Process for simultaneously producing pelleted and fluid cracking catalysts from clays

Claim 1

A PROCESS FOR THE SIMULTANEOUS PREPARATION OF RELATIVELY COARSE ADSORPTIVE CONTACT MASSES AND OF RELATIVELY FINE SPHERICAL ADSORPTIVE CONTACT MASSES FROM KAOLIN CLAY COMPRISING MIXING KAOLIN CLAY WITH SULFURIC ACID IN AN AMOUNT TO PROVIDE FROM 60 PERCENT TO 130 PERCENT BY WEIGHT OF H2SO4 BASED THE VOLATILE FRE WEIGHT OF SAID KAOLIN CLAY, FORMING RELATIVELY COARSE MASSES FROM THE RESULTING CLAY-ACID MIXTURE, AGING THE COARSE CLAY-ACID MASSES IN WHITE MINERAL OIL MAINTAINED WITHIN THE TEMPERATURE RANGE FROM ABOUT 220* TO ABOUT 400*F. FOR ONE TO TWENTY-FOUR HOURS, SEPARATING SUBSTANTIALLY WHOLE CLAY-ACID MASSES FROM FINES WHICH ACCUMULATED, SUBSTANTIALLY ELIMINATING SULFATE FROM THE WHOLE MASSES BY CALCINING SAID WHOLE MASSES AT A TEMPERATURE OF FROM 900* F. TO 1600*F. FORMING AN AQUEOUS SLURRY OF THE FINES WHICH WERE SEPARATED FROM THE WHOLE MASSES, DISPERSING SAID AQUEOUS SLURRY IN WHITE MINERAL OIL MAINTAINED WITIN THE TEMPERATURE RANGE FROM 250* TO 500*F. TO FORM SPHERICAL PARTICLES OF A SIZE SUBSTANTIALLY ELIMINATING SAID COARSE MASSES AND, FINALLY, SUBSTANTIALLY ELIMINATING SULFATE FROM SAID SPHERICAL PARTICLES BY CALCNING THEM AT A TEMPERATURE OF FROM 900*F. TO 1600*F.