Cracking catalysts comprising pillared clays

Claim 2

A process for preparing pillared interlayered clays comprising the steps of: (a) contacting a smectite clay containing material with a solution comprising at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature of at least 20° C. and for a period of time of at least one minute; (b) separating the clay product formed in step (a) from said contacting solution; (c) contacting the clay product which has undergone treatment comprising step (a) and (b) with a solution comprising at least one polymeric cationic hydroxy metal complex of at least one metal selected from the group consisting of aluminum, titanium, zirconium and chromium, under such conditions as to increase the content of said metal in said clay product which has undergone treatment comprising steps (a) and (b); (d) separating the clay product having increased metal content formed in step (c) from said solution comprising the at least one polymeric cationic hydroxy metal complex; and (e) heating the separated clay product having increased metal content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 3

A process in accordance with claim 1, wherein said smectite clay containing material used in step (a) is a cracking catalyst composition comprising zeolite and a smectite clay matrix, and step (e) produces a catalyst composition comprising zeolite and pillared interlayered clay matrix.

Claim 4

A process in accordance with claim 1, wherein in step (a) said temperature is in the range of from about 20° to about 100° C. and said period of time is in the range of from about 5 minutes to about 100 hours.

Claim 5

A process in accordance with claim 1 comprising the additional step, after step (b) and before step (c), of (b1) contacting the separated clay product obtained in step (b) with an aqueous solution comprising at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b).

Claim 6

A process in accordance with claim 1, wherein said solution used in step (a) additionally comprises alkali metal dithionite.

Claim 7

A process in accordance with claim 1, wherein said steps are: (a) contacting a smectite clay containing material with a solution comprising water and at least on dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature in the range of from about 20° to about 100° C. and for a period of time in the range of from about 5 minutes to about 100 hours; (b) separating the clay product formed in step (a) from said contacting solution; (c) contacting the clay product which has undergone treatment comprising steps (a) and (b) with a solution comprising water and at least one polymeric cationic hydroxy metal complex of aluminum under such conditions as to increase the content of aluminum in said clay product which has undergone treatment comprising steps (a) and (b); (d) separating the clay product having increased aluminum content formed in step (c) from said solution comprising said at least one polymeric cationic hydroxy metal complex of aluminum; and (e) heating the separated clay product having increased aluminum content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 8

A process in accordance with claim 6, wherein the smectite clay in said smectite clay containing material used in step (a) is selected from the group consisting of bentonite, montmorillonite, chlorite, vermiculite, nontronite, hectorite, saponite and beidellite.

Claim 9

A process in accordance with claim 7, wherein said smectite clay is bentonite.

Claim 10

A process in accordance with claim 6, wherein said smectite clay containing material used in step (a) is a cracking catalyst composition comprising zeolite and a smectite clay matrix, and step (e) produces a catalyst composition comprising zeolite and pillared interlayered clay matrix.

Claim 11

A process in accordance with claim 9, wherein said zeolite is selected from group consisting of faujasites, mordenites, X-zeolites and Y-zeolites.

Claim 12

A process in accordance with claim 9, wherein said cracking catalyst composition used in step (a) comprises about 5-50 weight-% zeolite and about 95-50 weight-% smectite clay matrix.

Claim 13

A process in accordance with claim 6, wherein the solution used in step (a) has a pH in the range of from about 3 to about 10.

Claim 14

A process in accordance with claim 6, wherein the solution used in step (a) has a pH in the range of from about 5 to about 9.

Claim 15

A process in accordance with claim 6, wherein the concentration of said at least one dissolved carbon and oxygen containing compound in the solution used in step (a) exceeds about 0.001 mol/l.

Claim 16

A process in accordance with claim 14, wherein said at least one dissolved carbon and oxygen containing compound in step (a) is selected from the group consisting of sodium bicarbonate, potassium bicarbonate, sodium citrate, potassium citrate, ammonium citrate, sodium tartrate, potassium tartrate and ammonium tartrate.

