A fluid catalytic cracking catalyst made from microspheres that initially
contain kaolin, a dispersible boehmite alumina and a sodium silicate or
silica sol binder. The kaolin portion contains hydrous kaolin and a
particular kaolin which has been calcined through its characteristic
exotherm and which produces a catalyst having a novel morphology
comprising a macroporous matrix and crystallized zeolite freely coating
the walls of the pores of the matrix. Calcination of the hydrous kaolin to
metakaolin and formation of in-situ zeolite by treatment with sodium
silicate yields a catalyst containing Y-faujasite and transforms the
dispersible boehmite into a transitional alumina. The catalyst can be used
to crack resid or resid-containing feeds as the alumina phase formed from
the dispersible boehmite passivates nickel and vanadium contaminants.