of the amorphous solid, preferably up to 10% by weight. In par- ticular, the catalyst support according to the present in- vention can contain, in a mixture, phosphorus oxides or phosphates not bonded to the matrix of amorphous silica and alumina. Other oxides which can be present are those of certain transition metals, particularly selected from Ti, Zr, V, Zn, Ga and Sn, whereas alkaline or alkaline earth metals are preferably absent or only present in traces.

These metals can advantageously provide the amorphous solid of the present invention with improved mechanical proper- ties and further catalytic functions, such as oxidation, which are requested for certain industrial processes.

Said amorphous support can be prepared by adapting various typical sol-gel methods for the preparation of mi- cro-or meso-porous amorphous silico-alumina, by the addi- tion of a suitable quantity of an appropriate phosphorus compound in any of the steps preceding calcination, pref- erably before or during the formation of gel. The phospho-

rus compound is preferably selected form organic or inor- ganic oxygenated compounds, capable of forming phosphorus oxide or a phosphate group after the oxidizing thermal treatment suitable for drying and calcining the gel, more preferably such as to avoid introducing traces of undesir- able metals in the matrix of porous oxide obtained after calcination.

Sol-gel methods for the preparation of amorphous silico-aluminas which can be adapted for the purpose, are described, for example, in European patent applications EP- A 160,145, EP-A 340,868 and EP-A 659,478 or in the publica- tion"Journal of Catalysis, Vol. 60 (1969), pages 156-166, whose contents are incorporated herein as reference, with- out limiting the scope of the present invention to said methods.

An advantageous preparation method of said amorphous active support (A), includes, in a first step, the prepara- tion of a mixture comprising a tetra-alkyl ammonium hydrox- ide, an aluminum compound and a silicon compound, which can be hydrolyzed to the corresponding oxide hydrates, an oxy- genated compound of phosphorus and a sufficient quantity of water to dissolve and hydrolyze said compounds, wherein said tetra-alkyl ammonium hydroxide comprises from 1 to 10 carbon atoms in each alkyl residue, said hydrolysable alu- minum compound is preferably an aluminum trialkoxide com-

prising from 1 to 10 carbon atoms in each alkoxide residue, said hydrolysable silicon compound is a silicate of at least one hydrocarbon residue, preferably a tetra-alkyl or- tho-silicate, comprising 1 to 10 carbon atoms for each al- kyl residue, and said oxygenated phosphorus compound is a salt or phosphate or phosphonic ester or the corresponding acid, preferably an ammonium salt or a phosphate or phos- phonic ester in which each alkyl residue comprises from 1 to 10 carbon atoms.

The aqueous mixture of the above compounds is then hy- drolyzed and gelled in a second step, by heating in an al- kaline environment, preferably at a pH greater than 10, ei- ther by refluxing in a closed vessel, at the normal boiling point or higher, or in an open vessel below this tempera- ture, so that there is essentially no exchange of material with the outside. The gel thus produced is subsequently subjected to a third drying and calcination step.

The aqueous mixture in said first step can be made up in water or in a mixture of water and a soluble oxygenated organic compound, preferably an alcohol having from 1 to 10 carbon atoms, in a quantity of up to 1/1 in moles with re- spect to the water. More preferably, the oxygenated com- pound is an alcohol having from 2 to 5 carbon atoms. During the hydrolysis, a further quantity of alcohol is released into the aqueous solvent.

The tetra-alkyl ammonium hydroxide which can be used for the purposes of the present invention is selected, for example, from tetra-ethyl, propyl-, isopropyl-, butyl-, isobutyl-, terbutyl, and pentyl-ammonium hydroxide and among these tetra-propyl-, tetra-isopropyl-and tetra-butyl ammonium hydroxide are preferred. The aluminum trialkoxide is selected, for example, from aluminum triethoxide, pro- poxide, iso-propoxide, butoxide, iso-butoxide and ter- butoxide and among these aluminum tri-propoxide and tri- iso-propoxide are preferred. The tetra-alkyl orthosilicate is selected for example from tetra-methyl-, tetra-ethyl-, propyl-, isopropyl-, butyl-, isobutyl-, terbutyl-, and pen- tyl-orthosilicate and among these, tetra-ethyl orthosili- cate is preferred.

The oxygenated phosphorus compound is preferably se- lected from organic or inorganic compounds soluble in the reaction mixture, comprising a phosphate, phosphite or phosphonic group. According to an embodiment of the present invention, the phosphorus compound can also be formed in situ in the reaction mixture, or it can be added to said mixture in the form of a solution in a suitable solvent, preferably an alcohol or water. Typical phosphorus com- pounds suitable for the purpose are, for example, phospho- ric acid, phosphorous acid, ammonium phosphate, quaternary ammonium phosphates with organic amines having from 1 to 5

carbon atoms for each residue bonded to the nitrogen atom, organic phosphites and phosphates of alcohols having from 1 to 10, preferably from 1 to 5 carbon atoms, acid phosphates of ammonium or quaternary ammonium, alkyl-phosphonates or alkyl-phosphinates of alkyl residues having from 1 to 10, preferably from 1 to 5, carbon atoms.

Particularly preferred phosphorus compounds are ammo- nium phosphate, acid ammonium phosphate and the correspond- ing quaternary phosphates with organic amines having from 1 to 4 carbon atoms per residue, especially in the form of a solution prepared by the addition in water of phosphoric acid and the corresponding stoichiometric quantity of ammo- nia or amine.

In the preparation of the aqueous mixture of said first step, the order of addition of the various reagents is not particularly critical. The phosphorus compound can be added or formed in situ initially, together with the ad- dition of the tetra-alkyl ammonium hydroxide, by regulating the quantities so as to respect the desired final ratios between atoms and components, or it can be added after the introduction of the Si and Al compounds. The mixture is prepared at room temperature or a slightly higher value, preferably between 30 and 80°C. Although the thus formed mixture preferably consists of a limpid solution, certain compounds, such as aluminum alkoxide for example, can re-

main partially undissolved, but are completely dissolved in the heating step and hydrolysis of the subsequent step. In certain cases, a time of up to five hours under stirring may be necessary for obtaining a solution.

In a preferred embodiment of the process for the preparation of said amorphous solid according to the pres- ent invention, an aqueous solution is first prepared, con- taining the tetra-alkyl ammonium hydroxide and the aluminum trialkoxide, operating at a temperature which is sufficient to guarantee an effective dissolution of the aluminum com- pound, preferably from 40 to 80°C. The tetra-alkyl ortho- silicate is added to said aqueous solution. If necessary, the pH is regulated to a value greater than 10, preferably between 11 and 12. This mixture is brought to a tempera- ture which is suitable for triggering the hydrolysis reac- tion. Said temperature is in relation to the composition of the reaction mixture (normally from 60 to 120°C). The hy- drolysis reaction is exothermic and therefore guarantees self-maintenance, once the reaction has been activated. The quantities of constituents of the mixture are selected so as to respect the atomic ratios between the elements to be obtained in the catalytically active solid at the end of the preparation; the following atomic or molar ratios are conveniently used: Si/Al from 10/1 to 250/1, (tetra-alkyl ammonium hydroxide) /Si from 0.05/1 to 0.2/1, H2O/SiO2 from

5/1 to 40/1, P/Al from 0.1 to 5.0. The preferred values for these ratios are: Si/Al from 20/1 to 150/1, (tetra-alkyl ammonium hydroxide) /Si from 0.05/1 to 0.2/1, P/Al from 0.5 to 3.5 and H2O/SiO2 from 10/1 to 25/1.

