Catalytic conversion of hydrocarbons with a crystalline alumino-silicate in a silica-alumina matrix

Claim 1

IN A CONTINUOUS CYCLIC PROCESS OF CRACKING A PETROLEUM GAS OIL TO PRODUCE A SELECTIVELY LARGE YIELD OF HIGH OCTANE GASOLINE, AND SELECTIVELY SMALL YIELDS OF DRY GAS AND COKE, THE STEPS OF: (A) CONTINUOUSLY PASSING A GAS OIL THROUGH A CRACKING ZONE MAINTAINED UNDER CATALYTIC CRACKING CONDITIONS; (B) IN CONTACT WITH A COMPOSITION CATALYST IN SAID CRACKING ZONE; (C) SAID COMPOSITE CATALYST COMPRISING AS A MAJOR PROPORTION POROUS SILICA-ALUMINA; (D) WHICH SILICA-ALUMINA IS CAPABLE, AS A CATALYST, OF EFFECTING AT LEAST 15 PERCENT CONVERSION OF MID-CONTIENT GAS OIL HAVING A BOILING RANGE OF 450* TO 950*F. AT A LIQUID HOURLY SPACE VELOCITY OF 2, A CATALYST TO OIL VOLUME RATIO OF 3, A TEMPERATURE OF 900*F. AND SUBSTANTIALLY ATMOSPHERIC PRESSURE; (E) AND NOT MORE THAN ABOUT 25 PERCENT BY WEIGHT OF A FINELY DIVIDED CRYSTALLINE ALUMINOSILICATE INTERMIXED OF RIGID THREE-DIMENSIONAL NETWORKS CHARACTERIZED BY TION OF THE ORIGINAL ALKALI METAL CONTENT OF SAID CRYSTALLINE ALUMINOSILICATE HAVING BEEN REPLACED BY ION EXCHANGE; (F) SAID CRYSTALLINE ALUMINOSILICATE HAVING A STRUCTURE OF RIGID THREE-DIMENSIONAL NEWTWORKS CHARACTERIZED BY A SYSTEM OF CAVITIES WITH INTERCONNECTING PORE OPENINGS HAVING MINIMUM DIAMETERS OF GREATER THAN 4 ANGSTROMS AND LESS THAN 15 AMGSTROMS, THE CAVITIES BEING CONNECTED WITH EACH OTHER IN THREE DEEMENSIONS BY SAID PORE OPENINGS; (B) SAID CRYSTALLINE ALUMINOSILICATE HAVING A CATALYTIC ACTIVITY WHICH IS SUBSTANTIALLY GREATER THAN THAT OF SAID SILICA-ALUMINA; (H) THE EXCHANGEABLE SODIUM CONTENT OF SAID COMPOSITE CATALYST BEING LESS THAN ABOUT 1% BY WEIGHT; (I) CONTINUOUSLY RECOVERING A LIQUID FRACTION RICH IN HIGH OCTANE GASOLINE; (J) CONTINUOUSLY WITHDRAWING SPENT COMPOSITE CATALYST FROM THE CRACKING ZONE; (K) SUBJECTING SAID WITHDRAWN SPENT CATALYST TO AN OPERATION TO REGENERATE CATALYTIC ACTIVITY OF BOTH SAID SILICA-ALUMINA AND SAID ZEOLITE; (L) AND RETURNING REGENERATED COMPOSITE CATALYST TO SAID CRACKING ZONE.