Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
  • B01J29/7038—MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
  • B01J37/10—Heat treatment in the presence of water, e.g. steam
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B39/00—Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
  • C01B39/02—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof; Direct preparation thereof; Preparation thereof starting from a reaction mixture containing a crystalline zeolite of another type, or from preformed reactants; After-treatment thereof
  • C01B39/36—Pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
  • C01B39/38—Type ZSM-5
  • C01B39/40—Type ZSM-5 using at least one organic template directing agent
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C1/00—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon
  • C07C1/20—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon starting from organic compounds containing only oxygen atoms as heteroatoms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/10—After treatment, characterised by the effect to be obtained
  • B01J2229/18—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself
  • B01J2229/186—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself not in framework positions
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/30—After treatment, characterised by the means used
  • B01J2229/40—Special temperature treatment, i.e. other than just for template removal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/30—After treatment, characterised by the means used
  • B01J2229/42—Addition of matrix or binder particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/03—Catalysts comprising molecular sieves not having base-exchange properties
  • B01J29/035—Microporous crystalline materials not having base exchange properties, such as silica polymorphs, e.g. silicalites
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/20—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state
  • B01J35/23—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state in a colloidal state
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65

Definitions

• the present invention relates to a process for the production of a zeolitic material having an MFI, MEL, and/or MWW-type framework structure. Furthermore, the present invention relates to a zeolitic material having an MFI, MEL, and/or MWW-type framework structure as such and to its use in a process for the conversion of oxygenates to olefins. Finally, the present invention further relates to the use of a zeolitic material having an MFI, MEL, and/or MWW-type framework structure according to the present invention.
• zeolitic materials have proven of high efficiency, wherein in particular zeolitic materials of the pentasil- type and more specifically those having an MFI- and MEL-type framework structures including such zeolites displaying an MFI-MEL-intergrowth type framework structure are employed.
• EP 2 460 784 A1 relates to a method for producing propylene from an oxygen-containing compound using a catalyst which can keep its stable activity for a prolonged period of time in the manufacturing process.
• DD 238 733 A1 relates to a synthetic procedure for the preparation of selective olefin catalysts. Mcintosh et al. in Applied Catalysis 1983, vol. 6, pp.
• Liu et al. in Chemistry Letters 2007, vol. 36, pp. 916 and 917 concerns a synthetic procedure for the preparation of MWW-type metallosilicates under alkali-free conditions.
• the De Baerdemaeker et al. in Microporous and Mesoporous Materials 201 1 , vol. 143, pp. 477-481 concerns the synthesis of MTW-type zeolites which is performed in an alkali- free and fluoride-free synthetic procedure.
• pp. 1 -6 the synthesis of alkali-free Ga-substituted MCM-41 catalysts is described.
• the formation, in particular the diameter, of the zeolite crystals obtained via alkali-free processes can be tuned by adjusting the temperature, stirring rate, concentration of the synthesis mixture and the duration of the crystallization. This may be of importance to adjust the diffusion properties of the zeolite for specific catalytic applications and to allow for optimal shaping and properties of the resulting shaped bodies. In particular, appropriate shaped bodies often need to be prepared prior to the introduction of the catalyst into a reactor to carry out the catalytic transformation.
• DE 103 56 184 A1 relates to a zeolitic material of the pentasil type having a molar ratio of Si to Al of from 250 to 1500, wherein furthermore at least 90% of the primary particles of the zeolitic material are spherical, wherein 95% by weight thereof have a diameter of less than or equal to 1 ⁇ .
• said document discloses a specific treatment of ZSM-5 powder with demineralized water under autogeneous pressure, wherein it is taught that both the activity and the selectivity would be improved by the water treatment of the ZSM-5 powder under hydrothermal conditions when employed in a process for the preparation of tetraethylenediamine from piperazine and ethylenediamine.
• DE 41 31 448 A1 on the other hand concerns essentially alkali-free borous silicate crystals having a zeolite structure and a size from
• the present invention relates to a process for the production of a zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprising YO2 and X2O3, wherein said process comprises
• step (1 ) crystallizing the mixture obtained in step (1 ) to obtain a zeolitic material having an
• step (3) impregnating the zeolitic material obtained in step (2) with one or more elements selected from the group of alkaline earth metals;
• the mixture crystallized in step (2) contains 3 wt.-% or less of one or more elements M based on 100 wt.-% of YO2, wherein M stands for sodium.
• one or more sources for YO2 are provided in step (1 ).
• said one or more sources may be provided in any conceivable form provided that a zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprising YO2 can be crystallized in step (2).
• YO2 is provided as such and/or as a compound which comprises YO2 as a chemical moiety and/or as a compound which (partly or entirely) is chemically transformed to YO2 during the inventive process.
• YO2 and/or precursors thereof employed in the inventive process there is no particular restriction as to the one or more elements for which Y stands, provided that said element is a tetravalent element and that it is comprised in the zeolitic material having an MFI, MEL, and/or MWW-type framework structure crystallized in step (2).
• YO2 is at least partially and preferably entirely comprised in the MFI, MEL, and/or MWW-type framework structure of the zeolitic material as structure- building element, as opposed to non-framework elements which can be present in the pores and cavities formed by the framework structure and typical for zeolitic materials in general.
• Y may stand for any conceivable tetravalent element, Y standing either for a single or several tetravalent elements.
• Preferred tetravalent elements according to the present invention include Si, Sn, Ti, Zr, Ge, as well as any mixture of two or more thereof. According to preferred embodiments of the present invention, Y stands for Si.
• Y is selected from the group consisting of Si, Sn, Ti, Zr, Ge, and mixtures of two or more thereof, Y preferably being Si.
• the source for S1O2 preferably provided in step (1 ) can also be any conceivable source.