The hydrolysis of the reagents and their gelation are preferably effected operating at a temperature equal to or higher than the boiling temperature, at atmospheric pres- sure, of any alcohol which develops as by-product of said hydrolysis reaction, without eliminating or substantially eliminating said alcohols from the reaction environment.

The hydrolysis and gelation temperature is therefore criti- cal, and is conveniently maintained at values higher than about 65°C up to about 110°C. Furthermore, in order to maintain the alcohol which was developed, within the reac- tion environment, it is possible to operate in an autoclave at the autogenous pressure of the system at the pre- selected temperature (normally in the order of 0.11-0. 15 MPa absolute), or at atmospheric pressure in a reactor equipped with a reflux condenser.

According to a particular embodiment of the process, the hydrolysis and gelation are carried out in the presence of a quantity of alcohol higher than that which develops as by-product. For this purpose, a free alcohol, preferably ethanol, is added to the reaction mixture in a quantity up to a maximum molar'ratio between alcohol added and Si02 of

8/1.

The time necessary for completing the hydrolysis and gelation, under the conditions indicated above, usually varies from 10 minutes to 3 hours and is preferably in the order of 1-2 hours.

It has also been found useful to subject the gel thus formed to aging, by maintaining the reaction mixture in the presence of the alcohol and at room temperature, for a pe- riod in the order of 1-24 hours.

The alcohol is finally removed from the gel which is dried, operating according to the known art, so as to avoid fracturing of the solid and substantially maintaining the pore structure unaltered. Reduced pressure is normally ap- plied, generally from 1 to 20 kPa and preferably from 3 to 6 kPa, together with a temperature ranging from 50 to 120°C, preferably from 100 to 110°C. According to a pre- ferred method, the drying is effected operating with a gra- dient (or profile) of (increasing) temperatures and (de- creasing) pressures within the above ranges to allow the gradual evaporation of the solvent. The dried gel is fi- nally subjected to calcination in an oxidizing atmosphere (normally in air), at a temperature ranging from 500 to 700°C for a period of 4-20 hours and preferably from 500- 600°C for 6-10 hours, also in this case preferably operat- ing with a suitable temperature gradient.

The amorphous support based on silicon, aluminum and phosphorus, thus obtained, has a composition corresponding to that of the reagents used, considering that the reaction yields are practically complete. Therefore, the Si/Al atomic ratio varies from 15/1 to 250/1 in the preferred case, the most preferred values ranging from 20/1 to 150/1 and specifically in the order of 100/1. This support re- sults substantially amorphous, when subjected to analysis by means of powder X-ray diffraction, it has a surface area of at least 200 m2/g and normally within the range of 300- 900 m2/g and a pore volume of between 0.5-2. 0 cm3/g, pref- erably of between 0.6 and 1.8 cm3/g.

According to what is known in the art with respect to heterogeneous catalysis, the above-mentioned amorphous sup- port (A) of the present invention catalyst, can be advanta- geously mixed and processed with other inert compounds such as, for example, pseudo-bohemite which, for calcination, becomes y-alumina, suitable for providing enhanced mechani- cal and morphological properties, desirable for industrial use, especially for improving the consistency and stability of the granules in the catalytic beds, thus increasing the durability, and for reducing the amounts of catalyst resi- dues in the product obtained. The incorporation of said in- ert component, commonly called"binder", into the catalyst support, can be effected both by addition to the amorphous

support (A) at the gel form, or after drying or calcina- tion, and by addition to the preformed catalyst, including the metal (B). The addition to the support is, in any case, preferred for the purposes of the present invention.

Therefore, in accordance with a particular aspect of the present invention, said support (A) can, when neces- sary, form a composition mixed with a suitable quantity of a binder consisting of an inert inorganic solid, generally added for the purpose of improving the mechanical proper- ties, such as for example, silica, alumina, clay, titanium oxide (Ti02) or zirconium oxide (ZrO2), boron oxide (B203) or mixtures thereof. It is generally preferably, in fact, for its industrial applications, for said solid to be used in granular rather than powder form, and for it to have a relatively narrow particle-size distribution. Furthermore, it is preferably endowed with sufficient mechanical resis- tance to compression and impact to avoid its progressive breakage during use, due to the fluid-dynamic and vibration stress effected by the process fluids.

Possible binders can be all those which are known to be suitable for the purpose, both natural and synthetic, preferably silica and alumina, and particularly alumina in all its known forms, for example gamma-alumina.

Said reinforced amorphous solid according to the pres- ent invention can be obtained by means of any of the mix-

ing, extrusion and granulation (palletizing) methods of solid materials in a mixture, for example, according to the methods described in European patent applications EP-A 550,922 and EP-A 665,055, the latter preferred, both filed by the Applicant, whose contents are incorporated herein as reference.

In particular, according to a preferred method, the gel obtained from the hydrolysis and gelation of the aque- ous mixture of Al alkoxide, tetra-alkyl silicate and oxy- genated phosphorus compound, prepared as described above, is mixed, before the calcination step, with the desired quantity of inorganic binder, based on the dry weight, nor- mally with a weight ratio between binder and gel (humid) within the range of 0.05 to 0.5. A plasticizer, selected from those generally known to be suitable for the purpose, is also preferably added, for example methyl cellulose, stearin, glycerol, more preferably methyl cellulose, to favour the formation of a homogeneous mixture which can be easily processed. This plasticizer is generally added in a quantity ranging from 5 to 20 g per 100 g of binder.

A suitable acidifying compound, selected from organic acids, such as acetic acid or acetic anhydride, oxalic acid, or inorganic acids, such as hydrochloric acid or phosphoric acid, is then added in a quantity preferably ranging from 0.5 to 8 g per 100 g of binder. Acetic acid is

particularly preferred.

The mixture thus obtained is homogenized by mixing and heating to a temperature ranging from 40 to 90°C, with par- tial evaporation of the solvent, until a paste is obtained, which is then extruded using suitable equipment. The ex- truded product is cut into cylindrical granules, preferably with a size of 2-10 mm in length and 0.5-4. 0 mm in diame- ter. According to an alternative embodiment, the above ho- mogeneous paste can also be dried in a suitable granulator, in order to obtain granules having the desired dimensions.

The granules thus obtained are subjected to progres- sive heating to eliminate-the residual quantities of sol- vent and finally calcined in an oxidizing atmosphere, gen- erally in a stream of air, at a temperature ranging from 400 to 600°C, for 4-20, preferably 6-12 hours.

A granular acid solid is thus obtained, having the de- sired catalytic and mechanical properties, containing a quantity of 1 to 70% by weight, preferably from 20 to 50% by weight, of said inert inorganic binder, the remaining percentage consisting of amorphous support (A), as previ- ously defined. The granular solid is preferably in the form of pellets having a size of about 2-5 mm in diameter and 2- 10 mm in length.

Both the porosity and surface area of the extruded product normally have average values with respect to the

values of the single components in the mixture, according to linear composition rules.

The catalytically active amorphous support of the pre- sent invention, both as such and mixed with other inert ma- terials, has acidic characteristics. It is distinguished by the advantageous combination of a pore diameter and surface area which are both relatively high. According to the stud- ies carried out by the Owner, this combination favours a particularly desirable catalysis selectivity and orienta- tion, especially in hydro-treatment processes of hydrocar- bons, and paraffins in particular, for example in the transformation processes of hydrocarbon fractions, such as hydrocracking, hydro-isomerization and dewaxing, with im- proved activity and selectivity with respect to the tradi- tional amorphous silica-alumina gel, particularly when a range of products, from kerosene to the lubricating bases, is to be obtained, by reducing as much as possible the use of dewaxing steps, separated or subsequent to the hy- drocracking step.