Claim 17

A process in accordance with claim 6, wherein in step (a) the concentration of said at least one dissolved carbon and oxygen containing compound in said solution is in the range of from about 0.01 to about 10 mol/l, the weight ratio of said solution is smectite clay contained in said smectite clay containing material is in the range of from about 1:1 to about 100:1, and the ratio of the number of gram-mols of said at least one carbon and oxygen containing compound to the number of grams of smectite clay contained in said smectite clay containing material is in the range of from about 10 -5 :1 to about 1:1.

Claim 18

A process in accordance with claim 6, wherein in step (a) the concentration of said at least one dissolved carbon and oxygen containing compound in said solution is in the range of from about 0.02 to about 1.0 mol/l, the weight ratio of said solution to smectite clay contained in said smectite clay containing material is in the range of from about 3:1 to about 20:1, and the ratio of the number of gram-mols of said at least one dissolved carbon and oxygen containing compound to the number of grams of smectite clay contained in said smectite clay containing material is in the range of from about 0.001:1 to about 0.01:1.

Claim 19

A process in accordance with claim 6, wherein the solution used in step (a) additionally comprises at least one alkali metal dithionite.

Claim 20

A process in accordance with claim 6, wherein the solution used in step (a) additionally comprises from about 0.01 to about 1.0 mol/l of at least one sodium dithionite, and the mol ratio of said at least one dissolved carbon and oxygen containing compound to said sodium dithionite is in the range of from about 1:1 to about 100:1.

Claim 21

A process in accordance with claim 19, wherein said solution used in step (a) comprises sodium citrate, sodium bicarbonate and sodium dithionite.

Claim 22

A process in accordance with claim 20, wherein said solution used in step (a) comprises about 0.1-1.0 mol/l sodium citrate, about 0.02-0.5 mol/l sodium bicarbonate and about 0.01-0.2 mol/l sodium dithionite.

Claim 23

A process in accordance with claim 6, wherein said temperature in step (a) is in the range of from about 50° C. to about 100° C. and said period of time in step (a) is in the range of from about 0.2 to about 10 hours.

Claim 24

A process in accordance with claim 6, wherein step (b) comprises filtration.

Claim 25

A process in accordance with claim 6, wherein said process comprises the additional step, after step (b) and before (c), of (b1) contacting the separated clay product obtained in step (b) with a solution comprising water and at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides, so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b), and wherein step (c) is carried out with the product of step (b1).

Claim 26

A process in accordance with claim 24, wherein said at least one compound used in step (b1) is selected from the group consisting of ammonium chloride, magnesium chloride, lathanum chloride, ammonium nitrate, magnesium nitrate and lanthanum nitrate.

Claim 27

A process in accordance with claim 24, wherein in step (b1) the concentration of said at least one dissolved compound in the solution used in step (b1) is in the range of from about 0.01 to about 10 mol/l, the weight ratio of the solution used in step (b1) to the clay produced obtained in step (b) is in the range of from about 1:1 to about 1000:1, and the ratio of the number of g-mols of said at least one dissolved compound obtained in the solution used in step (b1) to the clay product obtained in step (b) is in the range of from about 10 -5 :1 to about 10:1.

Claim 28

A process in accordance with claim 24, wherein in step (b1) the concentration of said at least one dissolved compound in the solution used in step (b1) is in the range of from about 0.1 to about 1.0 mol/l, the weight ratio of the solution used in step (b1) to the clay product obtained in step (b) is in the range of from about 10:1 to about 100:1, and the ratio of the number of g-mols of said at least one dissolved compound contained in the solution used in step (b1) to the clay product obtained in step (b) is in the range of from about 0.001:1 to about 0.1:1.

Claim 29

A process in accordance with claim 6, wherein said process comprises the additional steps, after step (b) and before step (c), of (b1) contacting the separated clay product obtained in step (b) with a solution comprising water and at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides, so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b), and (b2) separating the clay product obtained in step (b1) from the solution used in step (b1), and wherein step (c) is carried out with the product of step (b2).

Claim 30

A process in accordance with claim 6, wherein said polymeric cationic hydroxy metal complex of aluminum used in step (c) is polymeric hydroxy aluminum chloride.

Claim 31

A process in accordance with claim 29, wherein the solution used in step (c) contains about 0.01 to about 10 weight percent of said polymeric hydroxy aluminum chloride, and the weight ratio of said polymeric hydroxy aluminum chloride to said clay product which has undergone treatment comprising steps (a) and (b) is in the range of from about 0.001 to about 10:1.