• any type of silicas and/or silicates and/or silica derivatives may be used, wherein preferably the one or more sources for YO2 comprises one or more compounds selected from the group consisting of fumed silica, silica hydrosols, reactive amorphous solid silicas, silica gel, silicic acid, water glass, sesquisilicate, disilicate, colloidal silica, pyrogenic silica, silicic acid esters, or mixtures of any two or more of the afore-mentioned compounds may equally be used.
• elemental silicon may also be employed.
• the one or more sources for YO2 used in step (1 ) of the inventive process are selected from the group consisting of fumed silica, silica hydrosols, reactive amorphous solids, reactive amorphous sold silicas, silica gel, colloidal silica, pyrogenic silica, tetraalkoxy silanes, including mixtures of any two or more thereof.
• the one or more sources for YO2 are selected from the group consisting of fumed silica, reactive amorphous solid silicas, silica gel, pyrogenic silica, tetraalkoxy silanes, and mixtures of two or more thereof, wherein more preferably the one or more sources for YO2 are selected from the group consisting of fumed silica, tetraalkoxy silanes, as well as mixtures of two or more thereof, wherein even more preferably according to the inventive process, the one or more sources for YO2 comprises one or more tetraalkoxy silanes.
• said one or more esters preferably have the composition wherein x is 0, 1 , 2, 3 or 4, may be used as S1O2 source, where R and R' may be different from one another and may each be hydrogen, Ci-Cs-alkyl, for example methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl or octyl, C 4 -C8-cycloalkyl, such as cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl, aryl, alkylaryl or arylalkyl, or where R and R' may be identical and may each be hydrogen, Ci-Cs-alkyl, for example methyl, e
• R' is hydrogen and R is Ci-Cs-alkyl, for example methyl, ethyl, n-propyl, isopropyl, n- butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl or octyl.
• the one or more sources for YO2 and in particular for S1O2 comprises one or more tetraalkoxysilanes
• said one or more sources comprises one or more compounds of the general composition
• R is Ci-Cs-alkyl, for example methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert- butyl, pentyl, hexyl, heptyl or octyl, more preferably methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl or tert-butyl, more preferably methyl, ethyl, n-propyl or isopropyl, more preferably methyl or ethyl, particularly preferably ethyl.
• the mixture provided in step (1 ) further comprises one or more sources for X2O3, wherein X is a trivalent element.
• X is a trivalent element.
• the elements which may be employed as the trivalent element X comprised in the one or more sources for X2O3 provided in step (1 ) there is no particular restriction according to the present invention as to which elements or element mixtures may be employed, provided that a zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprising YO2 and X2O3 as framework elements may be obtained by crystallization in step (2).
• X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, wherein preferably X is Al and/or B. According to particularly preferred embodiments of the present invention, X comprises Al, wherein even more preferably X is Al.
• YO2 comprised in the zeolitic material having an MFI, MEL, and/or MWW-type framework structure within the meaning of the present invention, X2O3 is also at least partially and preferably entirely comprised in the framework structure of the zeolitic material as structure- building element as opposed to non-framework elements which can be present in the pores and cavities formed by the framework structure and typical for zeolitic materials in general.
• X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, X preferably being Al and/or Ga, and more preferably being Al.
• the source for AI2O3 preferably provided in step (1 ) can also be any conceivable source. In principle, any conceivable compounds which permit the preparation of the zeolitic material according to the present invention may be used as the aluminum source.
• the one or more sources for AI2O3 may comprise one or more compounds selected from aluminum, aluminum alkoxides, alumina, aluminates, and aluminum salts.
• the use of aluminum nitrate, aluminum sulfate or a trialkoxyaluminate of the composition AI(OR)3 or a mixture of two or more of these compounds as aluminum source is particularly preferred.
• the radicals R may be identical or different from one another and are Ci-Cs-alkyl, for example methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl or octyl, C4-C8- cycloalkyl, such as cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl, aryl, alkylaryl or arylalkyl.
• Ci-Cs-alkyl for example methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, pentyl, hexyl, heptyl or octyl, C4-C8- cycloalkyl,
• the aluminum source used is aluminum sulfate.
• the aluminum salts preferably employed these may be used in their dehydrated form and/or as one or more hydrates or hyd rated forms thereof.
• the amount in which the one or more sources for YO2 and X2O3 may be provided in step (1 ) of the inventive process no particular restriction applies provided that a zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprising YO2 and X2O3 may be crystallized in step (2).
• the YO2 : X2O3 molar ratio of the mixture may range anywhere from 10 to 1 ,500, wherein preferably molar ratios are provided comprised in the range of from 30 to 1 ,200, more preferably from 50 to 900, more preferably from 70 to 700, more preferably from 80 to 500, and even more preferably of from 90 to 300.
• the YO2 : X2O3 molar ratio of the mixture provided in step (1 ) is comprised in the range of from 100 to 250.
• the YO2 : X2O3 molar ratio of the mixture prepared in step (1 ) ranges from 10 to 1 ,500, preferably from 30 to 1 ,200, more preferably from 50 to 900, more preferably from 70 to 700, more preferably from 80 to 500, more preferably from 90 to 300, and even more preferably from 100 to 250.
• the YO2 : X2O3 molar ratio of the mixture may range anywhere from 10 to 300, wherein preferably molar ratios are provided comprised in the range of from 30 to 220, more preferably from 50 to 180, more preferably from 70 to 150, more preferably from 90 to 120, and even more preferably of from 95 to 105.
• the YO2 : X2O3 molar ratio of the mixture may range anywhere from 50 to 500, wherein preferably molar ratios are provided comprised in the range of from 100 to 400, more preferably from 150 to 350, more preferably from 200 to 300, more preferably from 220 to 280, and even more preferably of from 240 to 260.
• the mixture provided in step (1 ) further comprises one or more solvents.
