CA2072987C - Synthesis of a crystalline silicoaluminophosphate - Google Patents

Abstract

A silicoaluminophosphate molecular sieve is disclosed and is characterized in that the P2O5 to alumina mole ratio at the surface is about 0.80 or less, the P2O5 to alumina mole ratio of the bulk is 0.96 or greater and the silicon content at the surface is greater than that of the bulk.

Description

vl -1- 20'~298'~
SYNTHESIS OF A CRYSTALLINE
SILICOALUMINOPHOSPHATE
OS BACKGROUND OF THE INVENTION
This invention relates to a crystalline silico-aluminophosphate molecular sieve and to its synthesis. It more particularly relates to the synthesis of a crys-talline silicoaluminophosphate molecular sieve which has a bulk P205/A1203 mole ratio and bulk Si02/A1203 mole ratio different from their corresponding surface P205/A1203 and surface Si02/A1203 mole ratios.
Silicoaluminophosphates are taught in U.S.
Patent No. 4,440,871, for example. Silicoaluminophosphate materials are both microporous and crystalline and have a three-dimensional crystal framework of P02+, A102- and Si02 tetrahedral units and, exclusive of any alkali metal or other cation which may optionally be present, an as-synthesized empirical chemical composition on an anhy lU drous basis of:
mR:(SixAlyPz)02 wherein "R" represents at least one organic templating 2 5 a a nt g present in the intracrystalline pore system;" m"
represents the moles of "R" present per mole of (SixAlyPz)p2 and has a value of from 0 to 0.3, the maximum value in each case depending upon the molecular dimensions o f the templ ati ng ag ent and the av ail able void volume of 30 the ore s stem of the p y particular silicoaluminophosphate species involved; "x", "y", and "z" represent the mole fractions of silico n, aluminum, and phosphorus, respec-tively, present as tetrahedral oxides. The minimum value for each "x", "y", and "z" is 0.01 and preferably 0.02.
3S The maximum value for "x" is 0.98; for "y" is 0.60; and for "z" is 0.52.
It is disclosed in U.S. Patent No. 4.440,871 that while it is not essential to the synthesis- of SAPO
compositions, it has been found that in general, stirring or other moderate agitation of the reaction mixture and/or seeding the reaction mixture with seed crystals of either the SAPO species to be produced or a topologically similar aluminophosphate or aluminosilicate composition, facilitates the crystallization procedure. These silicoaluminophosphates exhibit several physical and chemical properties which are characteristics of aluminosilicate zeolites and aluminophosphates.
Silicoaluminophosphate SAPO-11 and its conventional method of preparation are taught in U.S. Patent No. 4,440,871.
SUMMARY OF THE INVENTION
The present invention is directed to a novel synthetic crystalline silicoaluminophosphate molecular sieve, hereinafter designated SM-3. In general, the SM-3 silicoaluminophosphate can be characterized to distinguish it from all other silicoaluminophosphate forms as being a silicoaluminophosphate having a phosphorus, silicon, and aluminum concentration in the bulk of the molecular sieve, and having the essential X-ray diffraction pattern of SAPO-11.
In accordance with an aspect of the present invention, there is provided a crystalline silicoaluminophosphate molecular sieve as synthesized having a composition in terms of mole ratio of oxides on an anhydrous basis expressed by the formula:
mR:A1203:nP205:qSi02 wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the moles of "R" present and has a value such that there are from 0.02 to 2 moles of R per mole of aluminum; n has a value of from 0.96 to 1.1, and q has a value of from O1 to 4, said silicoaluminophosphate having a characteristic X-ray powder diffraction pattern which contains at least the d-spacing of Table I, and wherein the P205 to alumina mole ratio of the surface of the silicoaluminophosphate is about 0.80 or less, the P205 to alumina mole ratio of the bulk of the silicoalumino-phosphate is 0.96 or greater, and the Si02 to alumina mole ratio at the surface A

of the silicoaluminophosphate is greater than the Si02 to alumina mole ratio in the bulk of the silicoaluminophosphate.
According to another aspect of the present invention is a process for preparing a crystalline silicoaluminophosphate sieve which comprises:
(a) preparing an aqueous reaction mixture containing a reactive source of Si02, aluminum isopropoxide, phosphoric acid, and an organic templating agent, said reaction mixture having a composition expressed in terms of mole ratio of oxides as follows:
aR:A1203:0.1-1.2 P205:0.1-4.0 Si02:bH20 wherein R is an organic templating agent; "a" has a value large enough to constitute an effective amount of R and preferably has a value such that there are from 0.2 to 2 moles of R per mole of aluminum oxide; "b" has a value such that there are 10 to 40 moles of H20 per mole of aluminum oxide; said reaction mixture having been formed by combining the alumina and phosphorus sources in the substantial absence of the silicon source and thereafter combining the resulting mixture sequentially with the silicon source and the organic templating agent to form the complete reaction mixture;
(b) insuring the pH of the reaction mixture is from about 6.0 to 8.5;
(c) heating the reaction mixture to a temperature in the range of from 170°C to 240°C until crystals of silicoaluminophosphate are formed; and (d) recovering said crystals.
Among other factors, the present invention is based on my finding that by controlling reaction conditions, a new silicoaluminophosphate molecular sieve may be A

01 '~ 0 4 formed which has a bulk composition which is different from its surface composition. By controlling the distrib-OS ution and position of the silicon on the surface of the silicoaluminophosphate, the activity of the silicoalumino-phosphate as a catalyst is increased while maintaining its selectivity.

FIG. 1 is a ternary diagram showing the composi-tional parameters of the silicoaluminophosphate of this invention in terms of mole fractions of silicon, aluminum and phosphorous.
FIG. 2 is a ternary diag ram showing the pre-(erred compositional parameters of the silicoaluminophos-phates of this invention in terms of mole fractions of silicon, aluminum and phosphorous.
DETAILED DESCRIPTION OF THE IP?VENTION
The silicoaluminophosphate material of the 1U Present invention will exhibit unique and useful catalytic and shape selective properties. The activity usually is determined by comparing the temperature at which various catalysts must be utilized under otherwise constant reac-tion conditions with the same hydrocarbonaceous feedstocks ZS and the same conversion rate of products. The lower the react ion temperature for a g iven extent of react ion, the more active the catalyst is for the specified process.
The silicoaluminophosphate of the present invention, which is a SAPO-11-type silicoaluminophosphate, shows superior 30 activity as compared to SAPO-11 prepared by the conven-tional method as taught in U.S. Patent No. 4,440,871, and at the same time, possesses the same or improved advan-tageous selectivity properties of the known SAPO-11 sili-coaluminophosphate. The selectivity is a measure of the 35 y field of a des fired product.
The novel SM-3 silicoaluminophosphate, as-syn-thesized, has a crystalline structure whose X-ray powder diffraction pattern shows the following characteristic lines.

TABLEI
28 d 100 x I/I"

9.4-9.65 9.41-9.17 m 20. 3-20.6 4.37-4.31 m 5 21.0-21.3 4.23-4.17 vs 22.1-22.35 4.02-3.99 m 22.5-22.9 (doublet) 3.95-3.92 m 23 .15-23 . 3 5 3. 84-3 . 81 m-s m = 20-70 s = 70-90 vs = 90-100 The x-ray powder diffraction patterns were determined by standard techniques. The radiation was the K-apha/doublet of copper and a scintillation counter spectrometer with a strip-chart pen recorder was used. The peak heights I and the positions, as a function of 20, where 0 is the Bragg angle, were read from the spectro-meter chart. From these measured values, the relative intensities 100I/Io, where Io is the intensity of the strongest line or peak and d, the interplanar spacing in Angstroms corresponding to the recorded lines, can be calculated. The x-ray diffraction pattern of Table I is characteristic of novel SM-3 silicoaluminophosphate and corresponds to the x-ray diffraction pattern for SAPO-11 as disclosed in U.S. Patent No.