Claim 32

A process in accordance with claim 29, wherein the solution used in step (c) contains about 0.1 to about 3 weight percent of said polymeric hydroxy aluminum chloride, the weight ratio of said polymeric hydroxy aluminum chloride to the clay product which has undergone treatment comprising steps (a) and (b) is in the range of from about 0.01:1 to about 1:1, and step (c) is carried out at a temperature in the range of from about 25° to about 80° C.

Claim 33

A process in accordance with claim 24, wherein the polymeric cationic hydroxy metal complex used in step (c) is polymeric hydroxy aluminum chloride.

Claim 34

A process in accordance with claim 32, wherein the solution and in step (c) contains about 0.01 to about 10 weight percent of said polymeric hydroxy aluminum chloride, the weight ratio of said polymeric hydroxy aluminum chloride to the clay product which has undergone treatment comprising steps (a), (b) and (b1) is in the range of from about 0.001:1 to about 10:1.

Claim 35

A process in accordance with claim 32, wherein the solution used in step (c) contains about 0.1 to about 3 weight percent of said polymeric hydroxy aluminum chloride, the weight ratio of said polymeric hydroxy aluminum chloride to the clay product which has undergone treatment comprising steps (a), (b) and (b1) is in the range of from about 0.01:1 to about 1:1, and step (c) is carried out at a temperature in the range of from about 25° to about 80° C.

Claim 36

A process in accordance with claim 28, wherein the polymeric cationic hydroxy metal complex used in step (c) is polymeric hydroxy aluminum chloride.

Claim 37

A process in accordance with claim 35, wherein the solution used in step (c) contains about 0.01 to about 10 weight percent of said polymeric hydroxy aluminum chloride, and the weight ratio of said polymeric hydroxy aluminum chloride to said clay product which has undergone treatment comprising steps (a), (b), (b1) and (b2) is in the range of from about 0.001 to about 10:1.

Claim 38

A process in accordance with claim 35, wherein the solution used in step (c) contains about 0.1 to about 3 weight percent of said polymeric hydroxy aluminum chloride, the weight ratio of said polymeric hydroxy aluminum chloride to the clay product which has undergone treatment comprising steps (a), (b), (b1) and (2) is in the range of from about 0.01:1 to about 1:1, and step (c) is carried out at a temperature in the range of from about 25° to about 80° C.

Claim 39

A process in accordance with claim 6, wherein heating step (e) is carried out at a temperature in the range of from about 200° to about 900° C.

Claim 40

A process in accordance with claim 38, wherein said heating in step (e) is carried out first at a temperature in the range of from about 100° to about 200° C., and thereafter at a temperature in the range of from about 300° to about 700° C.

Claim 41

A process in accordance with claim 39, wherein said heating at a temperature in the range of from about 300° to about 700° C. is carried out for a period of time in the range of from about 0.1 to about 100 hours.

Claim 42

A process in accordance with claim 6, comprising the additional step of impregnating the pillared interlayered clay obtained in step (e) with at least one compound of at least one transition metal selected from the group consisting of metals belonging to Groups IIIB, IVB, VB, VIB, VIIB, VIII and IB of the Periodic Table.

Claim 43

A process in accordance with claim 6 comprising the additional step of intimately admixing the pillared interlayered clay obtained in step (e) with zeolite.

Claim 44

A process in accordance with claim 24 comprising the additional step of intimately mixing the pillared interlayered clay obtained in step (e) with zeolite.

Claim 45

A process in accordance with claim 28, comprising the additional step of intimately admixing the pillared interlayered clay obtained in step (e) with zeolite.