• the one or more solvents comprise one or more polar solvents, wherein the one or more polar solvents are preferably selected from the group consisting of alkanols, water, and mixtures of two or more thereof.
• the one or more solvents comprise one or more polar solvents selected from the group consisting of methanol, ethanol and/or propanol, iso-propanol, water, and mixtures of two or more thereof, and more preferably from the group consisting of methanol, ethanol, water, and mixtures of two or more thereof.
• the one or more solvents and in particular the one or more polar solvents comprise water, and more preferably, distilled water, wherein according to particularly preferred embodiments distilled water is used as the only solvent in the mixture provided in step (1 ) and crystallized in step (2).
• the one or more solvents comprise one or more polar solvents, wherein the one or more polar solvents are preferably selected from the group consisting of alkanols, water, and mixtures of two or more thereof.
• the mixture prepared according to step (1 ) is subsequently crystallized in step (2), wherein said mixture crystallized in step (2) contains 3 wt.-% or less of one or more elements M based on 100 wt.-% of YO2.
• M stands for sodium which may be present in the mixture prepared in step (1 ) and crystallized in step (2) of the inventive process.
• the mixture crystallized in step (2) contains 3 wt.-% or less of both sodium and potassium based on 100 wt.-% of YO2, M accordingly standing for sodium and potassium.
• the mixture prepared in step (1 ) and crystallized in step (2) also does not contain any further alkali metal elements besides sodium and potassium in an amount wherein the total amount of alkali metal elements in the mixture provided in step (1 ) would not exceed 3 wt.-% based on 100 wt.-% of YO2.
• the mixture provided in step (1 ) and crystallized in step (2) contains 3 wt.-% or less of alkali metal elements, wherein it is further preferred that said mixture contains 3 wt.-% or less of both alkali and alkaline earth metal elements. Therefore, according to preferred embodiments of the inventive process, M stands for sodium and potassium, and preferably for the group of alkali metals, wherein more preferably M stands for the group of alkali and alkaline earth metals.
• the mixture provided in step (1 ) and crystallized in step (2) contains less than 1 wt.-% of one or more elements M according to any of the particular or preferred embodiments of the present invention based on 100 wt.-% of YO2, and more preferably 0.5 wt.-% or less of one or more elements M based on 100 wt.-% of YO2, more preferably 0.1 wt.-% or less, more preferably 0.05 wt.-% or less, more preferably 0.01 wt.-% or less, more preferably 0.005 wt.-% or less, more preferably 0.001 wt.-% or less and more preferably 0.0005 wt.-% or less.
• the mixture provided in step (1 ) and crystallized in step (2) contains 0.0003 wt.-% or less of one or more elements M based on 100 wt.-% of YO2, wherein it is yet further preferred that the mixture crystallized in step (2) of the inventive process contains less than 0.0001 wt.-% of one or more elements M therein and is therefore substantially free of the one or more elements M according to any of the particular or preferred embodiments of the present invention.
• the mixture provided in step (1 ) and crystallized in step (2) further comprises one or more organotemplates.
• the one or more organotemplates comprise one or more compounds selected from the group consisting of tetraalkylammonium and alkenyltrialkylammonium compounds.
• alkyl moieties which may be comprised in the tetraalkylammonium and alkenyltrialkylammonium compounds, again no particular restriction applies in this respect provided that a zeolitic material having an MFI, MEL, and/or MWW-type framework structure may be crystallized in step (2).
• any conceivable alkyl moieties including combinations of two or more alkyl moieties may be contained in the respective one or more tetraalkylammonium and/or one or more alkenyltrialkylammonium compounds wherein preferably the alkyl moieties are selected from the group consisting of Ci- Cs-alkyl, more preferably from the group consisting of Ci-C6-alkyl, more preferably Ci-Cs-alkyl, and more preferably from the group consisting of Ci-C4-alkyl.
• the alkyl moieties respectfully comprised in the one or more tetraalkylammonium and/or alkenyltrialkylammonium compounds is selected from the group consisting of Ci-C3-alkyl.
• alkenyl moiety contained in the alkenyltrialkylammonium cation of the one or more alkenyltrialkylammonium compounds preferably comprised among the one or more organotemplates, again, no particular restriction applies in this respect provided that a zeolitic material having an MFI, MEL, and/or MWW-type framework structure may be crystallized in step (2).
• the alkenyl moiety of the alkenyltrialkylammonium cation is selected from the group consisting of C2-C6-alkenyl, more preferably from the group consisting of C2-Cs-alkenyl, more preferably C2- C4-alkenyl, and even more preferably from the group consisting of C2-C3-alkenyl.
• the alkenyl moiety of the alkenyltrialkylammonium cation comprised in the one or more alkenyltrialkylammonium compounds preferably comprised among the one or more organotemplates is 2-propene-1 -yl, 1 -propene-1 -yl, or 1 -propene-2-yl, wherein according to particularly preferred embodiments thereof, the alkenyl moiety is 2- propene-1 -yl or 1 -propene-1 -yl.
• the mixture in step (1 ) further comprises one or more organotemplates, the one or more organotemplates preferably comprising one or more compounds selected from the group consisting of tetraalkylammonium and alkenyltrialkylammonium compounds.
• the one or more organotemplates preferably comprised in the mixture prepared in step (1 ) comprises one or more tetraalkylammonium compounds
• said compounds are selected from the group consisting of tetraethylammonium compounds, triethylpropylammonium compounds, diethyldipropylammonium compounds, ethyltripropylammonium compounds, tetrapropylammonium compounds, and mixtures of two or more thereof, wherein it is particularly preferred that the one or more organotemplates comprises one or more tetrapropylammonium compounds.