4,440,871.
After calcination, the SM-3 silicoaluminophosphate has a crystalline structure whose x-ray powder diffraction pattern shows the following characteristic lines as indicated in Table II below:
TABLE II

20 d 00 x I/h 8.1 10.92 m 9.85 8.98 m 12.8 6.92 m 16.1 5.5 m 21.95 4.05 vs 22.3-22.5 3.99-3.95 m 23.5 3.786 m O1 ~ U'~ 2 9 $'~ -6-The SM-3 silicoaluminophosphate molecular sieve as synthesized is characterized as comprising a three-05 dimensional microporous crystal framework structure of [Sio2], (Alo2], and (P02] tetrahedral units which has a composition in terms of mole ratio of oxides on an anhydrous basis expressed by the formula:
mR:A1203:np205:qSi02 (I) wherein "R" represents at least one organic templating agent (hereinafter also referred to as "template") present in the intracrystalline pore system; "m" represents the moles of "R" present and has a value such that there are from 0.02 to 2 moles of R per mole of alumina; n has a value of from 0.96 to 1.1 and preferably 0.96 to 1, and q has a value of from 0.1 to 4 and preferably 0.1 to 1.
The SM-3 silicoaluminophosphate molecular sieve 1U as synthesized may also be expressed in terms of its unit empirical formula. On an anhydrous basis it is expressed by the formula:
mR: ( SixAlyPz )02 ( I I ) wherein R and m are defined hereinabove; "x", "y", and "z"
represent the mole fractions of silicon, aluminum, and phosphorus, respectively, present as tetrahedral oxide units, said mole fractions being within the tetragonal compositional area defined by points, A, B, C, and D of the ternary compositional diagram depicted by FIG. 1 of the drawings where the points A, B, C, and D are repr e-sented b the followi " ", "y", and "z":
Y nq values for x Mole Fraction Point x ~ z A 0 02 0. 50 0.48 0.02 0.47 0.51 C 0.51 0.25 0.24 D 0.49 0.24 0:27 O1 _~_ In a preferred embodiment the values for "x", "y", and "z", in the Formula (II) above are within the tetragonal OS c°mpositional area defined by the points a, b, c, and d of the ternary diagram which is FIG. 2 of the drawings, wherein said points a, b, c, and d are represented by the following values for "x", "y", and "z":
Mole Fraction Point x ~ z a 002 0.50 0.48 b 0.02 0.49 0.49 c 0.2 0.41 0.39 d 0.2 0.40 0.40 l5 The SM-3 silicoaluminophosphate of this invention is fur-ther characterized in that the P205 to alumina mole ratio at the surface of the silicoaluminophosphate is about 0.80 or less and preferably in the range of 0.80 to 0.55, the lU P2~5 to alumina mole ratio of the bulk of the silicoalu-minophosphate is 0.96 or greater, preferably in the range of 0.96 to 1.1, anc' most preferably in the range of 0.96 t o 1 , and the S i02 to alumi na mo le rat io at the sur f ace of the silicoaluminophosphate is greater than the Si02 to 25 alumina mole ratio Within the bulk of the silicoalumi-nophosphate.
In the sieve of this invention, the silicon content, as evidenced by the silica to alumina mole ratio at the surface of the silicoaluminophosphate is greater 30 than in the bulk of the si eve.
By the term "silicon content at the surface of the sieve" is meant the amount of silicon at the surface of the sample as can be measured using X-ray photoelectron spectroscopy surface analysis (ESCA); this silicon content 3S will include any amorphous silica that is present. The sieves of this invention have higher silicon contents at the surface than in the bulk. In this comparison, either silica contents per se or the silica/alumina ratios can be c anpared.
t0 WO 91/13132 PC'T/US90/01162 20'~~9E'~
_g_ The term "unit empirical formula" is used herein according to its common meaning to designate the simplest 05 formula which gives the relative number of atoms of sil i-con, aluminum, and phosphorus which form a [P02], [A102], and [Si021 tetrahedral unit within a silicoaluminophos-phate molecular sieve and which forms the molecular frame-work of the SP4-3 composition. The unit empirical formula is given in terms of silicon, aluminum, and phosphorus as shown in Formula (II), above, and does not include other compounds, cations, or anions which may be present as a result of its preparation or the existence of other impurities or materials in the bulk composition not con-raining the aforementioned tetrahedral unit as the molecular framework. The amount of t emplat a R is part of the composition when the as-synthesized unit empirical formula is given, and water may also be reported unless such is defined as the anhydrous form. For convenience, 2~ coefficient "m" for template "R" is reported as a value that is normalized by dividing the number of moles of R by the total number of moles of alumina. When moles of water are reported the moles of water is reported as a value that is normalized by dividing the number of moles of water by the total moles of alumina. The values for x, y, and z are determined by dividing the number of moles of silicon, aluminum, and phosphorus individually by the total number of moles of silicon, aluminum, and phos-phorus.
The composition of Formula (I) as well as the unit empirical Formula (II) for an SM-3 silicoaluminophos-phate may be given on an "as-synthesized" basis or may be given after an "as-synthesized" SM-3 composition has been subjected to some post-treatment process, e.g., calcina-tion. The term "as-synthesized" herein shall be used to refer to the SM-3 composition formed as a result of the hydrothermal crystallization but before the SM-3 composi-tion has been subjected to post-treatment to remove any volatile components present therein.