Claim 46

A composition of matter comprising pillared interlayered clay which has been prepared by the process comprising the steps of: (a) contacting a smectite clay containing material with a solution comprising at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature of at least 20° C. and for a period of time of at least one minute; (b) separating the clay product formed in step (a) from said contacting solution; (c) containing the clay product which has undergone treatment comprising steps (a) and (b) with a solution comprising at least one polymeric cationic hydroxy metal complex of at least one metal selected from the group consisting of aluminum, titanium, zirconium and chromium, under such conditions as to increase the content of said metal in said separated clay product obtained in step (b); (d) separating the clay product having increased metal content formed in step (c) from said solution comprising the polymeric cationic hydroxy metal complex; and (e) heating the separated clay product having increased metal content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 47

A composition of matter comprising pillared interlayered clay which has been prepared by the process comprising the steps of: (a) contacting a smectite clay containing material with a solution comprising at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature of at least 20° C. and for a period of time of at least one minute; (b) separating the clay product formed in step (a) from said contacting solution; (c) containing the clay product which has undergone treatment comprising steps (a) and (b) with a solution comprising at least one polymeric cationic hydroxy metal complex of at least one metal selected from the group consisting of aluminum, titanium, zirconium and chromium, under such conditions as to increase the content of said metal in said separated clay product obtained in step (b); (d) separating the clay product having increased metal content formed in step (c) from said solution comprising the polymeric cationic hydroxy metal complex; and (e) heating the separated clay product having increased metal content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 48

A composition of matter in accordance with claim 45, wherein said process comprises the additional step of (b1) contacting the separated clay product obtained in step (b) with an aqueous solution comprising at least one compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b).

Claim 49

A composition of matter in accordance with claim 45, wherein said solution used in step (a) additionally comprises alkali metal dithionite.

Claim 50

A composition of matter in accordance with claim 45, wherein said process comprises the steps of (a) contacting a smectite clay containing material with a solution comprising water and at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature in the range of from about 20° to about 100° C. and for a period of in the range of from about 5 minutes to about 100 hours; (b) separating the clay product formed in step (a) from said contacting solution; (c) contacting the clay product which has undergone treatment comprising steps (a) and (b) with a solution comprising water and at least one polymeric cationic hydroxy metal complex of aluminum under such conditions as to increase the content of aluminum in said clay product which has undergone treatment comprising steps (a) and (b), (d) separating the clay product having increased aluminum content formed in step (c) from said solution comprising said at least one polymeric cationic hydroxy metal complex of aluminum; and (e) heating the separated clay product having increased aluminum content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 51

A composition of matter in accordance with claim 48, wherein the smectite clay in said smectite clay containing material is selected from the group consisting of bentonite, montmorillonite, chlorite, vermiculite, nontrolite, hectorite, saponite and beidellite.

Claim 52

A composition of matter in accordance with claim 49, wherein said smectite clay is bentonite.

Claim 53

A composition of matter in accordance with claim 48, wherein said smectite clay containing material used in step (a) is a cracking catalyst composition comprising zeolite and a smectite clay matrix, and in step (e) a catalyst composition comprising zeolite and pillared clay matrix is formed.

Claim 54

A composition of matter in accordance with claim 51, wherein said cracking catalyst composition used in step (a) comprises about 5-50 weight-% zeolite and about 95-50 weight-% smectite clay matrix.

Claim 55

A composition of matter in accordance with claim 48, wherein the solution used in step (a) additionally comprises at least one alkali metal dithionite.

Claim 56

A composition of matter in accordance with claim 48, wherein said solution used in step (a) comprises sodium citrate, sodium bicarbonate and sodium dithionite.

Claim 57

A composition of matter in accordance with claim 48, comprising the additional step of impregnating the pillared interlayered clay obtained in step (e) with at least one compound of at least one transition metal selected from the group consisting of metals belonging to Groups IIIB, IVB, VB, VIB, VIIB, VIII and IB of the Periodic Table.

Claim 58

A composition of matter in accordance with claim 48, wherein said process comprises the additional step of intimately admixing the pillared interlayered clay obtained in step (e) with zeolite at a weight ratio of about 30:1 to about 1:5, so as to provide a cracking catalyst composition.

Claim 59

A composition of matter in accordance with claim 48, wherein the surface area of the pillared interlayered claim obtained in step (e) has a surface area, as determined by ASTM D3037, in the range of from about 100 to about 500 m 2 /g.

Claim 60

A composition of matter in accordance with claim 57, wherein the pillared interlayered clay, after having been steam-treated at about 732° C., 1 atm steam for about 4 hours, has a surface area in the range of from about 40 to about 250 m 2 /g.