• the one or more organotemplates preferably comprised in the mixture prepared in step (1 ) comprise one or more alkenyltrialkylammonium compounds
• these are selected from the group consisting of A/-(C2-C5)-alkenyl-tri-(Ci-C5)-alkylammonium compounds, and more preferably are selected from the group consisting of A/-(C2-C4)-alkenyl-tri-(Ci-C4)- alkylammonium compounds, more preferably from the group consisting of A/-(C2-Cs) alkenyl-tri- (C2-C4) alkylammonium compounds, wherein even more preferably these are selected from the group consisting of A/-(2-propene-1 -yl)-tri-n-propylammonium compounds, A/-(1 -propene-1 -yl)- tri-n-propylammonium compounds, A/-((2-propene-1 -yl)- tri-n-propy
• the one or more alkenyltrialkylammonium compounds preferably comprised in the mixture prepared in step (1 ) is selected from the group consisting of A/-(2-propene-1 -yl)-tri-n- propylammonium compounds, A/-(1 -propene-1 -yl)-tri-n-propylammonium compounds, and mixtures of two or more thereof.
• said one or more compounds are accordingly provided in the form of a salt.
• the counterion to the one or more tetraalkylammonium and/or alkenyltrialkylammonium cations contained in said one or more compounds again no particular restriction applies according to the present invention provided that an MFI, MEL, and/or MWW- type framework structure may be crystallized in step (2) of the inventive process.
• any conceivable counterion to said one or more cations may be employed for providing the one or more tetraalkylammonium and/or alkenyltrialkylammonium compounds.
• the one or more counterions to the one or more tetraalkylammonium and/or alkenyltrialkylammonium salts may comprise one or more anions selected from the group consisting of chloride, fluoride, bromide, carbonate, hydrogen carbonate, hydroxide, nitrate, phosphate, hydrogen phosphate, dihydrogen phosphate, sulfate, hydrogen sulfate, acetate, formate, oxalate, cyanate, and mixtures of two or more thereof, more preferably from the group consisting of chloride, fluoride, bromide, hydrogen carbonate, hydroxide, nitrate, dihydrogen phosphate, hydrogen sulfate, acetate, formate, oxalate, and combinations of
• the one or more tetraalkylammonium and/or alkenyltrialkylammonium salts preferably added to the mixture prepared in step (1 ) and crystallized in step (2) of the inventive process are, independently from one another, a hydroxide and/or a halide salt, and more preferably a salt selected from the group consisting of hydroxide, chloride, bromide, and mixtures of two or more thereof, wherein even more preferably the salts comprise one or more hydroxides.
• the one or more organotemplates comprises one or more tetraalkylammonium compounds
• said one or more organotemplates comprises tetrapropylammonium hydroxide and/or chloride, and even more preferably tetrapropylammonium hydroxide.
• the one or more organotemplates preferably added to the mixture prepared in step (1 ) comprises one or more alkenyltrialkylammonium compounds
• the one or more organotemplates comprises N-(2- propene-1 -yl)-tri-n-propylammonium and/or A/-(1 -propene-1 -yl)-tri-n-propylammonium hydroxide and/or chloride, and even more preferably A/-(2-propene-1 -yl)-tri-n-propylammonium hydroxide and/or A/-(1 -propene-1 -yl)-tri-n-propylammonium hydroxide.
• the one or more organotemplates are preferably comprised in the mixture prepared in step 1 of the inventive process according to which one or more organotemplates are preferably provided for crystallizing a zeolitic material having an MFI , MEL, and/or MWW-type framework structure, no particular restriction applies.
• the molar ratio of the total amount of the one or more organotemplates of the mixture obtained in step (1 ) to YO2 may range anywhere from 1 :0.1 - 1 :30, wherein preferably the molar ratio ranges from 1 :0.5 - 1 :20, more preferably from 1 :1 - 1 : 15, more preferably from 1 :3 - 1 :10, and more preferably from 1 :4 - 1 :7.
• the molar ratio of the total amount of the one or more organotemplates to YO2 ranges from 1 :5 - 1 :5.6.
• the molar ratio of the total amount of the one or more organotemplates of the mixture obtained in step (1 ) to YO2 ranges from 1 : (0.1 - 30), preferably from 1 : (0.5 - 20), more preferably from 1 : (1 - 15), more preferably from 1 : (3 - 10), from 1 : (4 - 7), and even more preferably from 1 : (5 - 5.6).
• the mixture according to step (1 ) comprises one or more sources for OH " for crystallizing an MFI, MEL, and/or MWW-type framework structure in step (2) of the inventive process.
• sources for OH " for crystallizing an MFI, MEL, and/or MWW-type framework structure in step (2) of the inventive process.
• OH " anions may be directly and/or indirectly generated in the mixture prepared in step (1 ) and crystallized in step (2) of the inventive process.
• OH " anions are indirectly provided by any chemical reaction leading to the generation of OH " anions such as e.g. a reaction of a Lewis base with water, wherein a protonated form of the base and OH " are generated by chemical reaction of the former.
• the one or more sources for OH " preferably further comprised in the mixture according to step (1 ) preferably comprise one or more sources directly containing OH " and in particular one or more Bronsted bases, wherein even more preferably said one or more sources for OH " comprise one or more hydroxides of an organotemplate salt further comprised in the mixture prepared in step (1 ) according to any of the particular or preferred embodiments of the present invention.
• said one or more sources for OH " preferably comprise one or more hydroxides selected from the group consisting of tetraalkylammonium and/or alkenyltrialkylammonium hydroxides, and more preferably one or more hydroxides selected from the group consisting of tetraethylammonium hydroxide, triethylpropylammonium hydroxide, diethyldipropylammonium hydroxide, ethyltripropylammonium hydroxide, tetrapropylammonium hydroxide, A/-(2-propene-1 -yl)-tri-n-propylammonium hydroxide, A/-(1 -propene-1 -yl)-tri-n- propylammonium hydroxide, A/-(1 -propene-2-yl)-tri-n-propylammonium hydroxide, and mixtures of two or more thereof
• the mixture according to step (1 ) further comprises one or more sources for OH " , wherein said one or more sources for OH " preferably comprises a hydroxide of an organotemplate salt, more preferably one or more hydroxides selected from the group consisting of tetraalkylammonium and/or alkenyltrialkylammonium hydroxides.