m -9- _ 20'2987 The actual value of "m" for a post-treated SM-3 will depend on several factors (including: template, severity of the post-treatment in terms of its ability to OS
remove the template from th a SM-3, the proposed appli-cation of the SM-3 composition, etc.). The amount of template for the post-treated SM-3 can be within the range of values as defined for the as-synthesized SM-3 composi-Lion, although it is generally less. An SM-3 composition which is in the calcined or other post-treated form gener-ally has a composition represented by the Formula (I) or an empirical formula represented by Formula (II), except that the value of "m" , generally ranges from 0 to 0.3 moles of template per mole of alumina and most preferably from 0 to 0.1 and is generally less than about 0.02.
Under sufficiently severe post-treatment conditions, e.g., roasting in air at high temperature for long periods (over 1 hour), the value of "m" may be zero (0) or, in any 1U event, the template, R, is undetectable by normal analyt i-cal procedures.
In synthesizing the SM-3 composition of the present invention, it is preferred that the reaction mix-ture be essentially free of alkali metal cations, and accordingly a preferred reaction mixture composition expressed in terms of mole ratio of oxides is as follows:
aR:A1203:0.9-1.2 P205:0.1-4.0 Si02:bH20 wherein "R" is an organic templating agent; "a" has a value great enough to constitute an effective concentra-tion of "R" and preferably has a value such that there are from about 0.20 to 2 moles of R per mole of alumina and more preferably about 0.8 to 1.2; "b" has a value such 3S that there is 10 to 40 moles of H20 per mole of aluminum oxide, preferably 15 to 36;
In the synthesis method of the present inv en-tion, an aqueous reaction mixture is formed by combining the reactiv a aluminum and phosphorus sources in the sub-'0 stantial absence of the silicon source and thereafter combining the resulting reaction mixture comprising the aluminum and phosphorus sources with the silicon source OS and thereafter combining the mixture with the template.
If alkali metal cations are present in the reaction mix-ture, they should be present in sufficiently low concen-trations that it does not interfere with the formation of the SM-3 compos it ion.
Any inorganic cations and anions which may be present in the reaction mixture are generally not provided by separately added components. Rather, these cations and anions will frequently come fror.: compounds added to the reaction mixture to provide the other essential components such as the silicon source or such as the organic templat-irg agent or any pH adjustment agents which may be used.
More specifically, the synthesis method comprises:
(a) preparing an aqueous reaction mixture containing 1u aluminum isopropoxide and phosphoric acid, and thereafter combining the resulting mixture with a silicon oxide source followed by combining this mixture with an organic templating agent to form the complete reaction mixture in the relationship hereinbefore set forth;
(b) adjusting the pH of the reaction mixture at the start of the reaction to about 6.0 to 8.5 and preferably i n the range of from 6.0 to 8.0;
(c) heating the reaction mixture to a temperature in the range of from 170°C to 240°C and preferably from 180°C
to 225°C until crystals are formed, usually from 5 hours to 500 hours and preferably 24 to 500 hours; and (d) recovering the crystalline SM-3 silicoalumino-phosphate.
The crystallization is conducted under hydro-3S thermal conditions under pressure and usually in an auto-clave so that the reaction mixture is subject to auto-genous pressure and preferably with no stirring.
Following crystallization of the SM-3 material, the reaction mixture containing same is filtered and the recovered crystals are washed, for example, with water, _11- . ,.. ;20?298 Ol and then dried, such as by heating at from 25°C to 150°C
at atmospheric pressure. Preferably the supernatant 05 liquid above the crystals is removed prior to the initial filtering of the crystals.
The SM-3 prepared by the present method is bene-ficially subjected to thermal treatment to remove the organic templating agent. This thermal treatment is generally performed by heating at a temperature of 300°C
to 1000°C for at least 1 minute and generally not longer than 20 hours. While subatmospheric pressure can be employed for the thermal treatment, atmospheric pressure is desired for reasons of convenience. The thermally treated product is particularly useful in the catalysis f certain hydrocarbon conversion reactions.
Adding the silicon component last after well mixing the aluminum and phosphorus components results in high purity SM-3-type material.
z0 The SM-3 silicoaluminophosphate is prepared at low pH, in the range of from about 6.0 to about 8.5 and preferably from 6.0 to 8.0, and an H20/A1203 mole ratio of about 10 to 40 and preferably 15 to 36. Under these con-ditions, Si02 depolymerization is slow and nucleation is rapid. Crystallization under the reaction conditions of this invention is generally complete in less than 5 hours.
While not intending to be limited to theory, it appears Si02 does not enter the structure until late in crystallization such that under the conditions of the Process of this invention, in the early phases of the reaction, there is produced a near aluminophosphate phase surrounded by a Si02-rich amorphous phase. As P04-3 is depleted by reaction With A1+3 species, the pH of the mixture rises to about 10 to about 10.5. This increases 3S the dissolution of Si02 permitting silica incorporation into the structure such that a silicoaluminophosphate shell forms around the aluminophosphate core. From a macroscopic point of view, the siev a could almost be considered a crystalline aluminophosphate, since the P205 to alumina mole ratio within the bulk of the SM-3 WO 91/13132 ~'CT/US90/01162 m 2p;~2987 -12-silicoaluminophosphate is 0.96 or greater and preferably from 0.96 to 1.
05 The surface silica rich phase on the outside of the sieve contains a higher Si02/alumina ratio than the bulk. Material with higher surface silica to alumina ratios appears to show increased acidity and increased a ct iv i ty .
By controllirr~ the pH and the H20/A1203 ratio of the mix, the thickness of the SM-3 shell can be adjusted.
One way to reduce the thickness, for example, is by adding additional H3p04 to the mix. This will hold down the final pH, i.e., control the acidity, so that Si is not incorporated until the very end of the synthesis.
If necessary, the pH can be lowered into the proper region using acids such as HC1 o r H3P04, The 1 atter may be pref erred, s ince hav i ng a sl ig ht excess of P04 3 will help ensure that the P04-3 concentration is 1U never so low that the alumina and silica components hav a nothing to react with but each other.
An excess of water over the described range tends to lead to rapid incorporation of silica into the product. Excess water also leads to larger crystals which may diminish activity due to diffusion constraints. In the present invention, a crystallite size of less than 1 micron is produced with an average size less than 0.5 micron.
The activity of the SM-3 silicoaluminophosphate is improved as the synthesis temperature is increased, at least up to 240°C. The high temperature appears to enhance crystal growth and, therefore, the degree of crys-tallinity of the product. It also tends to give a more complete Si incorporation which leads to more active s ites.
The organic template or directing agent is selected from di-n-propylamine and di-isopropylamine or mixtures thereof.
The useful sources of silicon oxide include any one form of silicic acid or silicon dioxide, alkoxy- or 207298'~
Ol -13-other compounds of silicon. Preferably, a form of silicon oxide known as Cab-o-Sil is used.
05 The special characteristics of the catalyst result from its surface composition as determined by X-ray photoelectron spectroscopy surface analysis (ESCA), Lucchesi, E. A., et al., Jour. Chem. Ed. 50(5):A269 (May 1973) and Kelley, M. J., CHEMTECH, 99-105 (Feb. 1982).
The term "surface" refers to both the outermost layer of atoms and to a volume that extends about 50 angstroms below the outermost layer. The ESCA determination is a weighted averagc of the concentration in these layers, the weighting factor decreasing exponentially toward the interior.
A Hewlett Packard 5950A ESCA Spectrometer was used to measure the atomic ratios of elemental phos-phorous, silicon, aluminum and oxygen.
The instrument was run alternately scanning the 10 bands of interest and the oxygen is band. This scanning method allowed for a straight line normalization of all of the band intensities relative to the oxygen ls, thereby correcting for the decrease in sensitivity of the detector ove r the time required to analyze the sample.
Z5 Relative intensities were corrected using the following response factors, rather than theoretical Scofield cross sections. These response factors were determined by calibrations using amorphous aluminum phos-phate, alumina, silica, sodium hydrogen phosphate and 30 aluminum sulfate, and are similar to those found in Wagner, et al., Surf. Inter. Anal., 3, 211 (1981) and _S.
Evans, et al., J. Electron Spectros. Rel. Phenom. 14, 341 (1978).
Observed Scofield 35 Relative Relative Element Band Intensity Intensity O is 1.00 1.00 A1 2p 0.21 0.18 A1 2s 0.29 0.26 Si 2p 0.35 0.28 Si 2s 0.39 0.33 40 P 2P 0.55 0.41 P 2s 0.45 0.40 01 ~~7~98'~ -14-For each of the elements, silicon, aluminum and phosphorus, the amount of the element at the surface was OS calculated based on the intensity of both the 2s and 2p bands, which were weighted using the square root of the above response factors for each of these bands. Once the amount of each element was determined, atomic ratios and weight ratios and mole ratios were readily calculated.
Observed variances in individual elemental con-centrations are about 10%. However, the ratios of the elements can be determined more accurately, typically within 5%.
Bulk elemental determinations of silicon, alumi-num and phosphorus were made using the following proce-dure. This method first fused the molecular sieve sample with lithium metaborate, LiB02, and then dissolved the molten-fused bead in nitric acid solution. The resulting solution was analyzed by the Inductively Coupled Plasma 1U ( ICP) technique using matrix-matched standards. A
Model 3580 ICP sold by Applied Research Laboratories (ARL), California, was used.
Solutions for analysis were prepared by mixing 0.1 g of the sample with 1.4 g of LiB02 in a pre ignited graphite crucible. This mixture was fused in a muffle furnace set at 1000°C for 14 minutes. The crucible was immediately removed from the furnace, and, with a uniform motion, the molted fused-bead was poured into 60 mL of a 4% v /v HN03 acid solution in a polyethylene beaker. The fused salts were agitated until dissolved and then a 5 ppm scandium internal standard, diluted from a 1% concentrate purchased from VHG Laboratories. Andover, Massachusetts, was added. The resulting solution was diluted to 1 liter.
The sample weight was corrected to account for any water and residual organics by adjusting the sample weight for the % loss of ignition (LOI). A dry crucible containing a known weight of the sample was heated at 1000°C for 2 hours, and cooled to room temperature in a dessicator. The % LOI was calculated:

_ 20'~2~8'~

% LOI = 100 x Weight Before - Weight After We ig h t Af ten OS The sample weight was corrected for the % LOI.
Corrected sample weight = sample weight x 100 - % LOI
The corrected sample weight was used to determine the weight percent of silicon, aluminum, and phosphorus via ICP, based on the instrument response of the sample com-pared to a calibration curve for each element and the dilution factor (total volume/corrected sample weight) associated with each sample.
The calibration curve for each element was determined by preparing aqueous calibration standards (matrix-matched) in the manner described above for sample preparation, except no sample was added. Instead, just prior to diluting to 1 liter, known amounts of aqueous Al, 1U P and Si standards purchased from VHG were added. Once the amount of each element was determined, atomic ratios, weight ratios and mole ratios were readily calculated.
The SM-3 synthesized hereby can be used as cata-lyst in intimate combination with a metal component such as silver, tungsten, vanadium, molybdenum, rhenium, chro-mium, manganese, or a Group VIII metal, preferably plati-num or palladium where, for example, a hydrogenation-dehydrogenation or oxidation function is to be performed.
Such a compo vent can be ion-exchanged into the composi-tion, impregnated therein or intimately physically admixed therewith. Such component can be impregnated into or onto the composition, such as, for example, in the case of platinum, by treating the crystal with a solution contain-ing a platinum metal-containing ion. Thus, suitable 3S Platinum compounds include chloroplatinic acid, platinous chloride, and various.compounds containing the platinum amine complex.
The original ions, i.e., cations or anions, of the as-synthesized SM-3 can be replaced in accordance with techniques well known in the art, at least in part, by 01 ~ g -16-ion-exchange with other cations or anions. Preferred replacing cations include metal ions, hydrogen i , OS hydrogen precursor, e.g. , ammonium, ions and mixtures thereof. Particularly preferred cations include hydrogen, rare earth metals, and metals of Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB, VIB, and VIII of the Periodic Table of the Elements.
A typical ion-exchange technique would be to contact the synthetic crystalline SM-3 with a salt of the desired replacing ion or ions. Examples of such salts of cations include the halides, e.g., chlorides, nitrates, a nd sul f ates .
Further, the present SM-3, when employed either as an adsorbent, ion-exchanger, or as a catalyst in an organic compound conversion process should be dehydrated, at least partially. This can be done by heating to a temperature in the range of 200°C to 600°C in air or an inert atmosphere, such as nitrogen, etc., and at atmos-pheric, subatmospheric, or superatmospheric pressures for between 30 minutes and 48 hours. Dehydration can also be performed at room temperature merely by placing the crys-talline material in a vacuum, but a longer time is r eq ui red to obt ai n a suf f i ci ent amount of dehydrat ion.
Therefore, depending upon the degree of dehydration or thermal treatment desired for the SM-3, it may be sub-jected to heating at a temperature of from 200°C to 1000°C
for a time of from 1 minute to 48 hours.
The crystals of SM-3 prepared by the instant invention can be shaped into a wide variety of particle sizes. Generally speaking, the particles can be in the form of a powder, a granule, or a molded product, such as an extrudate having a particle size sufficient to pass 3S through a 2-mesh (Tyler) screen and be retained on a 400-mesh (Tyler) screen. In cases where the composition is molded, such as by extrusion, the crystals can be extruded before drying or partially dried and then a xt rud ed .