According to the present invention, the metal of com- ponent (B) of the catalyst is selected from those having a hydro-dehydrogenating activity, in the presence of hydro- gen/hydrocarbons mixtures, under the suitable process con- ditions. Metals especially suitable for the purpose are those of groups 6 to 10 of the periodic table. Combinations

of nickel with molybdenum, tungsten and cobalt as well as the noble metals platinum or palladium, or mixtures thereof, and preferably platinum and palladium, more pref- erably platinum, are of particular interest.

Combinations of metals of Group 6, especially tungsten or molybdenum, with the metal of group 9, especially nickel or cobalt, are particularly suitable, as is known for other catalysts of the art suitable for processing hydrocarbons, when the mixtures contain non-negligible amounts of sulphur and/or nitrogen.

According to the present invention, said catalyst can be prepared through a method which includes contact, under suitable conditions, of said active support (A) with a suitable compound of said metal (B). The metal is conven- iently distributed as uniformly as possible on the porous surface of the support, in order to maximize the catalytic surface which is effectively active. For this purpose, various known methods can be used, such as those described for example in European patent application EP-A 582,347, whose contents are incorporated herein as reference. In particular, according to the impregnation method, the amor- phous support (A), as such or preferably extruded, is put in contact with an aqueous or alcoholic solution of a solu- ble compound of the desired metal for a period sufficient to provide a homogeneous distribution of the metal in the

solid. This normally requires from a few minutes to several hours, preferably under stirring. Soluble salts suitable for the purpose are, for example, H2PtF6, H2PtCl6, [Pt (NH3) 4] C12, [Pt (NH3) 4] (OH) 2 and analogous salts of palla- dium; mixtures of salts also of different metals are equally included in the scope of the invention. The minimum quantity of aqueous liquid (normally water or an aqueous mixture with a second inert liquid or with an acid in a quantity lower than 50% by weight) is conveniently used, which is sufficient to dissolve the salt and uniformly im- pregnate said support, preferably with a weight ratio solu- tion/solid ranging from 1 to 3. The quantity of metal-is selected on the basis of its concentration which is to be obtained in the catalyst, as the whole metal is fixed on the support.

At the end of the impregnation, the solution is evapo- rated and the solid obtained is dried and calcined in an inert or reducing atmosphere, under analogous temperature and time conditions as those cited above for the calcina- tion of the amorphous solid or extruded product.

An alternative method to impregnation is the ion ex- change system. According to the latter, the amorphous sil- ica/alumina/phosphate solid is put in contact with an aque- ous solution of a salt of the metal as in the previous case, but the deposition takes place by exchange under con-

ditions made basic (pH between 8.5 and 11) by the addition of a sufficient quantity of an alkaline compound, normally an ammonium hydroxide. The suspended solid is then sepa- rated from the liquid by means of filtration or decanting and dried and calcined as specified above.

According to another alternative, the salt of the metal (B) can be included in the catalytically active sup- port in the gel preparation step, for example before hy- drolysis for the formation of humid gel, or before its cal- cination.

At the end, a catalyst is obtained for the hydrotreat- ing of hydrocarbons, in accordance with the present inven- tion, wherein metal M is uniformly dispersed in amounts ranging from 0.05 to 5% by weight, preferably from 0.1 to 2%, more preferably from 0.2 to 1% by weight, with respect to the total weight of the catalyst, especially when the metal is selected from Pt and Pd.

A typical method for the preparation of a catalyst in extruded form, comprising the active solid of the present invention as support, includes the following steps: (a) solution A is prepared of the hydrolysable components and ammonium phosphate as described above, in suitable quantities for obtaining the desired final composi- tion; (b) the above solution is heated to 60-70°C to cause its

hydrolysis and gelation and to obtain a gel mixture with a viscosity ranging from 0.01 to 100 Pa * sec; (c) a binder, belonging to the group of bohemites or pseu- dobohemites, is first added to the gel mixture, in a weight ratio with the same ranging from 0.05 to 0.5, followed by methyl cellulose as plasticizer in a quan- tity ranging from 10 to 20 g per 100 g of said binder; and finally a mineral or organic acid in a quantity ranging from 0.5 to 8.0 g per 100 g of said binder; (d) the mixture obtained under point (c) is heated under mixing to a temperature ranging from 40° to 90°C until a homogeneous. paste is-obtained, which is subjected to extrusion and granulation; (e) the extruded product obtained under (d) is dried and calcined in an oxidizing atmosphere.

In this way, a granular solid support is obtained, with an acidic catalytic activity, containing a quantity ranging from 30 to 70% by weight of inert inorganic binder, the remainder consisting of the active porous solid of silicon/aluminum/phosphorus oxide, having essentially the same characteristics of porosity, surface extension and structure as described above for the same porous solid without the binder. The granules are conveniently in the form of pellets having a size of about 2-5 mm in diameter and 2-10 mm in length.

The supporting step of the noble metal on the active granular solid is effected with the same procedure speci- fied above.

Before use, the catalyst thus obtained is normally subjected to activation in a reducing atmosphere, according to one of the known methods suitable for the purpose, which can also be carried out directly in the reactor pre- selected for the hydrocracking reaction. A typical method uses the procedure described hereunder: 1) 2 hours at room temperature in a nitrogen stream; 2) 2 hours at 50°C in a stream of hydrogen; 3) heating to 310-360°C with an increase of 3°C/miri-in a stream of hydrogen; 4) constant temperature of 310-360°C for 3 hours in a stream of hydrogen and cooling to 200°C.

During the activation, the pressure in the reactor is maintained between 3.0 and 8,1 MPa (30 to 80 atm).

The catalyst according to the present invention is advantageously used in processes for the hydrotreating of hydrocarbon, especially prevalently paraffinic fractions, particularly when they are linear.

Known hydrotreating processes are the processes for hydrorefining and hydroconverting hydrocarbon feeds such us petroleum cuts, cuts originating from coal, bituminous ex- tracts, cuts from other refinery processes, more particu-

larly for hydrogenation, hydroisomerisation, hydrodewaxing, dehydrogenation, hydrocracking, hydrodesulphuration and hy- drodemetallization of carbon-containing feeds, especially containing naphthenic compounds and/or paraffininc com- pounds, the feeds possibly containing metals and/or nitro- gen and/or oxygen and/or sulphur.

Hydrotreating processes of hydrocarbon feeds can be carried out in a continuous or batch reactor containing the catalyst of the invention in a fixed bed or as a slurry.

Such hydrotreatments can be applied, for example, to petro- leum fractions such as crude oils, atmospheric residues, vacuum residues, deasphalted oils, deasphalted vacuum resi- dues, heavy fuels, atmospheric distillates and vacuum dis- tillates.