• a zeolitic material having MFI, MEL, and/or MWW-type framework structure may be crystallized in step (2) of the inventive process.
• the OH _ :Y02 molar ratio of the mixture obtained in step (1 ) may range anywhere from 0.01 to 5, wherein preferably the ⁇ ⁇ 2 molar ratio ranges from 0.05 to 2, more preferably from 0.1 to 1 , more preferably from 0.12 to 0.5, and more preferably from 0.15 to 0.3.
• the ⁇ ⁇ 2 molar ratio of the mixture obtained in step (1 ) according to particular embodiments of the present invention ranges from 0.18 to 0.2.
• the mixture can be prepared by any conceivable means, wherein mixing by agitation is preferred, preferably by means of stirring.
• step (2) of the inventive process no particular restriction applies according to the present invention as to the actual means employed for allowing the crystallization of a zeolitic material having an MFI, MEL, and/or MWW-type framework structure from the mixture obtained in step (1 ).
• any suitable means may be employed, wherein it is preferred that the crystallization is achieved by heating of the mixture of step (1 ).
• the crystallization in step (2) is conducted under heating at a temperature comprised in the range of from 80 to 250 °C, more preferably from 100 to 220 °C, more preferably from 120 to 200 °C, more preferably from 140 to 180 °C, and more preferably from 145 to 175 °C.
• the preferred heating of the mixture provided in step (1 ) in step (2) for the crystallization of a zeolitic material having an MFI, MEL, and/or MWW-type framework structure is conducted at a temperature comprised in the range of from 150 to 170 °C.
• the heating preferably employed at step (2) of the inventive process as means for the crystallization of the zeolitic material having an MFI, MEL, and/or MWW-type framework structure
• said heating may in principle be conducted under any suitable pressure provided that crystallization is achieved.
• the mixture according to step (1 ) is subjected in step (2) to a pressure which is elevated with regard to normal pressure.
• normal pressure as used in the context of the present invention relates to a pressure of 101 ,325 Pa in the ideal case.
• this pressure may vary within boundaries known to the person skilled in the art.
• this pressure can be in the range of from 95,000 to 106,000 or of from 96,000 to 105,000, or of from 97,000 to 104,000, or of from 98,000 to 103,000, or of from 99,000 to 102,000 Pa.
• heating in step (2) is conducted under solvothermal conditions, meaning that the mixture is crystallized under autogenous pressure of the solvent which is used. This may for example be conducted by heating the mixture obtained in step (1 ) in an autoclave or other crystallization vessel suited for generated solvothermal conditions.
• heating in step (2) is accordingly preferably conducted under hydrothermal conditions.
• the apparatus which can be used in the present invention for crystallization is not particularly restricted, provided that the desired parameters for the crystallization process can be realized, in particular with respect to the preferred embodiments requiring particular crystallization conditions.
• any type of autoclave or digestion vessel can be used.
• heating may be performed for a period of at least 3 hours, wherein preferably the period of heating may range anywhere from 6 hours to 15 days, more preferably from 9 hours to 10 days, more preferably from 12 hours to 7 days, more preferably from 15 hours to 5 days, more preferably from 18 hours to 4 days, and more preferably from 21 hours to 3 days.
• heating in step (2) of the inventive process is conducted for a period of from 1 to 2 days.
• said heating may be conducted during the entire crystallization process or during only one or more portions thereof, provided that a zeolitic material is crystallized.
• heating is conducted during the entire duration of crystallization.
• agitation there is no particular restriction as to the means by which said agitation may be performed such that any one of vibrational means, rotation of the reaction vessel, and/or mechanical stirring of the reaction mixture may be employed to this effect wherein according to said embodiments it is preferred that agitation is achieved by stirring of the reaction mixture.
• crystallization is performed under static conditions, i.e. in the absence of any particular means of agitation during the crystallization process.
• the process of the present invention can optionally comprise further steps for the work-up and/or further physical and/or chemical transformation of the zeolitic material crystallized in step (2) from the mixture provided in step (1 ), wherein said work up steps are conducted prior to step (3) of impregnating the zeolitic material.
• the crystallized material can for example be subject to any sequence of isolation and/or washing procedures, wherein the zeolitic material obtained from crystallization in step (2) is preferably subject to at least one isolation and at least one washing procedure.
• Isolation of the crystallized product can be achieved by any conceivable means.
• isolation of the crystallized product can be achieved by means of filtration, ultrafiltration, diafiltration, centrifugation and/or decantation methods, wherein filtration methods can involve suction and/or pressure filtration steps.
• the reaction mixture is first adjusted to a pH comprised in the range of from 5 to 9, preferably of 6 to 8, more preferably of 6.5 to 7.8, and more preferably of 7 to 7.6 prior to isolation.
• pH values preferably refer to those values as determined via a standard glass electrode.
• any conceivable solvent can be used.
• Washing agents which may be used are, for example, water, alcohols, such as methanol, ethanol or propanol, or mixtures of two or more thereof.
• mixtures are mixtures of two or more alcohols, such as methanol and ethanol or methanol and propanol or ethanol and propanol or methanol and ethanol and propanol, or mixtures of water and at least one alcohol, such as water and methanol or water and ethanol or water and propanol or water and methanol and ethanol or water and methanol and propanol or water and ethanol and propanol or water and methanol and ethanol and propanol.
• Water or a mixture of water and at least one alcohol, preferably water and ethanol, is preferred, distilled water being very particularly preferred as the only washing agent.
• the separated zeolitic material is washed until the pH of the washing agent, preferably the washwater, is in the range of from 6 to 8, preferably from 6.5 to 7.5.
