Molecular sieve catalyst composition, its making and use in conversion processes

A method for formulating a molecular sieve catalyst composition, the method comprising the steps of:

• (a) making a shiny comprising a solid portion and a liquid portion, the solid portion comprising a synthesized molecular sieve, a binder, and optionally a matrix material, and the slurry has a solid content of from about 30 percent to about 50 percent based on the total weight of the slurry on a calcined basis;
• (b) mixing the slurry until at least 90 percent by volume of the solid portion comprises particles in the slurry having a diameter less than 20 μm;
• and, (c) forming the slurry to produce a formulated molecular sieve catalyst composition.

A method for making a formulated molecular sieve catalyst composition, the method comprising the steps of:

• (a) making a slurry comprising a liquid portion and a solid portion, the solid portion comprising a molecular sieve, a binder, and optionally a matrix material, wherein the slurry has a solid content of from about 30 percent to about 50 percent based on the total weight of the slurry on a calcined basis and the weight ratio of the binder to molecular sieve is in the range of from 0.1 to 0.5;
• (b) mixing the slimy to form a formulation composition;
• (c) forming the formulation composition to for a formulated catalyst composition.

A formulated molecular sieve catalyst composition made by the method comprising the steps of (a) forming a formulation composition, the formulation composition comprising a liquid medium, a binder, a matrix material and a synthesized molecular sieve, wherein at least 90 percent by volume of the formulation composition composes solid particles having a diameter of less than 10 μm;

• b) spray drying the formulation composition to form a formulated molecular sieve catalyst composition;
• and (c) calcining the formulated molecular sieve catalyst composition to form the calcined formulated molecular sieve catalyst composition, wherein the ARI of the formulated molecular sieve catalyst is in the range of from about 0.01 to 0.5 weight percent per hour.