Patent ID: 8383079

Claim:
A process for converting an organic starting material into a product, the process comprising contacting the starting material with a catalyst comprising a crystalline molecular sieve comprising at least [AlO 4 ] and [PO 4 ] tetrahedral units and comprising a first framework structure defining a first set of uniformly distributed pores having an average cross-sectional dimension of from about 0.3 to less than 2 nanometers and further comprising a second framework structure defining a second set of uniformly distributed pores having an average cross-sectional dimension of from 2 to 50 nanometers, wherein the crystalline molecular sieve is first made by the process of: (a) in a first crystallization step, preparing a first reaction mixture comprising an organic directing agent and a source of SiO 2 and Al 2 O 3 at a SiO 2 to Al 2 O 3 ratio within the range from 0 to 0.5 and capable of forming a CHA structure-type molecular sieve, crystallizing the first reaction mixture, followed by removing the crystallized CHA structure-type molecular sieve from the first reaction mixture to form a mother liquor, wherein the organic directing agent can be a compound having the formula: R 1 R 2 N—R 3 , wherein R 1 and R 2 are independently selected from the group consisting of alkyl groups having from 1 to 3 carbon atoms and hydroxyalkyl groups having from 1 to 3 carbon atoms and R 3 is selected from the group consisting of 4- to 8-membered cycloalkyl groups, optionally, substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms; and 4- to 8-membered heterocyclic groups having from 1 to 3 heteroatoms, said heterocyclic groups being, optionally, substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms and the heteroatoms in said heterocyclic groups being selected from the group consisting of O, N, and S; (b) acidifying the mother liquor having the crystallized CHA removed to a pH of about 6.0 to about 8.0 to form an acidified mother liquor, followed by combining the acidified mother liquor with nanoparticles of a removable material inert to the conditions used in (c); (c) in a second crystallization step, maintaining the mixture of acidified mother liquor and nanoparticles at a temperature within the range from 120 to 200° C. to form crystals of said molecular sieve between said nanoparticles; (d) removing said removable material; and (e) recovering said crystalline molecular sieve.