• the inventive process can optionally comprise one or more drying steps.
• any conceivable means of drying can be used.
• the drying procedure may include any suitable stationary or continuous drying procedures such as the use of a band dryer. Dry-milling and spinflash procedures may also be mentioned as possible alternatives. Drying procedures preferably include heating and/or applying vacuum to the zeolitic material.
• one or more drying steps may also involve spray drying, such as may be achieved by spray granulation of the zeolitic material.
• the drying temperatures are preferably in the range of from 25°C to 150°C, more preferably of from 60 to 140°C, more preferably of from 70 to 130°C and even more preferably in the range of from 75 to 125°C.
• the durations of drying are preferably in the range of from 2 to 24 h, more preferably in the range of 2.5 to 10 hours, more preferably of from 3 to 7 h, and even more preferably of from 3.5 to 5 h.
• the zeolitic material crystallized in step (2) is directly subject to at least one step of drying, preferably to spray drying and or spray granulation, without isolating, washing, or drying of the zeolitic material beforehand.
• Directly subjecting the mixture obtained from step (2) of the inventive process to a spray drying or spray granulation stage has the advantage that isolation and drying is performed in a single stage. Consequently, according to this embodiment of the present invention, an even more preferred process is provided wherein not only removal of organotemplate compounds is avoided, but also the number of post-synthesis workup steps is minimized, as a result of which the zeolitic material can be obtained from a highly simplified process.
• the optional washing and/or isolation and/or ion-exchange procedures comprised in the inventive process can be conducted in any conceivable order and repeated as often as desired.
• the optionally washed zeolitic material is subject to one or more steps of calcination.
• said one or more steps of calcination are particularly preferred with respect to particular embodiments of the inventive process, wherein the mixture prepared in step (1 ) further comprises one or more organotemplates for removing said organotemplates after the synthesis of the zeolitic material having an MFI, MEL, and/or MWW-type framework structure.
• one or more organotemplates are further comprised in the mixture prepared in step (1 )
• the conditions of the calcination and in particular the temperature and/or duration and/or number of repetitions of the calcination step is chosen such that the one or more organotemplates are substantially removed from the porous structure of the zeolitic material having an MFI, MEL, and/or MWW-type framework structure.
• the term "substantially”' and in particular the use of said term with respect to the amount of said one or more organotemplates which may at most remain in the porous structure of the zeolitic material after calcination thereof designates residual amounts of carbon and/or nitrogen originating from said one or more organotemplates which may at most remain in the porous structure of the zeolitic material.
• a zeolitic material having been crystallized in step (2) of the inventive process in the presence of one or more organotemplates is substantially free thereof within the meaning of the present invention in cases where the carbon and/or nitrogen content thereof is of 1 .0 wt.-% or less based on 100 wt.-% of YO2 contained in the framework structure of the zeolitic material having an MFI, MEL, and/or MWW-type framework structure, and preferably an amount of 0.5 wt.-% or less, more preferably of 0.2 wt.-% or less, more preferably of 0.1 wt.-% or less, more preferably of 0.05 wt.-% or less, more preferably of 0.01 wt.-% or less, more preferably of 0.005 wt.-% or less, and more preferably of 0.001 wt.-% or less based on 100 wt.-% of YO2 in the zeolitic material.
• the temperature of the calcination procedure employed in the inventive process may range anywhere from 300 to 850 °C, wherein preferably the calcination in step (2d) ranges from 350 to 700 °C, and more preferably from 400 to 600 °C. According to particularly preferred embodiments of the inventive process, the calcination in step (2d) is conducted at a temperature in the range of 450 to 550 °C.
• the duration of the one or more calcination steps according to step (2d) of the inventive process there is again no particular restriction in this respect such that the calcination may be conducted for a duration ranging anywhere from 1 to 80 hours, wherein preferably the duration of the calcination according to any of the particular and preferred embodiments described in the present application ranges from 2 to 24 h during which the temperature of calcination is maintained, more preferably from 2.5 to 12 h, more preferably from 3 to 10 h, more preferably from 3.5 to 8 h, and more preferably from 4 to 7 h.
• the duration thereof ranges from 4.5 to 6 h, during which the chosen temperature of calcination is maintained.
• the calcination procedure in step (2d) is conducted one to three times in step (2d), wherein more preferably the calcination procedure is conducted once or twice, wherein according to particularly preferred embodiments the calcination procedure is performed once in step (2d) of the inventive process.
• the zeolitic material is subject to a hydrothermal treatment step (2e).
• the hydrothermal treatment leads to a change in the zeolitic materials physical and/or chemical properties, wherein it is particularly preferred that the hydrothermal treatment leads to a reduction in the zeolitic material's hydrophobicity.
• the preferred hydrothermal treatment step may be conducted under any suitable conditions, and in particular any suitable pressure and temperature.
• the hydrothermal treatment is conducted under autogenous pressure, which may for example be achieved by using an autoclave or any suitable pressure digestion vessel.
• any suitable temperature may be employed, wherein it is preferred that the hydrothermal treatment in step (2e) is conducted under heating, and preferably at a temperature ranging from 80 to 250°C, more preferably from 100 to 220°C, more preferably from 120 to 200°C, more preferably from 140 to 190°C, and more preferably from 160 to 185°C. According to the present invention it is however particularly preferred that the hydrothermal treatment in step (2e) is conducted at a temperature comprised in the range of from 170 to 180°C.
• the duration of the hydrothermal treatment step may range anywhere from 2 to 72 h, wherein preferably the treatment in step (2e) is conducted for a duration ranging from 4 to 48 h, more preferably from 8 to 36 h, and more preferably from 12 to 30 h. According to the present invention it is particularly preferred that the hydrothermal treatment in step (2e) is conducted for a period ranging from 18 to 24 h.
