The invention provides methods for completely removing aluminum from existing zeolite frameworks that have been previously considered unalterable due to their small pore sizes and stable crystal structures. Consequently, new combinations of metal atoms and zeolite structures can now be made using the methods disclosed herein. Metal atoms that have useful properties for catalysis and adsorption have been integrated into zeolite structures that provide advantageous size selection or solvation properties to increase rates, conversions, and yields of catalytic processes. The disclosed catalysts and methods reduce the cost of synthesizing useful materials and zeolite structures with compositions of matter that have not been reported.

A modified Y-type molecular sieve has a rare earth content of about 4-11% by weight on the basis of rare earth oxide, a sodium content of no more than about 0.7% by weight on the basis of sodium oxide, a zinc content of about 0.5-5% by weight on the basis of zinc oxide, a phosphorus content of about 0.05-10% by weight on the basis of phosphorus pentoxide, a framework silica-alumina ratio of about 7-14 calculated on the basis of SiO.sub.2/Al.sub.2O.sub.3 molar ratio, a percentage of non-framework aluminum content to the total aluminum content of no more than about 20%, and a percentage of the pore volume of secondary pores having a pore size of 2-100 nm to the total pore volume of about 15-30%. The modified Y-type molecular sieve has a high crystallinity, a structure comprising secondary pores, and a high thermal and hydrothermal stability.

Process for preparing a catalyst composition containing a modified crystalline aluminosilicate and a binder, wherein the catalyst composition comprises from 5 to 95% by weight of crystalline aluminosilicate as based on the total weight of the catalyst composition, the process being remarkable in that it comprises a step of steaming said crystalline aluminosilicate: at a temperature ranging from 100° C. to 380° C.; under a gas phase atmosphere containing from 5 wt % to 100 wt % of steam; at a pressure ranging from 2 to 200 bars; at a partial pressure of H.sub.2O ranging from 2 to 200 bars; and said steaming being performed during at least 30 min and up to 144 h;
and in that the process also comprises a step of shaping, or of extruding, the crystalline aluminosilicate with a binder, wherein the binder is selected to comprise at least 85 wt % of silica as based on the total weight of the binder, and less than 1000 ppm by weight as based on the total weight of the binder of aluminium, gallium, boron, iron and/or chromium.

Disclosed are processes for conversion of a feedstock comprising C.sub.8+ aromatic hydrocarbons to lighter aromatic products in which the feedstock and optionally hydrogen are contacted in the presence of the catalyst composition under conversion conditions effective to dealkylate and transalkylate said C.sub.8+ aromatic hydrocarbons to produce said lighter aromatic products comprising benzene, toluene and xylene. The catalyst composition comprises a zeolite, a first metal, and a second metal, and is treated with a source of sulfur and/or a source of steam.

Methods and systems for the conversion of hydrocarbon feedstocks, in particular, naphtha feedstocks, into a hydrocarbon product stream containing a high yield of high-octane gasoline and chemicals products. In particular, the conversion takes place over a series of functionally distinctive catalyst beds, at least one of which includes a modified zeolitic catalyst comprising a zeolite, a transition metal, and optionally a binder. Systems provided include a hydrocarbon feed stream, which may be full-range naphtha, a hydrocarbon product stream, and a plurality of functionally distinctive catalyst beds arranged in series, wherein at least one of the catalyst beds comprises a modified zeolitic catalyst. A hydrocarbon feed stream may be conveyed through the plurality of functionally distinctive catalyst beds, producing an intermediate hydrocarbon stream between each, under conditions effective to convert the hydrocarbon feed stream to a hydrocarbon product stream comprising high-octane gasoline, xylenes, benzene, and/or toluene.

A method including subjecting an ultra-stable Y-type zeolite having a low silica-to-alumina molar ratio (SAR), such as in a range of 3 to 6, to acid treatment and heteroatom incorporation contemporaneously to give a framework-modified ultra-stable Y-type zeolite.

A NaY molecular sieve with an aluminum-rich surface is prepared using a process that includes the steps of: a. mixing a directing agent and a first silicon source to obtain a first mixture, wherein the directing agent has a molar composition of Na.sub.2O: Al.sub.2O.sub.3: SiO.sub.2: H.sub.2O=(6-25): 1: (6-25): (200-400); b. mixing the first mixture obtained in the step a with a second silicon source, an aluminum source and water to obtain a second mixture; c. carrying out hydrothermal crystallization on the second mixture obtained in the step b, and collecting a solid product. Calculated as SiO.sub.2, the weight ratio of the first silicon source to the second silicon source is 1: (0.01-12). The NaY molecular sieve has larger aluminum distribution gradient from the surface to the center of the particle than the conventional molecular sieve.

Process for preparing a catalyst composition containing a modified crystalline aluminosilicate and a binder, wherein the catalyst composition comprises from 5 to 95% by weight of crystalline aluminosilicate as based on the total weight of the catalyst composition, the process being remarkable in that it comprises a step of steaming said crystalline aluminosilicate: at a temperature ranging from 100 C. to 380 C.; under a gas phase atmosphere containing from 5 wt % to 100 wt % of steam; at a pressure ranging from 2 to 200 bars; at a partial pressure of H.sub.2O ranging from 2 to 200 bars; and said steaming being performed during at least 30 min and up to 144 h;
and in that the process also comprises a step of shaping, or of extruding, the crystalline aluminosilicate with a binder, wherein the binder is selected to comprise at least 85 wt % of silica as based on the total weight of the binder, and less than 1000 ppm by weight as based on the total weight of the binder of aluminium, gallium, boron, iron and/or chromium.

The invention relates to a process for dehydration of a mono-alcohol, or of a mixture of at least two mono-alcohols, having at least 2 carbon atoms and at most 7 carbon atoms into olefins having the same number of carbons, wherein the process uses a catalyst composition that comprises a modified crystalline aluminosilicate has an acidity between 350 and 500 mol/g that comprises, and further wherein the catalyst composition is obtained by a process comprising the steps of providing a crystalline aluminosilicate having a Si/Al framework molar ratio greater than 10; and steaming said crystalline aluminosilicate, or said shaped and/or calcined crystalline aluminosilicate at a temperature ranging from 100 C. to 380 C.; and under a gas phase atmosphere, without liquid, containing from 5 wt % to 100 wt % of steam; at a pressure ranging from 2 to 200 bars; at a partial pressure of H.sub.2O from 2 bars to 200 bars; and said steaming being performed during at least 30 min and up to 144 h.

The present invention relates to a process for producing monoaromatic hydrocarbons from a hydrocarbon feed comprising polyaromatics, the process comprising contacting the feed at process conditions with a catalyst comprising a mixture of zeolite Y and a hydrogenation catalyst comprising one or more hydrogenation metals on a solid catalyst support.