0 1 -- 1 7 - e.~ ~'.~
In the case of many catalysts, it is desired to incorporate the SM-3 with another material resistant to 05 the temperatures and other condition employed in organic conversion processes. Such materials include active and i nact iv a materi al and synth et is or natur al ly occurri ng zeolites as well as inorganic materials such as clays, silica and/or metal oxides. The latter may be either naturally occurring or in the form of gelatinous precipi-tates or gels including mixtures of silica and metal oxides. i7se of a material in conjunction with the SM-3, i.e., combined therewith, which is active, tends to improve the conversion and/or selectivity of the catalyst in certain organic conversion processes. Inactive mate-rials suitably serve as diluents to control the amount of conversion in a given process so that products can be obtained economically without employing other means for controlling the rate of reaction. These materials may be 1U incorporated into naturally occurring clays, e.g., bentonite and kaolin, to improve the crush strength of the catalyst under commercial operating conditions. Said materials, i.e., clays, oxides, etc., function as binders for the catalyst. It is desirable to provide a catalyst h~ing good crush strength because in commercial use it is desirable to prevent the catalyst from breaking down into powder-like materials. These clay binders have been employed normally only for the purpose of improving the crush strength of the catalyst.
Naturally occurring clays which can be composited with the new crystal include the montmorillo-nite and kaolin families which include the subbentonites, and the kaolins commonly known as Dixie, McNamee, Georgia, and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment, or chemical modif ication. Binders useful for compositing with the present crystal also include inorganic oxides, notably alumina or silica.

O1 ~ ~~~ _lg_ In addition to the foregoing materials, the SM-3 produced can be composited with a porous matrix material OS such as aluminum phosphate, silica-alumina, silica-mag nesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titanic as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirco nia, silica-alumina-magnesia, and silica-magnesia-zirconia. The rela-five proportions of finely divided crystalline SM-3 material and inorganic oxide gel matrix vary widely, with the crystal content ranging from 1 to 90% by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of 2 to 80 weight per-cent of the composite.
The crystalline material produced by the present process is readily convertible to catalytically active material for a variety of organic, e.g., hydrocarbon com-pound conversion processes.
2~ SM-3 catalyst, when containing a hydrogenation promoter, can be used in a process for selectively pro-ducing middle distillate hydrocarbon~ by hydrocracking a hydrocarbonaceous feed wherein at least 90% of the feed has a boiling point above about 600°F. The hydrocracking conditions include reaction temperatures which generally exceed about 500°F (260°C) and are usually above about 600°F (316°C), preferably between 600°F (316°C) and 900°F
(482°C). Hydrog en addition rates should be at least about 400, and are usually between about 1, 000 and about 15.000 standard cubic feet per barrel. Reaction pressures exceed 200 psig (13.7 bar) and are usually within the range of about 500 to about 3000 psig (32.4 to 207 bar).
Liquid hourly space velocities are less than about 15, preferably between about 0.2 and about 10.
3S The conditions should be chosen so that the overall conversion rate will correspond to the production of at least about 40%, and preferably at least about 50%
of products boiling below about 725°F (385°C) per pass and preferably below about 725°F and above about 300°F.
Midbarrel selectivity should be such that at least about Ql -19- ~~~2 40$, preferably at least about 50$ of the product is in the middle distillate range and preferably below about OS 725°F and above about 300°F. The process can maintain conversion levels in excess of about 50$ per pass at selectivities in excess of 60$ to middle distillate prod-ucts boiling between 300°F (149°C) and 725°F
(385°C). The pour point of the middle distillate effluent obtained by the process will be below about 0°F and preferably below -20°F.
The process can be operated as a single-stage hydroprocessing zone. It can also be the second stage of a two-stage hydrocracking scheme in which the first stage removes nitrogen and sulfur from the feedstock before contact with the middle distillate-producing catalyst.
The catalyst can also be used in the first stage of a multistep hydrocracking scheme. In operation as the first stage, the middle distillate-producing zone also denitri-lU fies and desulfurizes the feedstock; in addition, it allows the second stage using the same catalyst or a con-ventional hydrocracking catalyst to operate more effi-ciently so that more middle distillates are produced overall than in other process configurations.
In the process of the invention, the hydrocarbon feedstock is heated with the catalyst under conversion conditions which are appropriate for hydrocracking.
During the conversion, the aromatics and naphthenes which are present in the feedstock undergo hydrocracking reac-j0 tions such as de alkyl at ion, ring opening, and cracking, followed by hydrogenation. The long-chain paraffins, which are present in the feedstock, underg o mild cracking reactions to yield non-waxy products of higher molecular weight than compared to products obtained using the prior art dewaxing zeolitic catalysts such as ZSM-5, and at the same time, a measure of isomerization takes place so that not only is the pour point reduced by reason of the cracking reactions described above, but in addition the n-paraffins become isomerized to isoparaffins ~to form liquid-range materials which contribute to low viscosity, lower pour point products.
05 The feedstock for the process of the invention comprises a heavy hydrocarbon oil such as a gas oil, coker tower bottoms fractions, reduced crude, vacuum tower bottoms, deasphalted vacuum resids, FCC tower bottoms, or cycle oils. Oils derived from coal, shale, or tar sands may also be treated in this way. Oils of this kind gener-ally boil above 600°F (316°C) although the process is also useful with oils which have initial boiling points as low as 436°F ( 260°C) . Preferably at least 90% of the feed will boil above 600°F (316°C) and most preferably at least about 90% of the feed will boil between 700°F (371°C) and about 1200°F (649°C). These heavy oils comprise high molecular weight long-chain paraffins and high molecular weight ring compounds with a large proportion of fused ring compounds. During the processing, both the fused ZO ring aromatics and naphthenes and paraffinic compounds are cracked by the SM-3 containing catalyst to middle distil-late range products. A substantial fraction of the paraffinic components of the initial feedstock also under-go conversion to isoparaffins.
Th a process is of particular utility with highly paraffinic feeds because, with feeds of this kind, the greatest improvement in pour point may be obtained. How-ever, most feeds will contain a certain content of poly-cyclic compounds.
The process enables heavy feedstocks, such as g as oils, boiling above 600°F to be more selectively con-verted to middle distillate range products having improved pour points in contrast to prior processes using large pore catalysts, such as zeolite Y.
j5 The hydrocracking catalysts contain an effective amount of at least one hydrogenation catalyst (component) of the type commonly employed in hydrocracking catalysts.
The hydrogenation component is generally selected from the group of hydrogenation catalysts consisting of one or more metals of Group VIB and Group VIII, including the salts, _ 2029$7 -21_ complexes. and solutions containing such. The hydrog ena-tion catalyst is preferably selected from the group of 05 metals, salts, and complexes thereof of the group con-sisting of at least one of platinum, palladium, rhodium, iridium, and mixtures thereof or the group consisting of at least one of nickel, molybdenum, cobalt, tungsten, titanium, chromium, and mixtures thereof. Reference to the catalytically active metal or metals is intended to encompass such metal or metals in the elemental state or in some form such as an oxide, sulfide, halide, carboxy-late, and the like.
The hydrogenation catalyst is present in an effective amount to provide the hydrogenation function of the hydrocracking catalyst, and preferably in the range of from 0.05 to 25% by weight.
The SM-3 may be employed in conjunction with traditional hydrocracking catalysts, e.g., any alumi-1U nosilicate heretofore employed as a component in hydro-cracking catalysts. Representative of the zeolitic aluminosilicates disclosed heretofore as employable as component parts of hydrocracking catalysts are Zeolite Y
(including steam stabilized, e.g., ultra-stable Y), Zeolite X, Zeolite beta (U. S. Patent No. 3,308,069), Zeolite ZK-20 (U.S. Patent No. 3,445,727), Zeolite ZSM-3 (U. S. Patent No. 3,415,736), faujasite, LZ-10 (U. K.
Patent 2,014,970, June 9, 1982), ZSM-5-type zeolites, e.g., 2SM-5, ZSM-11. ZSM-12, ZSM-23, ZSM-35, ZSM-38, ZSM-48, crystalline silicates such as silicalite (U. S.
Patent No. 4,061,724), erionite, mordenite, offretite, chabazite, FU-1-type zeolite, NU-type zeolites, LZ-210-type zeolite, and mixtures thereof. Traditional crack ing catalysts containing amounts of Na20 less than 3S about 1% by weight are generally preferred. The relative amounts of the SM-3 component and traditional hydrocrack-ing component, if any, will depend, at least in part, on the selected hydrocarbon feedstock and on the desired product distribution to be obtained therefrom, but in all instances an effective amount of SM-3 is employed. When a of 20'~298'~ -22-traditional hydrocracking catalyst (THC) component is employed, the relative weight ratio of the TF3C to the SM-3 OS is generally between about 1:10 and about 500:1, desirably between about 1:10 and about 200:1, preferably between about 1:2 and about 50:1, and most preferably is between about 1:1 and about 20:1.
The hydrocracking catalysts are typically employed with an inorganic oxide matrix component which may be any of the inorganic oxide matrix components which have been employed heretofore in the formulation of hydro-cracking catalysts including: amorphous catalytic inor-ganic oxides, e.g., catalytically active silica-aluminas, clays, silicas. aluminas, silica-aluminas, silica-zirco-nias, silica-magnesias, alumina-borias, alumina-titanias and the like, and mixtures thereof . The traditional hydrocracking catalyst and SM-3 may be mixed separately with the matrix component and then mixed or the THC compo-lU nent and SM-3 may be mixed and then formed with the matrix component.
SM-3 can be used in a process to dewax hydrocar-bonaceous feeds. The catalytic dewaxing conditions are dependent in large measure on the feed used and upon the ~5 desired pour point. Generally, the temperature will be between about 200°C and about 475°C, preferably between about 250°C and about 450°C. The pressure is typic ally between about 15 psig and about 3000 psig, preferably between about 200 psig and 3000 psig. The liquid hourly 30 space velocity (LHSV) preferably will be from 0.1 to 20, preferably between about 0.2 and about 10.
Hydrogen is pref erably present in the react ion zone during the catalytic dewaxing process. The hydrogen to feed ratio is typically between about 500 and about 35 30,000 SCF/bbl (standard cubic feet per barrel), prefer-ably about 1000 to about 20,000 SCF/bbl. Generally, hydrogen will be separated from the product and recycled to the reaction zone.
It has been found that the present process pro-40 vides selective conversion of waxy n-paraffins to non-waxy 2~7~~8°~