In particular, using the present catalyst in a hydro- carbon hydrocracking process, it was possible to obtain, with an excellent yield, the conversion of heavy paraffin fractions (waxes with a boiling point of over 360+°C) into middle distillates having good properties at low tempera- tures, and contemporaneously produce a residue with a high content, preferably higher than 70% by weight, of lubricat- ing base having a high viscosity index and a suitable vis- cosity especially for use in motor vehicle engines. A fur- ther object of the present invention therefore relates to a process for the preparation of middle distillates and lu-

bricating bases starting from a mixture of mainly paraf- finic hydrocarbons, consisting for at least 30%, preferably at least 50%, of a high-boiling fraction with a distilla- tion temperature higher than 360°C, comprising: (i) at least one hydrocracking step, wherein said hydro- carbon mixture is reacted with hydrogen at a temperature of between 200 and 450°C and a pressure between 0.5 and 15 MPa, in the presence of a catalyst, for a time sufficient to convert at least 40%, preferably from 60 to 95%, of said high-boiling mixture, into a fraction of hydrocarbons which can be distilled at temperatures lower than 360°C ; (ii) at least one distillation step of the product of step (i) for separating at least a fraction of middle distillate and at least one residue with a boiling point higher than 340°C, used, at least partially, for the preparation of a lubricating base; characterized in that said hydrocracking step under (i) is carried out in the presence of a catalyst supported accord- ing to the present invention.

The hydrocarbon mixture fed to the above process, preferably consists of substantially linear paraffins, and can include a middle distillate fraction in addition to the fraction of high-boiling hydrocarbons (liquid and/or solid at room temperature). According to the process of the pres- ent invention, the amount of low-boiling fraction (<150°C,

naphtha and volatile matters) produced, even in the pres- ence of an amount of middle distillate higher than 50% in the feeding, is normally extremely limited, preferably lower than 15%, also with conversions per passage of be- tween 80 and 90%.

The hydrocarbon mixture suitable for feeding the proc- ess according to the present invention, can generally in- clude up to 20%, preferably up to 10% by weight, of an or- ganic non-paraffinic fraction. In particular, it has a re- duced sulphur content, preferably lower than 5,000 ppm by weight of S, preferably lower than 1, 000 ppm or even non- traceable.

For an optimum performance of the process according to the present invention, said feed mixture of the hydrocrack- ing step preferably consists, for at least 50%, preferably at least 80%, of linear paraffins having from 5 to 80, preferably from 15 to 70, even more preferably from 20 to 65 carbon atoms, and an initial boiling point ranging be- tween 45 and 675°C (by extrapolation), preferably between 170 and 630°C (by extrapolation).

According to a particular aspect of the present inven- tion, said feeding to step (i) includes at least 30% by weight, preferably from 40 to 80% by weight of a high- boiling fraction distillable at a temperature > 360°C, and up to 80%, preferably from 20 to 60% by weight of a hydro-

carbon fraction corresponding to the so-called"middle dis- tillate", divided into the traditional kerosene and gas oil cuts, previously defined.

According to a different aspect of the present inven- tion, the feed mixture has a boiling point of at least 260°C, more preferably of at least 350°C. It has been found that, under these conditions, especially if the feed con- sists of substantially linear hydrocarbons, it is possible to produce both middle distillates and lubricating bases having optimum characteristics, and in the desired relative amounts, within the limits imposed by the initial feeding composition.

Processes in which the feed is different from the pre- ferred feeds mentioned above, are not excluded from the present invention. The prevalently linear hydrocarbon mix- tures having distillation ranges equal to or higher than 260°C, are solid or semisolid at room temperature, for this reason they are normally called waxes.

Typical examples of suitable feeds are the prevalently paraffinic fractions obtained from oil processing, like certain distillation ends and the residues of de-paraffinic processes, so-called"slack waxes". Other examples consist of certain synthetic mixtures, such as, for example, those of linear oligomers obtained by ethylene oligomerization, or fractions deriving from the thermo-degradation of

polyolefins, mainly polyethylene.

The hydrocracking step of the process according to the present invention, can be generally carried out at the tem- peratures and pressures of traditional processes of this type, known in the art. Temperatures are normally selected from within a range of 250 to 450°C, preferably from 300 to 370°C, whereas the pressure is selected from 0.5 to 15 MPa, preferably between 1 and 10 MPa, also including the hydro- gen pressure. Hydrogen is used in a sufficient amount for effecting the desired conversion under the selected condi- tions. The mass ratio between hydrogen and hydrocarbons in the feeding (and consequent relative pressure of the same) can be easily selected by technical experts, depending on the other essential parameters of the process, such as the space velocity, the contact time, the catalyst activity and temperature, so to achieve the desired conversion degree.

Initial (hydrogen)/ (hydrocarbons) mass ratios of between 0.03 and 0.2 are normally considered to be satisfactory for carrying out the process, these values not being, however, limitative of the present invention. Under these condi- tions, only a small part of the hydrogen initially intro- duced is consumed, the remaining part can be easily sepa- rated and recycled using the common equipment suitable for this purpose. The use of essentially pure hydrogen, which is commercially available at low cost, is normally pre-

ferred, whereas in the most general case, the use of mix- tures of hydrogen with inert gases such as, for example, nitrogen, is not excluded.

The space velocity WHSV (defined as maximum flow rate as g/h, divided by the weight of the catalysts in grams), or the contact time (defined as the reciprocal of the space velocity : 1/WHSV), of the reagents under the conditions of the hydrocracking reaction, are generally selected as a function of the characteristics of the reactor and of the process parameters, so as to obtain the desired conversion degree. It is important for the contact time to be selected so that the a conversion degree-calculated as a mass of the 360+°C fraction in the feedstock, minus the mass of the 360+°C fraction in the products, divided for the mass of the 360+°C fraction in the feedstock [a = (360+inlet- 360+outlet)/(360+inlet)]-is maintained within the values over which significant undesired reactions take place, which jeopardize the production of the desired selectivity levels to middle distillate and lubricating base, for exam- ple by producing an excess of volatile products. Contact times are normally selected which allow a conversions of the high-boiling fraction (360+°C) of between 60 and 90%, more preferably between 65 and 80%.

According to a typical embodiment of the process of the present invention, a mix of hydrocarbons having the

above characteristics is preheated to a temperature of be- tween 90 and 150°C and fed in continuous, after pre-mixing with hydrogen, to a tubular fixed bed reactor operating in "down flow". The reactor is kept at a temperature of be- tween 300 and 360°C. The reactor pressure is maintained at between 3 and 10 MPa. The catalyst is previously activated, for example according to the typical method mentioned above, and the hydrocracking process can be subsequently effected, normally after a catalyst stabilization phase (about 60-100 hours).

The feeding preferably consists of a high-boiling mix comprising from 30 to 100% of waxes with a distillation point above 360°C. In the case of a feeding comprising sul- phonated, oxygenated or nitrogenated products, which can produce a progressive poisoning of the catalyst, technical experts can subject said feeding to a preliminary de- sulphuration and/or hydrogenation treatment, before the hy- drocracking step of the process according to the present invention, in order to avoid the above-mentioned drawbacks.

This treatment can consist, for example, of a selective hy- drogenation step, in the presence of one of the known cata- lysts suitable for the purpose and under conditions which reduce conversion to products with lower boiling points, to the minimum.

According to said typical embodiment, the supported

catalyst of the present invention is introduced into the reactor in granular form, preferably as a co-extruded prod- uct with a binder, for example y-alumina, according to what is previously described. The metal with a hydro- dehydrogenating activity is preferably palladium or plati- num, particularly platinum. A fixed bed is conveniently used, on which the reagent mix is passed. The contact time is selected so as to have a conversion of between 60 and 80%. The space velocity preferably ranges from 0.4 to 8 h-1, more preferably from 0.5 to 4 h-1 The reaction mix at the outlet of the reactor is ana- lyzed on line, by means of one of the known techniques, for example gas chromatography, and sent to said distilla- tion/separation step (ii), in the upper part of which the middle distillate product is obtained, whereas the high- boiling residue, suitable for the production of lubricating bases, is obtained at the tail.

