Patent ID: 6696378
Filing Date: 2004-02-24
Classification: B01J,C10G

Abstract:
A non-macroporous zeolitic fluid catalytic cracking catalyst produced by the steps comprising:(a) forming an aqueous slurry containing (i) hydrated kaolin clay, metakaolin or mixture thereof, (ii) kaolin clay that has been calcined through its characteristic exotherm and (iii) binder, said kaolin clay calcined through its characteristic exotherm being derived from a pulverized, ultrafine kaolin wherein 90 wt. % of said ultrafine kaolin is in particles having a diameter of less than 2 microns; (b) spray drying the aqueous slurry to obtain microspheres; (c) calcining the microspheres obtained in step (b) at a temperature and for a time sufficient to convert hydrated kaolin clay in microspheres substantially to metakaolin, but insufficient to cause metakaolin or hydrated kaolin to undergo the characteristic kaolin exotherm and to provide microspheres of calcined kaolin having a ratio of metakaolin to kaolin calcined through the exotherm in excess of 1:1; (d) mixing microspheres obtained in step (c) with sodium silicate and water to obtain an alkaline slurry; (e) heating the slurry of microspheres of calcined clay to a temperature and for a time sufficient to crystallize at least about 50% by weight Y-faujasite in the microspheres.