paraffins. During processing the waxy paraffins undergo mild cracking reactions to yield non-waxy products of OS higher molecular weight than compared to products obtained using the prior art zeolitic catalyst. At the same time, a measure of isomerization takes place, so that not only is the pour point reduced by reason of the cracking reac-tions described above, but in addition the n-paraffins become isomerized to iso-paraffins to form liquid range materials which contribute to a low viscosity, low pour point product.
The present process may be used to dewax a variety of feedstocks ranging from relatively light dis-tillate fractions up to high boiling stocks such as whole crude petroleum, reduced crudes, vacuum tower residua, cycle oils, synthetic crudes (e. g., shale oils, tar sand oils, etc.). gas oils, vacuum g as oils, foot oils, and other heavy oils. The feedstock will normally be a C10+
lU feedstock generally boiling above about 350°F since lighter oils will usually be free of significant quanti-ties of waxy components. However, the process is parti-cularly useful with waxy distillate stocks such as middle distillate stocks including gas oils, kerosenes, and jet fuels, lubricating oil stocks, heating oils and other distillation fractions whose pour point and viscosity need to be maintained within certain specification limits.
Lubricating oil stocks will generally boil above 230°C
(.450°F), more usually above 315°C (600°F).
Hydroprocessed stocks which include stocks which have been hydrotreated to lower metals, nitrogen and sulfur levels and/or hydro-cracked, are a convenient source of stocks of this kind and also of other distillate fractions since they normally contain significant amounts of waxy n-paraffins. The j5 feedstock of the present process will normally be a C10+
feedstock containing paraffins, olefins, naphthenes, aro-matics, and heterocyc.lic compounds and with a substantial proportion of higher molecular weight n-paraffins and slightly branched paraffins which contribute to the waxy ,0 nature of the feedstock. During the processing, the 2 ~0'~ 2 9 ~'~

n-paraffins and the slightly branched paraffins undergo some cracking or hydrocracking to form liquid range mate-05 rials which contribute to a low viscosity product. The degree of cracking which occurs is, however, limited so that the gas yield is reduced, thereby preserving the economic value of the feedstock.
Typical feedstocks include light gas oils, heavy gas oils, and reduced crudes boiling above 350°F.
While the process herein can be practiced with utility when the feed contains organic nitrogen (nitrogen-containing impurities), it is preferred that the organic nitrogen content of the feed be less than 50, more prefer-ably less than 10, ppmw.
When used in the present process, the SM-3 is employed in admixture with at least one Group VIII metal as, for example, the noble metals such as platinum and palladium, and optionally other catalytically active 2U metals such as molybdenum, vanadium, zinc, etc. The amount of metal ranges from about 0.01% to 10% and prefer-ably 0.2 to 5% by weight of the molecular sieve.
The Group VIII metal utilized in the process of this invention can mean one or more of the metals in its elemental state or in some form such as the sulfide or oxide and mixtures thereof. As is customary in the art of catalysis, when referring to the active metal or metals, it is intended to encompass the existence of such metal in the elementary state or in some form such as the oxide or sulfide as mentioned above, and regardless of the state in which the metallic component actually exists, the concen-trations are computed as if they existed in the elemental state.
The SM-3 silicoaluminophosphate molecular sieve 3S can be composited with other materials resistant to the temperatures and other conditions employed in the dewaxirg process. Such matrix materials include active and inac-tive materials and synthetic or naturally occurring zeo-lites as well as inorganic materials such as clays, silica, alumina, and metal oxides. Examples of zeolites include synthetic and natural faujasites (e.g., X and Y), erionites, mordenites, and those of the ZSM series, e.g., OS ZSM-5, etc. The combination of zeolites can also be com-posited in a porous inorganic matrix.
SM-3 can be used in a process to prepare lubri-cating oils. The process comprises (a) hydrocracking in a hydrocracking zone a hydrocarbonaceous feedstock to obtain an effluent comprising a hydrocracked oil; and (b) cata-lytically dewaxing in a catalytic dewaxing zone the hydro-cracked oil of step (a) with a catalyst comprising a crystalline silicoaluminophosphate SM-3 and a Group VIII
metal, preferably platinum or palladium.
t5 Another embodiment of this process includes an additional step of stabilizing said dewaxed hydrocrackate by catalytic hydrofinishing.
The hydrocarbonaceous feeds from which lube oils are made usually contain aromatic compounds as well as lU normal and branched paraffins of very long chain lengths.
These feeds usually boil in the g as oil range. Preferred feedstocks are vacuum gas oils with normal boiling ranges in the range of 350°C to 600°C, and deasphalted residual oils having normal boiling ranges from about 480°C to 25 650°C. Reduced topped crude oils, shale oils, liquified coal, coke distillates, flask or thermally cracked oils, atmospheric residua, and other heavy oils can also be used. The first step in the processing scheme is hydro-cracking. In commercial operations, hydrocracking can 30 take place as a single-step process, or as a multistep process using initial denitrification or desulfurization steps, all of which are well known.
Typically, hydrocracking process conditions include temperatures in the range of 250°C to 500°C, pres-35 sures in the range of about 425 to 3000 psig, or more, a hydrogen recycle rate of 400 to 15,000 SCF/bbl, and a LHSV
(v/v/hr) of 0.1 to 50.
During the hydrocracking step there are conver-sions of at least 10% to products boiling below 350°C.
'0 Catalysts employed in the hydrocracking zone or zones m 2 p'~ 2 9 ~'~
include those having hydrogenation-dehydrogenation activity, and active cracking supports. The support is often a refractory inorganic oxide such as silica-alumina, OS
silica-alumina-zirconia and silica-alumina-titania com-posites, acid-treated clays, crystalline aluminosilicate zeolitic molecular sieves (such as 2eolite A, faujasite, Zeolite X, and Zeolite Y), and combinations of the above.
Hydrogenation-dehydrogenation components of the hydrocracking catalyst usually comprise metals selected from Group VII and Group VIB of the Periodic Table, ar;
compounds including them. Preferred Group VIII components include cobalt, nickel, platinum, and palladium, particu-larly the oxides and sulfides of cobalt and nickel. Pre-ferred Group VIB components are the oxides and sulfides of molybdenum and tungsten. Thus, examples of hydrocracking catalysts which are preferred for use in the hydrocracking step are the combinations nickel-tungsten-silica-alumina 10 and nickel-molybdenum-silica-alumina.
A particularly preferred hydrocracking catalyst for use in the present process is nickel sulfide/tungsten sulfide on a silica-alumina base which contains discrete metal phosphate particles (described in U.S. Patent No. 3,493,517, incorporated herein by reference).
The nitrogen content of the hydrocrackate is as low as is consistent with economical refinery operations, but is preferably less than 50 ppm (w/w), and more prefer-ably less than about 10 ppm (w/w), and most preferably less than about 1 ppm (w/w).
The hydrocracking step yields two significant benefits. First, by lowering the nitrogen content, it dramatically increases the efficiency and ease of the catalytic dewaxing step. Second, the viscosity index is 3S 9 neatly increased as the aromatic compounds present in the feed, especially the polycyclic aromatics, are opened and hydrogenated. In the hydrocracking step, increases of at least 10 VI units will occur in the lube oil fraction, i.e. , that fraction boiling above 230°C and more prefer-ably abov a 315°C.