• step (2e) Concerning the effect of the hydrothermal treatment preferably conducted according to step (2e), there is no particular restriction as to the changes in physical and/or chemical properties of the zeolitic material which may be achieved, wherein it is particularly preferred that the conditions of hydrothermal treatment according to the preferred and particularly preferred embodiments of the inventive process in particular with respect to temperature, pressure, and duration lead to an increase in the zeolitic material's hydrophobicity.
• the zeolitic material obtained in step (2e) displays a decreased water uptake relative to the zeolitic material prior to the treatment in step (2e).
• step (2e) there is in principle no restriction according to the aforementioned preferred embodiments of the present invention provided that the zeolitic material's hydrophobicity is increased, i.e. that the water uptake of the zoelitic material decreases as a result of the treatment in step (2e).
• the water uptake of the zeolitic material obtained in step (2e) is not particularly restricted, such that the water uptake of the material obtained in said step may by way of example display a water uptake of 10.0 wt.-% or less, wherein preferably the hydrothermally treated zeolitic material obtained in step (2e) preferably displays a water uptake of 7.4 wt.-% or less, more preferably of 6.2 wt.-% or less, more preferably of 6.0 wt.-% or less, more preferably of 5.0 wt.-% or less, more preferably of 4.5 wt.-% or less, more preferably of 4.2 wt.-% or less, more preferably of 3 wt.-% or less, and more preferably of 2.2 wt.-% or less.
• the hydrothermally treated zeolitic material obtained in step (2e) displays a water uptake of 2 wt.-% or less, and more preferably
• the water uptake of a material and in particular of a zeolitic material as defined in any of the particular and preferred embodiments of the present invention expressed in wt.-% preferably refers to the water uptake of a material at 85 wt.-% relative humidity (RH) expressed in increase in weight compared to the dry sample, i.e. the weight of the sample measured at 0% RH.
• RH relative humidity
• the weight of the sample measured at 0% RH refers to the sample from which residual moisture has been removed by heating the sample to 100 °C (heating ramp of 5 °C/min) and holding it for 6 h under a nitrogen flow.
• the water uptake of a material as defined for any of the particular and preferred embodiments of the inventive process refers to the water uptake of a material and in particular of a zeolitic material at 85% RH as obtained according to the procedure for the measurement of the water adsorption/desorption isotherms as described in the experimental section of the present application.
• step (2) after step (2) and prior to step (3) the process further comprises
• (2b) isolating the zeolitic material from the product mixture obtained in (2), preferably by filtration, ultrafiltration, diafiltration, centrifugation and/or decantation methods;
• step (3) of the inventive process the zeolitic material obtained in step (2) is impregnated with one or more elements selected from the group of alkaline earth metals.
• the means for impregnation of the zeolitic material which may be employed in the inventive process, no particular restriction applies provided that the one or more elements selected from the group of alkaline earth metals may be effectively provided within the porous structure of the zeolitic material having an MFI, MEL, and/or MWW-type framework structure.
• any suitable impregnation method may be employed in step (3) of the inventive process, such as for example impregnation via a procedure involving the soaking of the zeolitic material in a suitable solution and/or suspension of one or more compounds containing the one or more elements selected from the group of alkaline earth metals, as well as by a spray impregnation procedure and/or by means of impregnation by incipient wetness, wherein the afore-mentioned procedures may be used by themselves or in any combination of two or more thereof.
• the impregnation of the zeolitic material is achieved by spray impregnation thereof.
• said elements may be employed in any suitable form allowing for their inclusion into the porous structure of the zeolitic material.
• said one or more elements may in principle be employed in elemental form and/or in the form of one or more compounds and in particular in the form of one or more salts thereof.
• the one or more element selected from the group of alkaline earth metals is employed in the form of one or more salts for impregnation into the zeolitic material.
• the one or more salts of said one or more elements is selected from the group consisting of halides, carbonates, hydroxide, nitrate, phosphates, sulfates, acetate, formate, oxalate, cyanide, and mixtures of two or more thereof, wherein preferably the one or more salts are selected from the group consisting of chloride, fluoride, bromide, hydrogen carbonate, hydroxide, nitrate, hydrogen phosphate, dihydrogen phosphate, hydrogen sulfate, acetate, and mixtures of two or more thereof, wherein more preferably the one or more salts is selected from the group consisting of chloride, bromide, hydroxide, nitrate, acetate, and mixtures of two or more thereof.
• the one or more salts of the one or more elements selected from the group of alkaline earth metals preferably employed in step (3) for the impregnation of the zeolitic material obtained in step (2) comprises one or more nitrate salts.
• any one or more of said alkaline earth metals may principally be impregnated in the zeolitic material and in particular any combination of two or more alkaline earth metals.
• the zeolitic material is impregnated with one or more elements selected from the group consisting of Mg, Ca, Ba, Sr, and mixtures of two or more thereof, wherein preferably the zeolitic material is impregnated with Mg and/or Ca, and more preferably with Mg.
• the zeolitic material may be impregnated such that 0.1 to 15 wt.-% of the one or more elements selected from the group of alkaline earth metals calculated as the element is impregnated into the zeolitic material based on the total weight thereof.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure is impregnated in step (3) with from 0.5 to 10 wt.-% of the one or more elements selected from the group of alkaline earth metals, more preferably with from 1 to 7 wt.-%, more preferably with from 2 to 5 wt.-%, more preferably with from 3 to 4.5 wt.-%, and more preferably with from 3.5 to 4.3 wt.-%.
• the zeolitic material obtained in step (2) is impregnated in step (3) with from 3.8 to 4.1 wt.-% of one or more elements selected from the group of alkaline earth metals based on the total weight of the zeolitic material.