The light hydrocarbon fraction (gas and naphtha) hav- ing distillation temperatures lower than 150°C, which is normally formed in amounts lower than 10% by weight of the product obtained in step (ii), is removed by distillation from the head of the column and normally destined for dif- ferent uses.

In accordance with the present invention, the high- boiling residue advantageously consists of an isomerized

hydrocarbon mix having a high content, preferably over 80%, more preferably over 90%, or even more preferably essen- tially consisting of a lubricating base with a high viscos- ity index, a low pour point, and a heat viscosity within a particularly desirable range. In particular, the lubricat- ing base which can be obtained with the present process has the following preferred characteristics: - pour point: <-18°C - viscosity at 100°C : > 4.0 cSt - Viscosity index (VI): > 135 - Noack : < 15%.

When necessary, on the basis of market requests, an aliquot of said residue, preferably not more than 90%, more preferably not exceeding 50% by weight, can be advanta- geously recycled to the hydrocracking step to produce fur- ther middle distillate. In this case, it is also possible to improve the isomerization degree by suitably regulating the recycling, as in the normal technique of hydrocracking processes.

The operative conditions and equipment for running the process of the present invention can be easily set up and optimized by the average technical expert, on the basis of the present description and parameters herein defined. A particularly advantageous aspect of this process consists of the fact that, in most cases, it can be essentially ef-

fected with a single reactive step (hydrocracking), nor- mally combined with a single separation and recycling step, downstream of the reactor, and a possible previous treat- ment in order to remove the compounds having heteroatoms, thus obtaining high commercial value products, without nec- essarily resorting to other distillation and transformation combinations, with the exception of a possible mild dewax- ing step on the high-boiling residue (for example 360+°C) and/or separation of the 550°C fraction from the above residue by means of vacuum distillation to isolate the de- sired lubricating base.

Several obvious variations of this process can be ef- fected by technical experts in the filed, without involving any further inventive activity.

The solid catalyst described above can be used in the process according to the present invention, as such, after activation, in the hydrocracking step of the process ac- cording to the present invention. As mentioned above, how- ever, said catalyst is preferably reinforced by the addi- tion and mixing of a suitable amount of a binder consisting of an inert inorganic solid, capable of improving the me- chanical properties.

According to a particular embodiment of the present invention, suitable for the treatment of hydrocarbon mix- tures containing heteroatoms, in particular S, N or O, said

process for the preparation of middle distillates and lu- bricating bases comprises, before the hydrocracking step, a hydrogenating treatment, such as, for example, hydro- desulphuration, hydrogenation of the aromatic or hetero- aromatic compounds or a hydrogenation of oxygenated or ni- trogenated groups, under such conditions as to not produce any substantial variation in its average molecular weight, to obtain a substantially saturated hydrocarbon mix, with- out heteroatoms.

Mixtures of the above type can be commonly obtained from refinery processes such as, for example, paraffin mix- tures obtained from the distillation of crude oils, con- taining sulphurated and/or nitrogenated compounds. In par- ticular, such a process variation is advantageously used for a substantially linear hydrocarbon mix, comprising up to 20%, preferably up to 10%, by weight of a non-paraffinic organic fraction.

The procedure for effecting said hydrogenating treat- ment is well known in the art, and does not represent a particular critical point for the process of the present invention, provided the degradation of the molecular weight of the fraction treated is practically negligible, in any case never over 15% of conversion to products included in the typical cut called naphtha, having a distillation tem- perature below 150°C. The hydrogenating step, in this case,

must be such that not more than 15%, preferably not more than 10% of the constituents of the feed mixture having a distillation temperature of over 150°C, is converted to products having a lower distillation temperature.

Typical but non-limiting reaction conditions of the hydrogenating step are: temperature within the range of 280-380°C, hydrogen pressure between 0.5 and 10 MPa, space velocity (WHSV) ranging from 0.5 to 4 h-l. The hydro- gen/feed ratio is between 200 and 2000 Nl/kg.

Said hydrogenation reaction is normally effected in the presence of a suitable catalyst. The latter, according to the known art, preferably includes a metal of groups-6, 8,9 or 10 of the periodic table of elements, dispersed on a support preferably consisting of an organic oxide, such as alumina, titania, silico-alumina, etc.. Preferred hydro- genation catalysts are those based on nickel, platinum or palladium, supported on alumina, silico-alumina, fluori- nated alumina, with a metal concentration which, according to the type, is between 0.1 and 70%, preferably from 0.5 to 10% by weight; preferred hydro-desulphuration catalysts are preferably based on the combination of metals of groups 9 or 10 and group 6, such as Ni-Mo or Co-W.

During the hydrogenation step, the reaction can also be carried out under such conditions and with such a cata- lyst as to obtain, when desired, a certain degree of iso-

merization of the hydrocarbon mix, according to the known art.

The hydrocarbon mix thus obtained is preferably sub- jected to a separation step, through distillation, of gas or volatile products (< 150°C) possibly present, and, even more preferably, water and/or other inorganic products de- riving from the hydrogenation.

According to a further embodiment of the process ac- cording to the present invention, step (i) can be preceded by a preliminary separation step of a low-boiling fraction from the feed mixture. Said preliminary step can typically include a flash separation of a mix having~ a final boiling point of between 150 and 370°C, preferably between 260 and 360°C. The low-boiling mix thus separated can be subse- quently processed according to one of the known techniques for obtaining middle distillates and/or fractions suitable for the production of gasoline. For example, it can be sub- jected to a hydrogenation step of the type previously de- scribed, followed by an isomerization step in suitable equipment in the presence of a catalyst and under such con- ditions as to favour an isomerization reaction with respect to a cracking reaction, such as those described, for exam- ple, in European patent EP 908.231. The desired fractions of middle distillates are separated from the product thus isomerized, by means of a normal fractionated distillation

column.

The high-boiling fraction obtained in this prelimi- nary step, forms the feeding of step (i) and is treated ac- cording to the process of the present invention for the production of high quality middle distillates and lubricat- ing bases. According to a preferred aspect, moreover, the subsequent step (ii) consists of a flash distillation for the separation of a low-boiling fraction comprising the volatile products (150-°C) and middle distillate, from the high-boiling isomerised residue suitable for the formation of the lubricating base. Said low-boiling fraction is then joined to the product of the above isomerization step and sent downstream to the fractionated distillation column, or sent, at least partially, to said isomerization step, in order to further increase the quality of the middle distil- late thus obtained, particularly of the kerosene fraction.

A typical embodiment of the process according to the present invention is described hereunder with reference to Figure 1, without limiting in any way the overall scope of the invention as claimed herein.

In particular, Figure 1 schematically illustrates a plant for the embodiment of the process according to the present invention, comprising a hydrocracking step and a distillation step of the product mix obtained.

According to the plant scheme of Figure 1, a stream 1

of substantially linear and preferably sulphur-free hydro- carbons is fed to the hydrocracking unit (HCK) of step (i) of the present process together with the necessary amount of hydrogen, through line 2.

An aliquot of residue 8 is also possibly fed to the same unit, through line 9, coming from the subsequent sepa- ration of the middle distillate, preferably having a boil- ing point over 350°C, in a mass ratio preferably ranging from 0 to 90%, more preferably between 10 and 30% with re- spect to the total residue volume.