20'~298'~
The hydrocrackate is preferably distilled by conventional means to remove those products boiling below OS 230°C, and more preferably below 315°C to yield one or more lube oil boiling range streams. Depending upon the particular lube oil desired, for example, a light, medium, or heavy lube oil, the raw hydrocrackate may be distilled into light, medium, or heavy oil fractions. Among the lower boiling products removed are light nitrogen containing compounds such as NH3. This yields a lube oil stream with a reduced nitrogen level, so that th a SM-3 crystalline silicoaluminophosphate molecular sieve in the dewaxing catalyst achieves maximum activity in the dewaxing step. Lubricating oils of different boiling ranges can be prepared by the process of this invention.
These would include light neutral, medium neutral, heavy natural, and bright stock, where the neutral oils are prepared from distillate fractions and bright stock from 2U residual fractions.
The great efficiency of the present invention comes in part from the combination of hydrocracking to produce a very low nitrogen, high viscosity index stock which is then extremely efficiently dewaxed to achieve a Z5 very low pour point and improved viscosity and viscosity index. It can be appreciated that the higher the activity of the dewaxing catalyst, the lower the reactor tempera-ture necessary to achieve a particular degree of dewaxing.
A sig nif icant benef it is, therefore, the greater energy 30 savings from using the enhanced efficiency catalyst and usually longer cycle life. Additionally, since the SM-3 crystalline silicoaluminophosphate dewaxing catalyst is shape-selective, it reacts preferentially with the waxy components of the feedstock responsible for high pour 35 points, i.e., the normal paraffins as well as the slightly branched paraffins and alkyl-substituted cycloparaffins which comprise the so-called microcrystalline wax.
When used in the present process, the SM-3 sili-coaluminophosphate is preferably employed in admixture 40 with at least one of the noble metals platinum, palladium, and optionally other catalytically active metals such as molybdenum, nickel, vanadium, cobalt, tungsten, zinc, OS etc. , and mixtures thereof. The amount of metal ranges from about 0.01% to 10% and preferably 0.2 to 5% by weight of the molecular sieve.
The metal utilized in the process of this inven-tion can mean one or more of the metals in its elemental state or in some form such as the sulfide or oxide and mixtures thereof. As is customary in the art of catal-ysis, when referring to the activ a metal or metals it is intended to encompass the existence of such metal in the elementary state or in some form such as the oxide or sulfide as mentioned above, and regardless of the state in which the metallic component actually exists the concen-trations are computed as if they existed in the elemental s tate.
The dewaxing step may be carried out in the same 1U reactor as the hydrocracking step but is preferably car-ried out in a separate reactor. The catalytic dewaxirg conditions are dependent in large measure on the feed used and upon the desired pour point. Generally, the tempera-ture will be between about 200°C and about 475°C, prefer-ably between about 250°C and about 450°C. The pressure is typically between about 15 psig and about 3000 psig, pre-ferably between about 200 prig and 3000 psig. The liquid hourly space velocity (LHSV) preferably will be from 0.1 to 20, preferably between about 0.2 and about 10.
Hydrogen is preferably present in the reaction zone during the catalytic dewaxing process. The hydrogen to feed ratio is typically between about 500 and about 30,000 SCF/bbl (standard cubic feet per barrel), prefera-bly about 1,000 to about 20,000 SC F/bbl. Gener ally, 3S hYdrog en will be separated from the product and recycled to the reaction zone.
The SM-3 crystalline silicoaluminophosphate catalyst used in the dewaxing step provides selective conversion of the waxy components to non-waxy components.
,0 During processing the waxy paraffins undergo mild cracking -29_ reactions to yield non-waxy products of higher molecular weight than compared to products obtained using the prior OS art zeolite catalysts. At the same time, a measure of isomerization takes place so that not only is the pour point reduced by reaso n of the cracking reactions described above, but in addition the waxy components become isomerized to form liquid range materials which contribute to a low viscosity, low pour point product having excellent VI properties.
The SM-3 crystalline silicoaluminophosphate molecular sieve can be composited with other materials resistant to the temperatures and other conditions employed in the dewaxing process. Such matrix materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic mate-rials such as clays, silica, alumina, and metal oxides.
Examples of zeolites include synthetic and natural 1U faujasites (e.g., X and Y), erionites, mordenites, and those of the ZSM series, e.g., ZSM-5, etc. The combina-tion of zeolites can also be composited in a porous inor-ganic matrix.
It is often desirable to use mild hydrogenation (sometimes referred to as hydrofinishing) to produce more stable lubricating oils.
The hydrofinishing step can be performed either before or after the dewaxing step, and preferably after.
H.ydrof finishing is typically conducted at temperatures ranging from about 190°C to about 340°C at pressures from about 400 psig to about 3000 psig at space velocities (LHSV) between about 0.1 and 20 and hydrogen recycle rates of 400 to about 1500 SCF/bbl. The hydrogenation catalyst employed must be active enough not only to hydrogenate the 3S olefins, diolefins, and color bodies within the lube oil fractions, but also to reduce the aromatic content. The hydrofinishing step is beneficial in preparing an accepta-bly stable lubricating oil since lubricant oils prepared from hydrocracked stocks tend to be unstable to air and light and tend to form sludges spontaneously and quickly.

