A novel approach to synthesize in-situ crystallized zeolite/kaolin composites with high zeolite content

Abstract We present an alkali solution aided (ASA) activation approach to activate kaolin microspheres and its application to synthesize in-situ crystallized zeolite/kaolin composite materials. Compared with conventional thermal activation methods, the ASA activation can high-effectively convert silicon and aluminum species in kaolin microspheres into active silica and alumina for synthesizing zeolite/kaolin composites, leading to a successful synthesis of zeolite/kaolin composites with high zeolite content and outstanding attrition resistance. When used as a fluid catalytic cracking catalyst, the resulting zeolite Y/kaolin composite gave high conversion efficiency of vacuum oil and high selectivity to valuable products.