The reaction product of the hydrocracking step, con- sisting of a hydrocarbon mix having an isomerization degree (non-linear hydrocarbon mass/mixture mass) preferably over 50%, more preferably over 70%, is fed, through line 3, to a separation step by distillation (DIST), preferably in a suitable column running at atmospheric pressure or slightly higher, from which the middle distillates, suitable as fu- els according to the present invention, are collected by means of line 6 (kerosene) and 7 (gas oil). From the unit DIST in Figure 1, the following products are also obtained: through line 4 a gaseous fraction C1-C5, of little signifi- cance, and, through line 5, a hydrocarbon light fraction, preferably having a boiling point lower than 150°C (naph- tha), in an overall amount advantageously lower than 20% by weight, preferably lower than 15, with respect to the hy-

drocarbon mix fed through line 1.

According to a particularly distinct aspect of the present invention, the use of the above catalyst supported on a silico-alumino-phosphate amorphous solid in the hy- drocracking step (i), allows a high quality middle distil- late fraction to be obtained, with a high yield (low pro- duction of 150-°C volatile products), also having, in par- ticular, excellent low temperature properties and a high cetane number, together with a high-boiling residue having a surprisingly low content of linear paraffins, which is particularly suitable for obtaining lubricating bases, ei- ther as such or after dewaxing treatment with advanta- geously reduced contact times and conversions.

In particular, it has been found that it is possible to obtain, by means of the present process, middle distil- lates having the following characteristics: Kerosene (150-250°C) Smoke point > 50 mm Flash point > 40°C Freezing point <-47°C Aromatic compounds < 0. 1 % Sulphur < 0.1 ppm Gas oil (250-360°C) B. C. N. > 70 Flash point > 160°C Pour point <-12 °C Aromatic compounds < 0.1 % Sulphur < 0. 1 ppm

The residual fraction can be used as such for particu- lar uses, or is preferably sent to a dewaxing step (not shown in Figure 1) for producing lubricating bases. Accord- ing to a preferred aspect, it is partially recycled to the hydrocracking step (HCK) through line 9, for regulating the productivity of the process or varying the isomerization degree according to the production demands.

The isomerization degree of the residual fraction sent to line 20 is preferably higher than 85%.

As the amount of linear paraffins is-reduced, the-de- waxing step, when necessary, can be advantageously ef- fected, according to the process of the present invention, under particularly favourable contact time and lubricating base yield conditions.

Said dewaxing step (DWX) can be effected according to the known techniques, both with a solvent and, preferably, in the presence of a catalyst suitable for the purpose. In this latter case, the partially isomerised mix is again re- acted, in the presence of hydrogen and a suitable solid catalyst, preferably comprising a metal with a hydro-de- hydrogenating activity, usually a noble metal, supported on a zeolite or other crystalline porous solid.

In this case, contrary to what takes place in solvent

dewaxing, where the paraffin crystals are physically sepa- rated, the paraffins are selectively transformed into iso- paraffin compounds or lighter cracking products, according to the catalyst used. The cracking products are mainly low molecular weight paraffins and olefins, partially (up to 50% by weight) consisting of C5-compounds, the remaining part being a material having a molecular weight within the gasoline range.

The catalytic materials mostly used are medium pore zeolites (such as mordenite, ZMS-5, SAPO-11) and, in some cases, large pore materials (such as beta zeolites and HY), but also other materials have been proposed. According to a particular embodiment, the catalyst according to the pres- ent invention can be selected for this purpose.

The catalytic dewaxing can be effected, according to use, at pressures which can vary from 2 to 20 MPa, offering higher operative pressures, advantages in terms of catalyst life cycle, higher yields and viscosity indexes of the de- waxed products. The preferred temperature conditions WABT and space velocity LHSV are those typical of hydrotreating, the WABT ranging from 315 to 400°C and LSHV from 0.3 to 1.5 h-1.

Downstream of the catalytic dewaxing, a treatment is normally envisaged on a typical"finishing"catalyst for improving the colour and removing any traces of reactive

molecules such as olefins, in order to confer a better sta- bility to the product.

At the end of said dewaxing step, after removing the last residues (< 3% by weight) of volatile products formed as a result of the partial hydrocracking, a liquid, isomer- ized product is obtained having excellent properties at low temperatures and a high viscosity, having an initial boil- ing point of over 350°C, preferably > 360°C and with a dis- tillation temperature (extrapolated) of 90% of the mix (T90) lower than 700°C (by extrapolation).

Some examples of practical embodiments are provided for a more detailed description of the present invention, which however are purely illustrative of some of the par- ticular aspects of the invention and should in no way be considered as limiting its overall protection scope.

Examples The following analysis and characterization methods were used for running the practical embodiments of the present invention: - X-ray diffractometry from powders (XRD): the analysis was carried out using a vertical Philips X'PERT dif- fractometer equipped with a proportional pulsation me- ter and a secondary curved graphite crystal mono- chromator; two. different measurements were effected for each sample: the first in the angular region 1.5 < 20

<10° with a step of 0. 05° 26 and accumulation times of 20s/step and fixed divergent slips of 1/6° ; the second within the spectral range of 3 < 20 < 53° with a step of 0. 05° 26 and accumulation times of 10s/step and fixed divergent slips of 1° ; in both cases the radia- tion was Cul = 1.54178 A).

The information on the characteristics of the catalysts under examination are deduced from the evaluation of the adsorption/desorption isotherms of N2 at the tem- perature of the liquid N2, obtained by using a ASAP 2010 instrument (Micrometrics) and a Sorptomatic 1990 (ex Carlo Erba).

The samples (-0. 3 g) have been degassed for 16 hours at 350°C at reduced pressure, before the acquisition of the isotherms.

The total specific pore volume (Vp) was calculated us- ing the Gurvitsch method at p/p° = 0. 995. When the ad- sorption isotherms end with a plateau, it is possible to exclude phenomena due to macropores or inter- particles porosity, therefore a precise determination of this parameter is possible. When the isotherms do not end with a plateau, Vp is only indicative.

Measurement of the pore dimensions: the average pore diameter was determined by means of the DFT (density functional theory) method, of which details are pro-

vided in the publication of P. A. Webb and C. Orr, in "Analytical Methods in Fine Particle Technology", Mi- crometrics Instruments Corp. (1997), page 81.

Measurement of the specific surface area: the specific surface area was evaluated by means of the BET linear graph with two parameters within the range of p/p° 0.01-0. 2 applying the DFT (density functional theory) method.

Pour point: according to the regulation ASTM D97 Viscosity at 100 cSt: according to the regulation ASTM D445 Viscosity index: according to the regulation ASTM D2270 Reagents and materials The commercial reagents listed below were used during the preparations described in the examples: tetrapropyl ammonium hydroxide (TPA-OH) SACHEM aluminum triisopropoxide FLUKA tetraethyl silicate DYNAMIT NOBEL alumina (VERSAL 250, Pseudo-Boehmite) LAROCHE methyl cellulose (METHOCEL) FLUKA phosphoric acid CARLO ERBA The reagents and/or solvents used and not indicated above are those most commonly used and can be easily found at the normal commercial suppliers specialized in the field.