Suitable hydrogenation catalysts include conventional metallic hydrogenation catalysts, particularly the Group VIII metals such as cobalt, nickel, palladium., and platinum. The metal is typically associated with Garners such as bauxite, alumina, silica gel, silica-alumina composites, and crystalline aluminosilicate 5 zeolites. Palladium is a particularly preferred hydrogenation metal. If desired, non-noble Group VIII metals can be used with molybdates. Metal oxides or sulfides can be used. Suitable catalysts are detailed, for instance, in U.S. Patent Nos.
3,852,207;
4,157,294; 3,904,153; and 4,673,487.
The improved process of this invention will now be illustrated by 10 examples which are not to be construed as limiting the invention as described in this specification including the attached claims.
EXAMPLES
Examples 1-5 Five preparations of SM-3 were made which had bulk Si02/A1203 15 ratios of 0.375 ~ 0.005 but different surface ratios. These were made as follows:
Example 1. 231.2 g of 85% R3p04 were added to 118 g of distilled H20 in a Teflon beaker, with the beaker in an ice bath. 408.4 g of aluminum isopropoxide (AlfUC3H,13) were slowly added with mixing and then mixed until homogeneous. Then 38 g of fumed silica (Cabosil M-5) in 168 g of distilled water 20 were added with mixing. Next, 91.2 g of di-n-propylamine (PrzNH) were added followed by mixing with a Polytron. The mixture had a pH of 6.0 and the following composition, expressed in molar ratios of oxides:
0.9Pr2NH:0.6 Si02:A1203:P20518 H20 The mixture was placed in a Teflon bottle in a stainless steel pressure vessel and 25 heated for 5 days at 200°C with no stirnng and autogenous pressure.
The supernatant liquid was removed and the product was filtered, washed of -31- 20'2987 with water, dried overnight at 127°C, and calcined in air for 8 hours at 538°C. The average crystallite size was 05 less than 0.5 micron.
Example 2. 462.4 g of 85% H3P04 were added to 236 g of distilled water in a Teflon beaker, with the beaker cooled in an ice bath. 816.8 g of A1(OC3H7)3 were slowly added with mixing and then mixed until homogene-ous. Then 120 g of Cabosil HS-5 in 480 g of distilled water were added with mixing and mixed for 15 minutes.
182.4 g of di-n-propylamine were then added and mixed for about 15 minutes. The mixture had a pH of 6.4 and the following composition, expressed in molar ratios of oxides:
0.9 Pr2NH:Si02:A1203:p205:22 H20 The mixture was placed in a Teflon bottle in a stainless 1U steel pressure vessel and heated for 5 days at 200°C with no stirring and autog enous pressure. The supernatant liquid was removed and the product was filtered, washed with water, dried for 8 hours at 121°C, and calcined in air for 8 hours at 566°C. The average crystallite size was less than 0.5 micron.
Example 3. 231.2 g of 85% H3P04 were added to 238 g of distilled H20 in a Teflon beaker, with the beaker in an ice bath. 408.4 g of A1(OC3H7)3 were slowly added with mixing and then mixed until homogeneous with a Polytron. 60 g of Cabosil M-5 were added with mixing and mixed until homogeneous. Then 91.2 g of di-n-propylamine were added with mixing. The pH of the mixture was then adjusted to 6.5 using concentrated HC1. The mixture had a composition, expressed in molar ratios of oxides, of:
0.9 Pr2NH:Si02:A1203:P205:15 H20 The mixture was placed in a stainless steel pressure vessel with a Teflon insert and heated for 8 days at 200°C
with no stirring and autogenous pressure. The supernatant liquid was removed and the product was filtered, washed with water, dried overnight at 121°C, and calcined in air for 8 hours at 593°C. The average crystallite size was OS
less than 0.5 micron.
Example 4. 472.4 g of 85% H3P04 were added to 1208 g of distilled H20 in a Teflon beaker, with the beaker in an ice bath. 816.8 g of A1(OC3H7)3 were added slowly with mixing and then mixed with a Polytron until homogeneous. 120 g of Cabosil M-5 were added with mixing and then mixed for an additional 15 minutes. 182.4 g of di-n-propylamine were added with mixing and mixed an addi-tional 15 minutes. Then an additional 9.6 g of 85% H3P04 were added with mixing. The mixture had a pH of 6.5 and a composition, expressed in molar ratios of oxides, of:
0.9 Pr2NH:Si02:A1203:1.04 P205:36 H20 2U The mixture was placed in a Teflon bottle in a stainless steel pressure vessel and heated for S days at 200°C with no stirring and autogenous pressure. The supernatant liquid was removed and the product was filtered, washed with water, dried overnight at 121°C, and then calcined in air for 8 hours at 566°C. The average crystallite size was less than 0.5 micro n.
Example 5. 472.4 g of 85% H3p04 were added to 1208 g of distilled H20 in a Teflon beaker, with the beaker in an ice bath. 816.8 g of Al(OC3H7)3 were slowly added with mixing and then mixed with a Fblytron until homogeneous. 120 g of Cabosil M-5 were added with mixing and mixed an additional 15 minutes. 182.4 g of di-n-pro-pylamine were then added and mixed for 15 minutes. An additional 30 g of 85% H3p04 were then added with mixing.
3S The mixture had a pH of 6.5 and a composition, expressed in molar ratios of oxides, of:
0.9 Pr2NH:1.0 Si02:A1203:1.09 P205:36 H20 _3 Th mixture was placed in a Teflon bottle in a stainless steel pressure vessel and heated for 5 days at 200°C with 05 no stirring and autogenous pressure. The supernatant liquid was removed and the product was filtered, washed with water, dried overnight at 121°C, and calcined in air for 8 hours at 566°C. The average crystallite s ize was less than 0.5 micron.
The X-ray diffraction pattern for each of Examples 1-5 as synthesized and as calcined were charac-teristic of SAPO-11 as disclosed in Tables I and II, respectively, and in U.S. Patent No. 4,440,871.
The sieves of Examples 1-5 were impregnated with 1 wt % Pt by the pore-f ill method usi ng an aqueous solu-tion of Pt(NH3)4(N03)2. The sieves were dried overnight at 121°C and calcined in air for 4 hours at 204°C and 4 hours at 454°C. They were then tested in a C8 Activity Test, performed as follows:
1U 0~5 g of 24 x 42 mesh catalyst is placed in a 3/16-inch-I. D. stainless steel reactor with the remaining space filled with acid-washed and neutralized 24-mesh alundum. The reactor is placed in a clam-shell furnace of a hig h-pressure continuous flow pilot plant equipped with a sampling v aloe and a Hewlett Packard 5880 gas chromato-g raph using a capillary column. The catalyst is tested at 1000 psig, 2.8 WHSV, and 16 H2/HC with a feed consisting of a 50/50 by weight mixture of 2,2,4-trimethylpentane and n-octane. The reactor temperature is adjusted to provide a nC8 conversion of 40%.
The C8 Activity Test gives information as to the activity of the catalyst.
ESCA analysis of the sieves of Examples 1-5 prior to impregnation with platinum are given in 3S Table III.
Also, the results of the Activity Tests on the sieves after impregnation with platinum and calcination are given in Table III.

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Examples 6-9 The preparations of Examples 6, 7 and 8 below 05 were made in which the reaction mixture had the molar composition, expressed as oxides, of:
0.9 Pr2NH:0.6 Si02:A1203:P205:bH20 where b was varied. The product Si02/A1203 bulk ratio was 0.20 t 0.02. Example 9 below corresponds to Example 17 of U.S. Patent No. 4,440,877.
Example 6. 115.6 g of 85$ H3P04 were added to 59 g of distilled water in a Teflon beaker, with the beaker in an ice bath. 204.2 g of A1(OC3H7)3 were slowly added with mixing and then mixed until homogeneous. Then 19 g of Cabosil M-5 in 42 g of distilled H20 were added with mixing. 45.6 g of di-n-propylamine were added and mixed with a Polytron. The mixture had a pH of 6.0 and an 10 H20/A1203 molar ratio of 13. The mixture was placed in a Teflon bottle in a stainless steel pressure vessel and heated for 5 days at 200°C with no stirring and autogenous pressure. The supernatant liquid was removed and the product Was filtered, washed with water, dried overnight at 121°C, and calcined for 8 hours in air at 538°C. The average crystallite size was less than 0.5 micron.
Example 7. SM-3 was prepared as in Example 6, but enough distilled water was added to th a H3P04 to bring the mixture H20/A1203 molar ratio up to 33. The reaction mixture pH was 6.1. The average crystallite size was about 0.5 micron.
Comparative Example 8. A sieve was prepared as in Example 6, but enough distilled water was added to the H3P04 to bring the mixture H20/A1203 molar ratio up to 62 and outside the range of the invention. The reaction mixture pH (7.5) was lowered to 6.5 by addition of concen-trated HC1. The average crystallite size was in the range of 0.5 micron.
~0 Comparative Example 9. A SAPO-11 silicoalumino-phosphate was prepared following the procedure of 05 Example 17 of U.S. Patent No. 4,440,871, using two times the quantities of materials as indicated therein. The reaction mixture pH was 10.7. The average crystallite size was less than about 1 micron. The X-ray diffraction pattern for each of Examples 6-9 as synthesized and as calcined were characteristic of SAPO-11 as disclosed in Tables I and II respectively and in U.S. Patent No. 4,440,871.
The sieves of Examples 6-9 were impregnated with platinum and calcined as in Examples 1-5.
ESCA sieve analysis for Examples 6-9 prior to impregnation with platinum are shown in Table IV. Also, the Activity Test date for the sieves of Examples 6-9 after impregnation with platinum and calcination are shown in Table IV.

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The sieves of Examples 6 and 7, which are within the scope of the invention with respect to the P205/A1203 OS mole ratio and Si02/A1203 mole ratio in the bulk and at the surface show improved activity compared to Examples 8 and 9 which are outside the scope of this invention.

Claims (53)

1. A process for preparing a crystalline silicoaluminophosphate molecular sieve which comprises:
(a) preparing an aqueous reaction mixture containing a reactive source of SiO2, aluminum isopropoxide, phosphoric acid, and an organic templating agent, said reaction mixture having a composition expressed in terms of mole ratios of oxides of:

aR:Al2O3:0.9-1.2 P2O5:0.1-4.0 SiO2:bH2O
wherein R represents at least one organic templating agent; "a" has a value such that there are from 0.2 to 2 moles R per mole of alumina; "b" has a value such that there are 15 to 40 moles of H20 per mole of aluminum oxide; said reaction mixture having been formed by combining the alumina and phosphorus sources in the substantial absence of the silicon source, thereafter combining the resulting mixture with the silicon source, and then combining this mixture with the organic templating agent to form the complete reaction mixture;
(b) insuring the pH of the reaction mixture is from 6.0 to 8.5;
(c) heating the reaction mixture to a temperature in the range of from 170°C
to 240°C until crystals of silicoaluminophosphate are formed; and (d) recovering said crystals.

2. The process according to claim 1, wherein b has a value such that there are 15 to 36 moles of H2O per mole of alumina.

3. The process according to claim 1 or 2, wherein "a" has a value such that there are from 0.8 to 1.2 moles of R per mole of alumina.

4 The process according to any one of claims 1 to 3, wherein the organic template agent is selected from the group consisting of di-n-propylamine and di-isopropylamine or a mixture thereof.

5. The process according to any one of claims 1 to 3, wherein the organic template agent is di-n-propylamine.

6. The process according to any one of claims 1 to 5, wherein the pH is in the range of 6.0 to 8Ø

7. The process according to any one of claims 1 to 6, wherein the crystallite size of the recovered crystals is less than 1 µm.

8. The process according to any one of claims 1 to 7, wherein the average crystallite size of the recovered crystals is less than 0.5 µm.

9. The process according to any one of claims 1 to 8 wherein the temperature ranges from 200°C to 225°C.

10. A crystalline silicoaluminophosphate molecular sieve when produced in accordance with the process of any one of claims 1 to 9.

