Patent ID: 7772337

Claim:
A method of making a molecular sieve catalyst composition comprising the steps of: a) combining molecular sieve crystals with binder and liquid to form a binder-sieve mixture; b) combining the binder-sieve mixture with matrix material to form a binder-sieve-matrix mixture; c) mixing the binder-sieve-matrix mixture under conditions sufficient to form a slurry having a solids content of at least 40 wt %, based on total weight of the slurry; d) progressing the mixing until slurry viscosity decreases without significant additional dilution of the slurry, so that the slurry solids content does not significantly decrease; and e) drying the decreased viscosity slurry to produce a dried molecular sieve catalyst composition having an attrition rate index of not greater than 2.0 wt %/hr, wherein the combining in step b) and the mixing in step c) result in a maximum viscosity below 30,000 cPs, wherein the decreased viscosity slurry formed in step d) has a final viscosity not greater than 15,000 cPs, and wherein the ratio of the final viscosity to the maximum viscosity is from 20% to 65%.