Patent ID: 8293854

Claim:
A method of forming an olefin-based polymer product comprising: (a) preparing a silicoaluminophosphate molecular sieve comprising; (i) combining a source of phosphorus and a source of aluminum with a liquid mixture medium to form a primary mixture, wherein said source of silicon comprises an organosilicate and said source of phosphorus comprises an organophosphate; (ii) aging the primary mixture for an aging time and under aging conditions sufficient to allow homogenization of the primary mixture, physico-chemical interaction between the source of phosphorus and the source of aluminum, or both; (iii) adding a source of silicon, N,N-dimethylcyclohexylamine organic template, and optionally additional liquid mixture medium, to the aged primary mixture to form a synthesis mixture; and (iv) inducing crystallization of a silicoaluminophosphate molecular sieve, which exhibits 90% or greater CHA framework type character, from said synthesis mixture at a crystallization temperature, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 μm; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins; (d) polymerizing at least one of the one or more olefins, optionally with one or more other comonomers and optionally in the presence of a polymerization catalyst, under conditions sufficient to form an olefin-based (co)polymer.