11. A crystalline silicoaluminophosphate molecular sieve having a characteristic X-ray powder diffraction pattern which contains at least the d-spacings of Table I, 20 d 100 x I/I0 9.4 ~ 9.65 9.41 ~ 9.17 m 20.3 ~ 20.6 4.37 ~ 4.31 m 21.0 ~ 21.3 4.23 ~ 4.17 vs 22.1 ~ 22.35 4.02 ~ 3.99 m 22.5 ~ 22.9 (doublet) 3.95 ~ 3.92 m 23.15 ~ 23.35 3.84 ~ 3.81 m-s m = 20-70 s = 70-90 s = 70 ~ 90 vs = 90 ~ 100 wherein the P2O5 to alumina mole ratio at the surface of the silicoaluminophosphate is 0.80 or less, the P2O5 to alumina mole ratio in the bulk of the silicoaluminophosphate is 0.96 or greater, and the SiO2 to alumina mole ratio at the surface is greater than in the bulk of the silicoalumino-phosphate.

12. The crystalline silicoaluminophosphate molecular sieve according to claim or 11 having a composition in terms of mole ratios of oxides on an anhydrous basis expressed by the formula:

mR:A12O3:n P2O5 qSi02 wherein "R" is as defined above and is present in the intracrystalline pore system; "m"
represents the moles of R present and has a value such that there are from 0.02 to 2.0 moles of R per mole of aluminum; n has a value of from 0.96 to 1.1, and q has a value of from 0.1 to 4.

13. The crystalline silicoaluminophosphate molecular sieve according to claim 12, wherein m has a value of from 0.4 to 1.5; n has a value of from 0.96 to 1; and q has a value of from 0.1 to 1.

14. The crystalline silicoaluminophosphate molecular sieve according to any one of claims 10 to 13, wherein the P2O5 to alumina mole ratio at the surface is in the range of from 0.80 to 0.55 and the P2O5 to alumina mole ratio in the bulk is in the range of from 0.96 to 1.

15. A silicoaluminophosphate resulting from thermal treatment by heating the crystalline silicoaluminophosphate molecular sieve of any one of claims 10 to 14 at a temperature of 300°C to 1000°C for at least 1 minute.

16. The silicoaluminophosphate according to claim 14 having the characteristic x-ray powder diffraction pattern shown in Table II.

20 d 00 x I/I0 8.1 10.92 m 9.85 8.98 m 12.8 6.92 m 16.1 5.5 m 21.95 4.05 vs 22.3 ~ 22.5 3.99 ~ 3.95 m 23.5 3.786 m

17. The silicoaluminophosphate according to any one of claims 10 to 16 which further contains rare earth metals, Group IIA metals, Group VI or Group VIII
metals.

18. The silicoaluminophosphate according to any one of claims 10 to 17 which has undergone ion exchange with hydrogen, ammonium, rare earth metal, Group IIA
metal, Group VI or Group VIII metal ions.

19. The silicoaluminophosphate according to any one of claims 10 to 17 wherein rare earth metals, Group IIA metals, Group VI or Group VIII metals are occluded in the silicoaluminophosphate.

20. The silicoaluminophosphate according to any one of claims 10 to 17 wherein rare earth metals, Group IIA metals, Group VI or Group VIII metals are impregnated in the silicoaluminophosphate.

21. A silicoaluminophosphate composition comprising the silicoaluminophosphate of any one of claims 10 to 20 and an inorganic matrix.

22. A process for converting hydrocarbons comprising contacting a hydrocarbonaceous feed at hydrocarbon converting conditions with the silicoaluminophosphate of any one of claims 10 to 20 or the silicoaluminophosphate composition of claim 21.

23. The process of Claim 22 for selectively producing middle distillate hydrocarbons by hydrocracking and isomerizing a hydrocarbonaceous feed wherein at least 90% of said feed has a boiling point above about 315°C
(600°F) comprising:
(a) contacting under hydrocracking conditions said hydrocarbonaceous feed with a catalyst comprising the crystalline silicoaluminophosphate molecular sieve and at least one hydrogenation component; and (b) recovering a hydrocarbonaceous effluent wherein more than about 40% by volume of said effluent boils above about 148°C (300°F) and below about 385°C
(725°F) and has a pour point below -17.8°C (O°F)

24. The process of Claim 23 wherein the hydrogenation component is platinum.

25. The process of Claim 23 wherein the hydrogenation component is palladium.

26. The process of Claim 23, wherein the hydrogenating component is present in the range of 0.01%. to 10%. based on the weight of molecular sieve.

27. The process of Claim 23 wherein said process is conducted at a temperature of from about 260°C to 482°C, a pressure of about 200 psig to about 3000 psig, a liquid hourly space velocity of from about 0.1 hr-1 to about 20 hr-1 , and a hydrogen circulation rate of from 400 to 15,000 SCF/bbl.

28. The process of Claim 23 wherein said catalyst further comprises an inorganic oxide matrix.

29. The process of Claim 23 wherein said matrix is alumina.

30. The process of Claim 23 wherein said catalyst further comprises a nickel, cobalt, molybdenum, or tungsten component, or mixtures thereof.

31. The process of Claim 23 wherein said feed is a gas oil.

32. The process as in Claim 23, wherein said feed has a content of nitrogen-containing impurities, calculated as nitrogen, which is below 10 ppm.

33. The process as in Claim 23, wherein said hydrocarbon feed is selected from the group consisting of petroleum distillates, solvent deasphalted residua, and shale oils.

34. The process of Claim 23, wherein greater than 50% by weight of converted product boils above 148 (300°F) and below 385°C (725°F).

35. A process of Claim 23 wherein said catalyst is disposed downstream of a reaction zone in which a hydrocarbon feed is contacted under hydroprocessing conditions with an active hydrodenitrogenation catalyst.

36. A process as in Claim 35 wherein said hydrodenitrogenation catalyst is disposed in a single reactor with said catalyst.

37 The process of Claim 22 for catalytically dewaxing a hydrocarbon oil feedstock boiling above about 176°C (350°F) and containing straight-chain and slightly branched-chain hydrocarbons, which comprises contacting said hydrocarbon oil feedstock with a catalyst comprising the crystalline silicoaluminophosphate molecular sieve and at least one Group VIII metal.

38 The process of Claim 37 wherein the Group VIII metal is selected from the group consisting of platinum and palladium.

39. The process of Claim 38 wherein the metal is platinum.

40. The process of Claim 38 wherein the Group VIII metal is present in the range of 0.01 % to 10% based on the weight of molecular sieve.

41. The process of Claim 37 wherein said process is conducted at a temperature of from about 200°C to 475°C, a pressure of about 15 psig to about 3000 psig, a liquid hourly space velocity of from about 0.1 hr-1 to about 20 hr -1 and a hydrogen circulation rate of from 500 to about 30,000 SCF/bbl.

42. The process of Claim 37 wherein the feedstock is a middle distillate oil.

43. The process of Claim 37 wherein the feedstock is a lube oil.

44. The process of Claim 37 wherein the feedstock contains less than 50 ppm of nitrogen.

45. The process of Claim 37 wherein the feedstock contains less than 10 ppm of nitrogen.

46. The process of Claim 22 for preparing a lubricating oil which comprises:
(a) hydrocracking in a hydrocracking zone a hydrocarbonaceous feedstock to obtain an effluent comprising a hydrocracked oil; and (b) catalytically dewaxing in a catalytic dewaxing zone the hydrocracked oil with a catalyst comprising a crystalline silicoalumino-phosphate molecular sieve according to Claim 10 and a Group VIII metal.

47. The process of Claim 46 wherein said metal is platinum or palladium.

48. The process of Claim 46 wherein the hydrocracked oil to be dewaxed contains less than 50 ppm by weight nitrogen.

49. The process of Claim 46 wherein the hydrocracked oil to be dewaxed contains less than 10 ppm by weight of nitrogen.

50. The process of Claim 46 wherein the metal is present in the range of from 0.018 to 10% based on the weight of the molecular sieve.

51. The process of Claim 46 wherein the hydrocracking step is conducted at a temperature of from 250°C to 500°C, a pressure of about 425 psig to about 3000 psig, a liquid hourly space velocity of from about 0.1 hr-1 to about 50 hr-1, and a hydrogen circulation rate of from 400 to about 15,000 SCF/bbl.

52. The process of Claim 45 wherein the dewaxing step is conducted at a temperature of from about 200°C to 475°C, a pressure of about 15 psig to about 3000 psig, a liquid hourly space velocity of from about 0.1 hr-1, to about 20 hr-1, and a hydrogen circulation rate of from 500 to about 30,000 SCF/bbl.

53. The process of Claim 46 which further includes hydrogenating the dewaxed product over a hydrogenation catalyst under hydrogenation conditions.