Hydrocarbon cracking with catalytic phosphate-silica-aluminosilicate compositions of improved crushing strength

Claim 1

THE HYDROCARBON CONVERSION PROCESS COMPRISING THE STEPS OF PASSING A FLUID HYDROCARBON STREAM HAVING AN INITIAL BOILING POINT OF AT LEAST ABOUT 400=F OVER THE PARTICULATE CATALYST COMPOSITION HEREINAFTER DETAILED UNDER HYDROCARBON CONVERSION CONDITIONS INCLUDING A TEMPERATURE OF AT LEAST ABOUT 500*F, A PRESSURE OF AT LEAST ABOUT 500 PSIG. AND A FLOW RATE SUFFICIENT TO CONVERT SAID HYDROCARBONS IN THE PRESENCE OF SAID CATALYST PARTICLES AND CAUSE THE PHYSICAL ATTRITION OF SAID CATALYST PARTICLES, WHEREIN SAID CATALYST COMPRISES A STRUCTURALLY STABLE SILICA-BONDED AGGREGATE CONTAINING AT LEAST ABOUT 2 WEIGHT PERCENT OF A PARTICULATE SILICATE SELECTED FROM THE GROUP CONSISTING OF SILICA GELS, PHYSICAL MIXTURES AND COGELS OF SILICA AND ANOTHER REFRACTORY OXIDE, AND CRYSTALLINE ALUMINOSLICATE ZEOLITES, AND AN AMOUNT OF PHOSPHOROUS CORRESPONDING TO ABOUT 1 TO ABOUT 30 WEIGHT PERCENT OF P2O5, FORMED BY THE METHOD CONSISTING ESSENTIALLY OF THE STEPS OF REACTING A MIXTURE OF SAID SILICATE AND A COLLOIDAL HYDROUS SILICA SOL IN THE PRESENCE OF WATER AND AT A TEMPERATURE OF AT LEAST ABOUT 40*F FOR A PERIOD OF AT LEAST ABOUT 10 MINUTES SUFFICIENT TO REACT SAID SILICA SOL WITH SAID SILICATE WHEREIN SAID SILICA SOL HAS AN AVERAGE PARTICL DIAMETER BELOW ABOUT 1 MICRON AND CONSTITUTES AT LEAST ABOUT 5 WEIGHT PERCENT OF SAID AGGREGATE ON A DRY WEIGHT BASIS, ADMIXING WITH THE RESULTANT COMBINATION OF SAID SILICATE AND SILICA SOL ABOUT 1 TO ABOUT 30 WEIGHT PERCENT DETERMINED AS P2O5 OF A POLYPHOSPHATE OR POLYPHOSPHATE PRECURSOR CONVERTIBLE TO A POLYPHOSPHATE AT ELEVATED TEMPERATURES SELECTED FROM THE GROUP CONSISTING OF PHOSPHORIC ACIDS, AMMONIUM SALTS OF PHOSPHORIC ACIDS, AND HYDROGEN AND AMMONIUM PHOSPHATES OF POLYVALENT METAL CATIONS HAVING IONIC RADII LESS THAN ABOUT 1 ANGSTROM, FORMING PARTICLE-FORM AGGREGATES OF THE RESULTANT COMBINATION OF SAID SILICATE PARTICLES, SILICA SOL AND POLYPHOSPHATE OR POLYPHOSPHATE PRECURSOR, AND DRYING THE RESULTANT COMBINATION AT A TEMPERATUE OF AT LEAST ABOUT 200* F FOR AT LEAST ABOUT 30 MINUTES.