Claim 61

A composition of matter in accordance with claim 51, wherein said zeolite is selected from the group consisting of faujasites, mordenites, X-zeolites and Y-zeolites.

Claim 62

A composition of matter in accordance with claim 56, wherein said zeolite is selected from the group consisting of faujasites, mordenites, X-zeolites and Y-zeolites.

Claim 63

A pillared interlayered clay prepared by a process comprising the steps of: (a) contacting a smectite clay containing material with a solution comprising at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature of at least 20° C. and for a period of time of at least one minute; (b) separating the clay product formed in step (a) from said contacting solution; (b1) contacting the separated clay product obtained in step (b) with an aqueous solution comprising at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b); (c) contacting the clay product which has undergone treatment comprising step (a), (b) and (b1) with a solution comprising at least one polymeric cationic hydroxy metal complex of at least one metal selected from the group consisting of aluminum, titanium, zirconium and chromium, under such conditions as to increase the content of said metal in said clay product which has undergone treatment comprising steps (a) and (b); (d) separating the clay product having increased metal content formed in step (c) from said solution comprising the at least one polymeric cationic hydroxy metal complex; and (e) heating the separated clay product having increased metal content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 64

A pillared interlayered clay prepared by a process comprising the steps of: (a) contacting a smectite clay containing material with a solution comprising at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature of at least 20° C. and for a period of time of at least one minute; (b) separating the clay product formed in step (a) from said contacting solution; (b1) contacting the separated clay product obtained in step (b) with an aqueous solution comprising at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b); (c) contacting the clay product which has undergone treatment comprising step (a), (b) and (b1) with a solution comprising at least one polymeric cationic hydroxy metal complex of at least one metal selected from the group consisting of aluminum, titanium, zirconium and chromium, under such conditions as to increase the content of said metal in said clay product which has undergone treatment comprising steps (a) and (b); (d) separating the clay product having increased metal content formed in step (c) from said solution comprising the at least one polymeric cationic hydroxy metal complex; and (e) heating the separated clay product having increased metal content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 65

A composition of matter in accordance with claim 61, wherein said solution used in step (a) additionally comprises alkali method dithionite.

Claim 66

A composition of matter in accordance with claim 61, wherein said process comprises the step of: (a) contacting a smectite clay containing material with a solution comprising water and at least one dissolved carbon and oxygen containing compound selected from the group consisting of ammonium carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal carboxylates containing from 1 to 20 carbon atoms per carboxylate group, alkali metal bicarbonates and alkali metal carbonates, at a temperature in the range of from about 20° to about 100° C. and for a period of time in the range of from about 5 minutes to about 100 hours; (b) separating the clay product formed in step (a) from said contacting solution; (b1) contacting the separated clay product obtained in step (b) with an aqueous solution comprising at least one dissolved compound selected from the group consisting of inorganic ammonium compounds, compounds of Group IIA metals and compounds of lanthanides so as to incorporate ionic species selected from the group consisting of ammonium ion, Group IIA metal ions, lanthanide ions and mixtures of two or more of these ions into said clay product obtained in step (b); (c) contacting the clay product which has undergone treatment comprising steps (a), (b) and (b1) with a solution comprising water and at least one polymeric cationic hydroxy metal complex of aluminum, under such conditions as to increase the content of aluminum in said clay product which has undergone treatment comprising steps (a) and (b); (d) separating the clay product having increased aluminum content formed in step (c) from said solution comprising said at least one polymeric cationic hydroxy metal complex of aluminum; and (e) heating the separated clay product having increased aluminum content obtained in step (d) under such conditions as to remove at least a portion of water from said separated clay product obtained in step (d) so as to form a pillared interlayered clay.

Claim 67

A composition of matter in accordance with claim 63, wherein said process comprises the additional step of (b2) separating the clay product obtained in step (b1) from the solution used in step (b1), and wherein step (c) is carried out with the product of step (b2).

Claim 68

A composition of matter in accordance with claim 63, wherein the smectite clay in said smectite clay containing material used in step (a) is selected from the group consisting of bentonite, montmorillonite, chlorite, vermiculite, nontronite, hectorite, saponite and beidellite.

