Crystalline aluminosilicate hydrocarbon conversion catalyst composite and method of preparation thereof

Claim 1

A METHOD FOR PREPARING IMPROVED HYDROCARBON CONVERSION CATALYST CHARACTERIZED BY HIGH ATTRITION RESISTANCE AND HIGH CONVERSION ACTIVITY WHICH COMPRISES PREPARING A RARE EARTH CRYSTALLINE ALUMINOSILICATE SILICA-METAL OXIDE GEL COMPOSITE BY INTIMATELY ADMIXING IN A SILICA-METAL OXIDE SOL: (1) A FINELY DIVDED RARE EARTH CRYSTALLINE ALUMINOSILICATE HAVING UNIFORM PORE OPENINGS GREATER THAN 6 ANGSTROM UITS IN AMOUNTS RANGING FROM MINOR AMOUNTS TO ABOUT 29 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE AND (2) FINELY DIVIDED RARE EARTH CRYSTALLINE ALUMINOSILICATE-SILICEOUS OXIDE GEL WHICH HAS A WEIGHT MEAN PARTICLE DIAMETER BELOW ABOUT 10 MICRONS, IN AMOUNTS RANGING FROM ABOUAT 1 TO ABOUT 29 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE; THE TOTAL AMOUNT OF FINES OF RARE EARTH CRYSTALLINE ALUMINOSILICATE AND RARE EARTH CRYSTALLINE ALUMINOSILICATE-SILICEOUS OXIDE GEL RANGING FROM ABOUT 15 TO ABOUT 30 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE; EFFECTING GELATION OF THE RESULTING SILICA-METAL OXIDE SOL AT A PH IN THE RANGE FROM ABOUT 7.2 TO ABOUT 8.5; BASE EXCHANGING THE RESULTING COMPOSITE WITH A SOLUTION CHARACTERIZED BY A PH IN EXCESS OF 4.5 CONTAINING AMMONIUM IONS TO EFFECTIVELY REDUCE THE SODIUM METAL CONTENT OF THE BASE-EXHCHANGED COMPOSITE; WASHING THE BASE-EXCHANGED COMPOSITE FREE OF SOLUBLE MATTER; DRYING AND HEATING THE RESULTING PRODUCT BY SUBJECTING THE SAME TO A TEMPERATURE IN THE RANGE FROM AOBUT 500*F. TO ABOUT 1500*F. FOR AT LEAST 1 HOUR.

Claim 2

A METHOD FOR PREPARING IMPROVED HYDROCARBON CONVERSION CATALYST CHARACTERIZED BY HIGH ATTRITION RESISTANCE AND HIGH CONVERSION ACTIVITY WHICH COMPRISES PREPARING A RARE EARTH CRYSTALLINE ALUMINOSILICATE SILICA-METAL OXIDE GEL COMPOSITE BY INTIMATELY ADMIXING IN A SILICA-METAL OXIDE SOL: (1) A FINELY DIVDED RARE EARTH CRYSTALLINE ALUMINOSILICATE HAVING UNIFORM PORE OPENINGS GREATER THAN 6 ANGSTROM UITS IN AMOUNTS RANGING FROM MINOR AMOUNTS TO ABOUT 29 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE AND (2) FINELY DIVIDED RARE EARTH CRYSTALLINE ALUMINOSILICATE-SILICEOUS OXIDE GEL WHICH HAS A WEIGHT MEAN PARTICLE DIAMETER BELOW ABOUT 10 MICRONS, IN AMOUNTS RANGING FROM ABOUAT 1 TO ABOUT 29 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE; THE TOTAL AMOUNT OF FINES OF RARE EARTH CRYSTALLINE ALUMINOSILICATE AND RARE EARTH CRYSTALLINE ALUMINOSILICATE-SILICEOUS OXIDE GEL RANGING FROM ABOUT 15 TO ABOUT 30 WEIGHT PERCENT ON A DRY SOLIDS BASIS OF SAID COMPOSITE; EFFECTING GELATION OF THE RESULTING SILICA-METAL OXIDE SOL AT A PH IN THE RANGE FROM ABOUT 7.2 TO ABOUT 8.5; BASE EXCHANGING THE RESULTING COMPOSITE WITH A SOLUTION CHARACTERIZED BY A PH IN EXCESS OF 4.5 CONTAINING AMMONIUM IONS TO EFFECTIVELY REDUCE THE SODIUM METAL CONTENT OF THE BASE-EXHCHANGED COMPOSITE; WASHING THE BASE-EXCHANGED COMPOSITE FREE OF SOLUBLE MATTER; DRYING AND HEATING THE RESULTING PRODUCT BY SUBJECTING THE SAME TO A TEMPERATURE IN THE RANGE FROM AOBUT 500*F. TO ABOUT 1500*F. FOR AT LEAST 1 HOUR.