Process for the preparation of synthetic faujasite

Claim 1

A PROCESS FOR PREPARING SYNTHETIC FAUJASITE HAVING THE APPROXIMATE GROSS COMPOSITION NA2O:AL2O3:3.2 TO 5.8 SIO2:NH2O WHEREIN N HAS A VALUE LESS THAN 9 HAVING AN EFFECTIVE PORE SIZE OF ABOUT 13 ANGSTROM UNITS, AND CAPABLE OF BEING CONVERTED TO THE HYDROGEN FORM WITHOUT COLLAPSE OF THE CRYSTAL STRUCTURE WHEREIN AN AMORPHOUS FINE-SIZED SILICA CONTAINING FROM 4.5 TO 11 WEIGHT PERCENT WATER IS ONE OF THE PRINCIPAL REACTANTS, WHICH CONSISTS ESSENTIALLY OF: (A) DEHYDRATING AND ACTIVATING SAID SILICA BY CALCINING THE SILICA AT A TEMPERATURE OF 310 TO 1100* F. FOR A PERIOD OF 0.1 TO 72 HOURS, WHEREIN THE WATER CONTENT IS REDUCED TO 0.5 TO 4.2%, (B) PREPARING A SOLUTION OF SODIUM HYDROXIDE, (C) DISSOLVING ALUMINA IN SAID SOLUTION, (D) PREPARING A SODIUM HYDROXIDE-ALUMINA-CALCINED SILICA SLURRY BY RAPIDLY MIXING A SLURRY OF THE CALCINED FINE SIZED SILICA WITH THE SOLUTION OF SODIUM HYDROXIDE AND ALUMINA, (E) AGING SAID SLURRY AT A TEMPERATURE OF 20 TO 60* C. FOR ABOUT 3 TO 300 HOURS, (F) HEATING THE AGED MASS AT A TEMPERATURE OF 75 TO 100* C. FOR 3 TO 72 HOURS, THE MOLE RATION OF REACTANTS BEING: 0.17 TO 0.60 MOLE OF SODIUM OXIDE PER MOLE OF SILICA, 6 TO 12 MOLES OF SILICA PER MOLE OF ALUMINA, 25 TO 75 MOLES OF WATER PER MOLE OF SODIUM OXIDE.