Example 1 : catalyst with P/Al = 1 239.50 ml of demineralized water, 3.40 g of an ammonia solution at 30% by weight and 2.30 g of a solution of phos- phoric acid at 85% by weight (equivalent to 0.02 moles of tri-ammonium phosphate (NH3) 3PO4), are charged into a three- necked flask, equipped with a rod stirrer and a bubble cooler. 50.80 g of an aqueous solution at 40% by weight of tetrapropyl ammonium hydroxide (TPA-OH, 0.01 moles) and 4.08 g of aluminum tri-isopropoxide (0.02 moles) are added to the mixture thus prepared. The mixture is maintained un- der stirring at room temperature for about 60 minutes, un- til a limpid solution is obtained. 208 g of tetra-ethyl or- thosilicate (TEOS; 1.00 moles) are rapidly added to this solution and the temperature is brought to 60°C, the whole mixture being maintained under stirring under these condi- tions for a further 3 hours. At the end the formation of a gel is observed, which is cooled to room temperature and left to rest for 20 hours. In this way a homogeneous gel is obtained, characterized by the following molar ratios be- tween the constituents: Si/Al = 51 ; TPA-OH/Si = 0. 098; H2O/Si = 15; Si/P = 50.

The gel thus obtained is first dried in air for about 3 hours and then calcined by heating, still in a stream of air, at 550°C for 5 hours. At the end, an amorphous solid is obtained according to the present invention, identified

by the following empirical formula: SiAI0 02Po. 0202. 0Ôr The complete absence of crystalline aggregates was con- firmed by means of X-ray diffraction. By means of NMR spec- troscopy applied to the 31p and 2'ail isotopes, it was found that at least 80% of the phosphorus is bonded by Al-O-P bonds to the amorphous silico-alumina matrix. The results of the morphological analysis are summarized in Table 1 be- low.

EXAMPLES 2 and 3 The procedure according to the previous example 1 was repeated modifying each time the quantity of tri-ammonium phosphate initially produced by'mixing'ammonia and-phospho- ric acid in aqueous solution, so that the P/Al ratio in the gel ranges from 0.5 to 2 for Examples 2 and 3, respec- tively.

The results of the morphological analysis and elemen- tal analysis are summarized in Table 1 below.

Example 4 The procedure of Example 1 was repeated exactly, with the only difference that the hydrolysis and gelation step is carried out in an ethanol/water mixture in which the mo- lar ratios ethanol/SiO2 = 8 and H20/Si02 = 8. At the end the product thus obtained is subjected to characterization ac- cording to the above techniques. The morphological data are indicated in Table 1 below.

Example 5 239.50 ml of demineralized water, 6.78 g of an ammonia solution at 30% by weight and 4.59 g of a solution of phos- phoric acid at 85% by weight (equivalent to 0.040 moles of tri-ammonium phosphate (NH3) 3PO4), are charged into a three- necked flask, equipped with a rod stirrer and a bubble cooler. 50.8 g of an aqueous solution at 40% by weight of tetrapropyl ammonium hydroxide (TPA-OH, 0.10 moles) and 8.13 g of aluminum tri-isopropoxide (0.04 moles) are added to the mixture thus prepared. The mixture is maintained un- der stirring at room temperature for about 60 minutes, un- til a limpid solution is obtained. 208 g of tetra-ethyl or- thosilicate (TEOS ; 1.00 moles) are rapidly added to this solution and the procedure is the same as in the previous example 1. At the end, an amorphous solid is obtained ac- cording to the present invention, identified by the follow- ing empirical formula: SiAIo. o2Po. 0202. o8. which is characterized according to the above-mentioned techniques. The morpho- logical data are shown in Table 1 below.

The structure of the solid catalysts obtained in accor- dance with the previous examples 2 to 5 was determined, as for the product obtained in accordance with example 1, by means of X rays diffraction and NMR spectroscopy, and proved to be completely amorphous solids wherein at least 80% of phosphorus is bonded by means of Al-O-P links to the

silico-alumina matrix.

Example 6 (comparative) The procedure of Example 1 was repeated exactly, with the only difference that the P/Al ratio in the gel was equal to 5, instead of 1.

The structure of the solid thus obtained, determined by means of X-ray diffraction and NMR spectroscopy, proved to be analogous to that of the product of Example 1, but the pore structure was greatly modified, with a partial collapse of the same, as shown by the significant reduction in their volume.

Example 7 (comparative) An amorphous silica-alumina solid support was prepared not containing phosphorus, repeating the same procedure as the previous Example 1, but without introducing the solu- tion of tri-ammonium phosphate. The results of the charac- terization are summarized in Table 1 below. A significant reduction in the average pore diameter is observed.

Table 1: Morphological properties of the catalysts

Example Si/Al P/A1 SBET VP dDFT (m2/g) (ml/g) (nm) 1 50 1.0 700 0.96 6.1 2 50 0.5 720 0.84 5.3 3 50 2.0 520 1.62 25.0 4 50 2.0 760 1.57 13.0 5 25 1.0 500 1.35 19.0 6 (comp. ) 50 5 80 0. 06- 7 (comp. ) 50 0 760 0.49 2.3 Example 8 : extruded catalyst 5 kg of a humid gel prepared by exactly repeating the procedure of the previous Example 1, but omitting the dry- ing and calcination step, 1.466 kg of alumina (pseudo- bohemite, VERSAL 150), previously dried for 3 hours in air at 150°C, and 0.205 kg of methyl cellulose are charged into a 10 litre plough mixer, maintained at a stirring rate of 70-80 revs per minute, and the mixture is left under stir- ring for about 1 hour. 50 ml of glacial acetic acid are then added and the temperature of the mixer is brought to about 60°C, continuing the stirring until a homogeneous paste is obtained, having the desired consistency for the subsequent extrusion. The mixture is charged into an ex- truder of the HUTT type, extruded and cut into cylindrical

pellets of the desired size (about 2 x 4 mm). The product is left to rest for about 6-8 hours and then dried by main- taining it in a stream of air at 100°C for 5 hours. It is finally calcined in a muffle at 550°C for 5 hours in a stream of air.

A porous extruded solid is thus obtained, with acidic characteristics (indicated hereunder with the term "extruded product"for the sake of simplicity), essentially consisting of an amorphous silica/alumina/phosphate phase (60% by weight, by means of X-ray diffraction) and an alu- mina crystalline phase (pseudo-bohemite), whose morphologi- cal characteristics are specified in Table 2 below.

Examples 9, to 12 and 13 (comparative) The same procedure was repeated as the previous Exam- ple 8, but substituting the amorphous solid prepared ac- cording to Example 1 with the solids prepared according to the respective examples as indicated in the second column of Table 2 below.

Porous extruded solids are thus obtained, whose mor- phological characteristics are specified in Table 2.

Table 2: Morphological properties of the extruded products

Example Amorphous phase P/A1 S BET VP dDFT (Example Nr.) (m/g) (ml/g) (nm) 8 1 1 540 0.91 7.6 9 3 2 460 1.26 18.0 10 4 2 510 1.25 16.0 11 2 0.5 n. d. n. d. n. d. 12 5 1 400 1.12 18.0 13 (comp) 7 0 590 0.88 < 6.0 EXAMPLE 14 : formation of a hydrocracking catalyst based on- platinum In order to demonstrate the advantageous properties of the amorphous solid of the present invention as a catalyti- cally active support in hydro-treatment processes of hydro- carbons, a hydrocracking catalyst was prepared, containing platinum as hydro-dehydrogenation metal.

In order to disperse the platinum on the support an aqueous solution of hexachloroplatinic acid (H2PtCl6), hy- drochloric acid and acetic acid was used in the following molar ratios: H2PtCl6/HCl/CH3COOH = 1/0. 84/0.05, having a platinum concentration of 7. 69*10-3 M. 60 ml of this solu- tion were added to 30 g of the extruded solid, obtained ac- cording to the previous Example 8, so that the whole solid

was covered by the solution, in order to avoid heterogene- ity in the platinum distribution. The suspension thus ob- tained was maintained under stirring for about an hour and then degassed by suction under vacuum (about 1 kPa) at room temperature. The solvent was subsequently removed by heat- ing to about 70°C in a stream of air. The dry product was finally calcined in a stream of air with the following tem- perature profile 25-350°C in 2 hours, to 350°C for 2 hours, 350-400°C in 50 min. , to 400°C for 3 hours.

