Abstract: A precipitated alumina-silica cogel which possesses a high total pore volume and wide pore size distribution. The precipitated cogel is used to prepare catalysts and catalyst supports that are used in the catalytic conversion and processing of hydrocarbons.

Abstract: Catalysts and catalyst supports are prepared by forming and drying, preferably spray-drying, an aqueous slurry of inorganic solids such as zeolites, clay, silica, alumina, and silica-alumina gel, and aluminum chlorhydrol to obtain particulate composites. The particulate composites are then reacted with ammonia in the absence of free liquid water to convert the aluminum chlorhydrol into a cohesive binder. The ammonia-reacted composites may then be washed, ion exchanged and thermally activated to obtain active attrition resistant catalysts and catalyst components.

Abstract: Binderless zeolite sieve extrudates are made by extruding a mixture containing about 40-60% zeolites with the remainder being a metakaolin clay that has mixed with it about 90-120% of the stoichiometric amount of sodium hydroxide to convert the clay to a zeolite. After extrusion the particles are allowed to dry age during which time most of the clay is converted to the zeolite. A further heat treatment in a dilute caustic aqueous solution insures complete crystallization with subsequent washing and calcination to produce an adsorbent product.

Abstract: Zeolite containing cracking catalysts are prepared by combining an alumina stabilized crystalline zeolite with an inorganic oxide matrix. The alumina stabilized zeolite is obtained by precipitating hydrous alumina onto a finely divided zeolite under alkaline reaction conditions.

Abstract: A process for preparing a silica gel bound zeolite containing catalyst by preparing an acidic silica sol and alkaline zeolite slurry feed streams, rapidly and homogeneously mixing the streams to form a rapidly gelling mixture, and spraying the mixture to produce gelled particles of catalyst.

Abstract: A process for preparing a hydrocarbon cracking catalyst is disclosed. The process consists of preparing a silica sol by passing sodium silicate through an ion exchange resin column to form a silica sol containing about 5% silica. Clay and zeolitic components are added and the product is spray dried. This process is advantageous in that it produces a more dense and hence more attrition resistant catalyst.