Catalytic composition from reaction of high silica zeolites with binder

Claim 1

A method for enhancing the acid activity of a high silica-containing crystalline zeolite containing from about 50 ppm to less than about 1000 ppm alumina and having an Alpha Value of less than about 5, which comprises the steps of: (1) mulling said zeolite with an acidic inorganic oxide selected from the group consisting of alumina, zirconia, titiania and mixtures thereof in the presence of water, (2) forming or shaping the composition of step (1) into a desired shape at a pressure of from about 2 to about 50 tons per square inch, (3) calcining the formed or shaped composition of step (2) in a non-oxidizing atmosphere at from about 900° F. to about 1200° F. for from about 1 hour to about 5 hours, (4) treating said calcined composition from step (3) by base-exchange in order to reduce the sodium content thereof to less than about 0.02 wt.%, and (5) calcining said treated composition of step (4) at elevated temperature.

Claim 2

A method for enhancing the acid activity of a high silica-containing crystalline zeolite containing from about 50 ppm to less than about 1000 ppm alumina and having an Alpha Value of less than about 5, which comprises the steps of: (1) mulling said zeolite with an acidic inorganic oxide selected from the group consisting of alumina, zirconia, titiania and mixtures thereof in the presence of water, (2) forming or shaping the composition of step (1) into a desired shape at a pressure of from about 2 to about 50 tons per square inch, (3) calcining the formed or shaped composition of step (2) in a non-oxidizing atmosphere at from about 900° F. to about 1200° F. for from about 1 hour to about 5 hours, (4) treating said calcined composition from step (3) by base-exchange in order to reduce the sodium content thereof to less than about 0.02 wt.%, and (5) calcining said treated composition of step (4) at elevated temperature.

Claim 3

A method for enhancing the acid activity of a crystalline silicate having the structure of ZSM-5, a silica/alumina mole ratio of greater than about 1600 and an Alpha Value of less than about 5, which comprises the steps of: (1) mulling said silicate with alpha alumina monohydrate in the presence of water to form a wet composite mixture, (2) extruding the wet mixture of step (1) at a pressure of from about 2 to about 50 tons per square inch to form discrete composite particles, (3) calcining the discrete composite particles of step (2) in a non-oxidizing atmosphere at a temperature of from about 900° F. to about 1200° F. for at least one hour, (4) treating the calcined composite particles of step (3) with ammonium cations, and (5) calcining the treated composite particles of step (4) at elevated temperature.

Claim 4

A method for enhancing the acid activity of a crystalline silicate having the structure of ZSM-5, a silica/alumina mole ratio of greater than about 1600 and an Alpha Value of less than about 5, which comprises the steps of: (1) mulling said silicate with alpha alumina monohydrate in the presence of water to form a wet composite mixture, (2) extruding the wet mixture of step (1) at a pressure of from about 2 to about 50 tons per square inch to form discrete composite particles, (3) calcining the discrete composite particles of step (2) in a non-oxidizing atmosphere at a temperature of from about 900° F. to about 1200° F. for at least one hour, (4) treating the calcined composite particles of step (3) with ammonium cations, and (5) calcining the treated composite particles of step (4) at elevated temperature.