At the end, a supported catalyst for hydrocracking is obtained, having the following characteristics: 59. 8% by weight of active amorphous solid (molar ratio Si/Al = 51, P/A1 = 1) 39.9% by weight of gamma-alumina 0. 3% by weight of platinum EXAMPLES 15,16 and 17 (comparative) A further three samples of hydrocracking catalyst were prepared, exactly repeating the procedure of the previous Example 14, but using the extruded products according to Examples 9,10 and 13 (comparative), in Examples 15,16 and 17 (comparative), respectively. The composition character- istics relating to amorphous phase, gamma-alumina and platinum content of the catalysts obtained are essentially the same as Example 14, whereas the morphological measure- ments are specified in Table 3 below.

Table 3: morphological characteristics of the catalysts with 0. 3% Pt

Example P/Al SBET VP dDFT (m2/g) (ml/g) (nm) 14 1 490 0.84 7.3 15 2 430 1.12 15.0 16 2 470 1.02 16.0 17 (comp) 0 510 0.82 n. d.

EXAMPLE 18 120 ml of the aqueous solution of hexachloroplatinic acid used in the previous examples (H2PtCl6/HCl/CH3COOH = 1/0.84/0. 05, [Pt] = 7. 69d10-3 M), were added to 30 g of the extruded solid obtained according to the previous Example 8, so that the whole solid is covered by the solution, in order to avoid heterogeneity in the platinum distribution.

The suspension thus obtained was treated with the same pro- cedure described in the previous Example 14, to obtain at the end, after calcination, a supported catalyst for hy- drocracking, having the following characteristics: 59.8% by weight of active amorphous solid (molar ratio Si/Al = 51, P/Al = 1) 39.9% by weight of gamma-alumina 0. 59% by weight of platinum

Examples 19,20 and 21 (comparative) Three further samples of catalyst for hydrocracking were prepared, containing 0. 6% by weight of platinum, by exactly repeating the process of the previous example 18, but using the extruded products in accordance with the ex- amples 11,12 and 13 (comparative), in the examples 19,20 and 21 (comparative), respectively. The composition charac- teristics relating to amorphous phase, gamma-alumina and platinum content of the catalysts obtained are essentially the same as Example 18, whereas the morphological charac- teristics do not significantly differ from those of the original active support.

EXAMPLES 22 to 26: catalytic activity tests in the hy- drocracking reaction of paraffinic waxes.

In order to verify the advantages of the catalytically active solid of the present invention when used as active support, various hydrocracking tests were carried out on a mixture of paraffins with a melting point higher than room temperature, using the catalysts of the previous Examples 14 to 18.

The hydrocracking tests were effected in a fixed bed tubular reactor having a useful charge volume of 15 ml, corresponding to a height of the catalytic bed in the iso- therm section of about 10 cm. The reactor is equipped with suitable connections for the continuous cocurrent feeding

of the reagents and the collection of the reaction mixture.

Hydrogen is fed at the desired pressure by means of a mass flow meter; the mixture of paraffins is maintained in the liquid state at a temperature of about 110°C and fed by means of a pump.

The temperature of the reactor is controlled by means of a thermostat system capable of operating at up to 400°C.

An adequate analytical instrumentation is connected on line for analysis in real time of the composition of the reac- tion product.

8 g of catalyst are charged into the reactor and acti- vated according to the method described above.

A mixture of paraffins is used as feeding, obtained by mixing pure linear paraffins or mixtures with a very narrow distribution, having the following composition: Fraction < 150°C absent Kerosene (from 150 to 260°C) 29.0 Gas oil (from 260 to 370°C) 25.7 Fraction > 370°C 45.3 Various hydrocracking tests were carried out on said paraffinic composition, at a total pressure of about 5 MPa and a weight ratio hydrogen/ (hydrocarbon mixture) of about 0.1. Table 4 below indicates the experimental conditions and catalysts used in Examples 22 to 26. The contact time (1/WHSV) was regulated according to the usual technique in order to have the desired conversion degrees at the end.

Table 4: Process conditions

Conditions Ex. 22 Ex. 23 Ex. 24 Ex. 25 Ex. 26 (*) Temperature (°C) 335 340 333 340 353 H2/waxes (w/w) 0.10 0.13 0.113 0.11 012 Pressure (MPa) 5.0 5.0 5.0 4.75 4.75 Catalyst (Ex. Nr) Ex. 14 Ex. 15 Ex. 16 Ex. 18 Ex. 17 (comp) P/AI 1 2 2 2 0 WHSV (h-') 1 1.5 3 1.5 2 (*) comparative A fractionation was effected on the outgoing mixture by means of gas-chromatographic analysis, and on this ba- sis, the conversion degree is measured of the hydrocarbon fraction having more than 22 carbon atoms C22+, correspond- ing, more or less, to the fraction with a boiling point > 370°C. Table 5 below indicates the composition data relating to the yields in the various distillation cuts ob- tained at the end of the process.

An aliquot of the hydrocracking products is distilled at 360°C and the content of lubricating base is determined on the residue, according to the method explained herebe- low. The 360+ residue is dissolved at 40°C in a 1/1 vol/vol mixture of methyl-ethylketone and toluene. The (sol-

vent)/ (360+ residue) ratio is 4/1 vol/vol; an aliquot of the solvent (about 1/8 of the total) is used in the washing step of the paraffin collected on the filter. The tempera- ture of the solution is lowered to-20°C at a rate of 1°C/min. At the end, the mixture is filtered at a tempera- ture of-20°C. The de-waxed product is separated from the solvent by distillation under vacuum and subsequent strip- ping in a stream of nitrogen at 80°C.

The quantity of product obtained, is measured to de- termine the content of lubricating base of said 360+ resi- due. The lubricating base is then characterized by measur- ing the viscosity at 100°C and the viscosity index. The re- sults are indicated in Table 5 below, which clearly demon- strates the surprising improvements obtained with the cata- lytically active support of the present invention, with re- spect to a silica-alumina support having an analogous com- position but not containing phosphorus. In particular, ac- cording to Examples 22 to 25 according to the present in- vention, it is possible to obtain, by means of a single hy- drocracking step, a high yield to middle distillates (col- umns 150-260 and 260-370) and a high-boiling residue con- taining over 80% by weight of lubricating base having a much higher viscosity than that obtained under the same process conditions with a catalyst of the known art (com- parative Example 26).

Table 5 : Composition and properties of the hydrocracking products. Ex. Temp. WHSV C22+ con-Yields to hydrocracking products (wo) Lubricating base (°C) version (distillation ranges of fractions in °C) Yield % on Viscosity Viscosity the 360+°C at 100°C <150 150-260 260-370 > 370 residue index (est) 22 335 1 78.7 7. 2 42. 5 40. 7 9.6 89 4.33 147 23 340 1.5 72.3 6. 6 40. 8 40. 1 12. 5 88 4.47 135 24 338 1.5 74.5 7.6 43.7 37.2 11.5 92 4.31 145 25 333 3 79.0 10.8 43.5 36.2 9. 5 84 4.27 142 26 (*) 352 2 83 9.3 40. 5 42.5 7.7 91 2.73 143 (*) Comparative