Catalyst and method of manufacture

A method of preparing a catalyst composition comprising the steps of:

• (a) heating MCM-22 in a nitrogen atmosphere to a temperature of between about 100.degree. C. to about 595.degree. C. for between about 30 minutes and about 48 hours to thereby produce a nitrogen precalcined MCM-22;
• (b) combining the MCM-22 prepared according to step (a) with a source of phosphorus and, optionally, a source of clay, a source of silica, a source of alumina, or combinations thereof, the source of phosphorus being selected from the group consisting of ammonium monohydrogen phosphate, ammonium dihydrogen phosphate, triammonium phosphate, ammonium hypophosphate, ammonium orthophosphate, ammonium dihydrogen orthophosphate, ammonium monohydrogen orthophosphate, ammonium hypophosphite, ammonium dihydrogen orthophosphite, phosphoric acid and mixtures thereof;
• and
• (c) forming a catalyst particle from the combination of step (b).

A method for manufacture of a catalyst composition from MCM-22, a source of phosphorus and, optionally, a source of clay, a source of alumina, a source of silica, or combinations thereof, the method being selected from the group consisting of:

• (a) first, combining MCM-22 and a source of clay into a slurry, then adding a source of phosphorus selected from the group consisting of ammonium monohydrogen phosphate, ammonium dihydrogen phosphate, triammonium phosphate, ammonium hypophosphate, ammonium orthophosphate, ammonium dihydrogen orthophosphate, ammonium monohydrogen orthophosphate, ammonium hypophosphite, ammonium dihydrogen orthophosphite, phosphoric acid and mixtures thereof to the slurry and, optionally, adding a source of alumina, a source of silica, or combinations thereof to the slurry, and finally, forming the slurry into catalyst particles;
• (b) first, combining MCM-22 and a source of phosphorus selected from the group consisting of ammonium monohydrogen phosphate, ammonium dihydrogen phosphate, triammonium phosphate, ammonium hypophosphate, ammonium orthophosphate, ammonium dihydrogen orthophosphate, ammonium monohydrogen orthophosphate, ammonium hypophosphite, ammonium dihydrogen orthophosphite, phosphoric acid and mixtures thereof into a slurry, then, optionally adding a source of clay, a source of alumina, a source of silica, or combinations thereof to the slurry, and finally, forming the slurry into catalyst particles;
• and
• (c) first, combining MCM-22 and at least one of a source of clay, a source of alumina, a source of silica, and combinations thereof into a slurry, then forming the slurry into catalyst particles, and finally, contacting the formed catalyst particles with a source of phosphorus selected from the group consisting of ammonium monohydrogen phosphate, ammonium dihydrogen phosphate, triammonium phosphate, ammonium hypophosphate, ammonium orthophosphate, ammonium dihydrogen orthophosphate, ammonium monohydrogen orthophosphate, ammonium hypophosphite, ammonium dihydrogen orthophosphite, phosphoric acid and mixtures thereof.