Claim 69

A composition of matter in accordance with claim 63, wherein said smectite clay is bentonite.

Claim 70

A composition of matter in accordance with claim 63, wherein said smectite clay containing material used in step (a) is a cracking catalyst composition comprising zeolite and a smectite clay matrix, and step (e) produces a catalyst composition comprising zeolite and pillared interlayered clay matrix.

Claim 71

A composition of matter in accordance with claim 67, wherein said zeolite is selected from group consisting of faujasites, mordenites, X-zeolites and Y-zeolites.

Claim 72

A composition of matter in accordance with claim 67, wherein said cracking catalyst composition used in step (a) comprises about 5-50 weight-% zeolite and about 95-50 weight-% smectite clay matrix.

Claim 73

A composition of matter in accordance with claim 63, wherein the solution used in step (a) has a pH in the range of from about 3 to about 10.

Claim 74

A composition of matter in accordance with claim 63, wherein the concentration of said at least one dissolved carbon and oxygen containing compound in the solution used in step (a) exceeds about 0.001 mol/l.

Claim 75

A composition of matter in accordance with claim 63, wherein said at least one dissolved carbon and oxygen containing compound in step (a) is selected from the group consisting of sodium bicarbonate, potassium bicarbonate, sodium citrate, potassium citrate, ammonium citrate, sodium tartrate, potassium tartrate and ammonium tartrate.

Claim 76

A composition of matter in accordance with claim 63, wherein the solution used in step (a) additionally comprises at least one alkali metal dithionite.

Claim 77

A compositiom of matter in accordance with claim 63, wherein the solution used in step (a) additionally comprises from about 0.01 to about 1.0 mol/l of at least one sodium dithionite, and the mol ratio of said at least one dissolved carbon and oxygen containing compound to said sodium dithionite is in the range of from about 1:1 to about 100:1.

Claim 78

A composition of matter in accordance with claim 74, wherein said solution used in step (a) comprises sodium citrate, sodium bicarbonate and sodium dithionite.

Claim 79

A composition of matter in accordance with claim 74, wherein said at least one compound used in step (b1) is selected from the group consisting of ammonium chloride, magnesium chloride, lanthanum chloride, ammonium nitrate, magnesium nitrate and lanthanum nitrate.

Claim 80

A composition of matter in accordance with claim 63, wherein the concentration of said at least one dissolved compound in the solution used in step (b1) is in the range of from about 0.01 to about 10 mol/l, the weight ratio of the solution used in step (b1) to the clay product obtained in step (b) is in the range of from about 1:1 to about 1000:1, and the ratio of the number of g-mols of said at least one dissolved compound contained in the solution used in step (b1) to the clay product obtained in step (b) is in the range of from about 10 -5 :1 to about 10:1.

Claim 81

A composition of matter in accordance with claim 63, wherein said polymeric cationic hydroxy metal complex of aluminum used in step (c) is polymeric hydroxy aluminum chloride.

Claim 82

A composition of matter in accordance with claim 63, wherein said process comprises the additional step of impregnating the pillared interlayered clay obtained in step (e) with at least one compound of at least one transition metal selected from the group consisting of metals belonging to Groups IIIB, IVB, VB, VIB, VIIB, VIII and IB of the Periodic Table.

Claim 83

A composition of matter in accordance with claim 63 wherein said process comprises the additional step of intimately admixing the pillared interlayered clay obtained in step (e) with zeolite at a weight ratio of 30:1 to about 1:5, so as to provide a cracking catalyst composition.

Claim 84

A composition of matter in accordance with claim 80, wherein said zeolite is selected from the group consisting of faujasites, mordenites, X-zeolites, and Y-zeolites.

Claim 85

A composition of matter in accordance with claim 63, wherein the pillared clay obtained in step (e) has a surface area, determined by ASTM D3037, in the range of from about 100 to about 500 m 2 /g.

Claim 86

A composition of matter in accordance with claim 82, wherein said pillared interlayered clay, after having been steam-treated at about 732° C., 1 atm steam for about 4 hours, has a surface area in the range of from about 40 to about 250 m 2 /g.