• the zeolitic material obtained according to the inventive process may be any conceivable zeolitic material having an MFI, MEL, and/or MWW-type framework structure, wherein preferably said zeolitic material formed in step (2) comprises one or more zeolites having the MFI-type framework structure.
• zeolitic materials comprising one or more zeolites having the MFI-type framework structure, there is no particular restriction neither with respect to the type and/or number thereof, nor with respect to the amount thereof in the zeolitic material.
• the zeolitic material obtained comprises one or more zeolites having an MWW-type framework structure
• the zeolitic material obtained comprises one or more zeolites having an MWW-type framework structure
• the one or more zeolites having an MWW-type framework structure which may be obtained according to the inventive process may include one or more zeolites selected from the group consisting of MCM-22, [Ga-Si-0]-MWW, [Ti-Si-0]-MWW, ERB-1 , ITQ-1 , PSH-3, SSZ- 25, and mixtures of two or more thereof, wherein preferably, one or more zeolites which may be employed for the conversion of oxygenates to olefins are comprised in the zeolitic material obtained according to the inventive process, wherein in particular the zeolitic material preferably comprises MCM-22 and/or MCM-36.
• the one or more zeolites having an MEL-type framework structure which may be comprised in the zeolitic material obtained according to the inventive process may include one or more zeolites selected from the group consisting of ZSM-1 1 , [Si-B-0]-MEL, Bor-D (MFI/MEL-intergrowth), Boralite D, SSZ-46, Silicalite 2, TS-2, and mixtures of two or more thereof.
• the one or more zeolites having an MEL-type framework structure may be employed for the conversion of oxygenates to olefins, such that according to a particularly preferred embodiment of the inventive process, the zeolitic material obtained comprises ZSM-1 1 .
• the zeolitic material obtained according to the inventive process comprised one or more zeolites having an MFI-type framework structure, and in particular zeolites of the MFI-type framework structure which may be employed in the conversion of oxygenates to olefins.
• the zeolitic material may by way of example comprise one or more zeolites having an MFI-type framework structure selected from the group consisting of ZSM-5, ZBM-10, [As-Si-0]-MFI, [Fe-Si-0]-MFI, [Ga-Si-O]- MFI, AMS-1 B, AZ-1 , Bor-C, Boralite C, Encilite, FZ-1 , LZ-105, monoclinic H-ZSM-5, Mutinaite, NU-4, NU-5, Silicalite, TS-1 , TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, and mixtures of two or more thereof.
• the zeolitic material obtained according to the inventive process comprises ZSM-5 and/or ZBM-10 as the one or more zeolites having an MFI-type framework preferably contained therein.
• ZBM-10 and in particular its production, reference is made herewith to the disclosure of EP 0 007 081 A1 and of EP 0 034 727 A2, respectively.
• the zeolitic material obtained comprises ZSM-5 as the preferred zeolite having an MFI-type framework structure.
• the present invention also relates to a zeolitic material having an MFI, MEL, and/or MWW-type framework structure which is either obtained by the process according to the present invention or by any conceivable process which leads to a zeolitic material having an MFI, MEL, and/or MWW-type framework structure as obtainable according to the inventive process, wherein in particular the inventive process designates any of the particular and preferred embodiments thereof as defined in the present application.
• the present invention also relates to a zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprising YO2 and X2O3 as such, wherein Y is a tetravalent element, and X is a trivalent element, wherein the zeolitic material contains 3 wt.-% or less of one or more elements M based on 100 wt-% of YO2, wherein M stands for sodium, wherein the zeolitic material further comprises one or more elements selected from the group of alkaline earth metals, and wherein 95% by weight or more of the primary particles have a diameter of less than or equal to 1 ⁇ .
• inventive zeolitic material having an MFI, MEL, and/or MWW-type framework structure as defined according to the particular and preferred embodiments thereof in the present application is obtained by the process according to the present invention or by any conceivable process leading to said zeolitic material according to the present invention and, in particular, particular and preferred embodiments thereof as defined herein.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure comprises YO2.
• Y stands for any conceivable tetravalent element, Y standing for either one or several tetravalent elements.
• Preferred tetravalent elements according to the present invention include Si, Sn, Ti, Zr, Ge, and mixtures of two or more thereof. According to the present invention, however, it is particularly preferred that Y comprises Si, wherein more preferably Y is Si.
• X may in principle stand for any conceivable trivalent element, wherein X stands for one or more several trivalent elements.
• Preferred trivalent elements according to the present invention include Al, B, In, Ga, and mixtures of two or more thereof. More preferably, X stands for Al, B, Ga, or mixtures of any two or more of said trivalent elements, wherein more preferably X comprises Al and/or Ga.
• X comprises Al, wherein more preferably X stands for Al.
• 96% by weight or more, more preferably 97% by weight or more, more preferably 98% by weight or more, in particular 99% by weight or more of the primary particles of the zeolitic material have a diameter of less than or equal to 1 ⁇ .
• the primary particles of the present invention there is no particular restriction as to their crystal habit, wherein according to the present invention it is preferred that at least a portion of the primary particles are spherical.
• spherical denotes primary particles which, on investigation by scanning electron microscopy (SEM) at a magnification of from 0.5 x 10 4 to 2.0 x 10 4 , and preferably of from 2.0 x 10 4 to 75 x 10 4 are substantially free of sharp edges. Accordingly, the term “spherical” denotes, for example, purely spherical or deformed spherical, for example elliptical or cuboid primary particles, wherein the edges are rounded and not sharp in the case of the cuboid primary particles in the abovementioned investigation method in said resolution range.
• the primary particles are spherical
• 50% or more of the primary particles are spherical, more preferably 60% or more, more preferably 70% or more, more preferably 80% or more, more preferably 85% or more, and more preferably 90% or more.
• 91 % or more of the primary particles are spherical.
• diameters of less than 1 ⁇ are preferred for 95% by weight or more thereof, wherein according to preferred embodiments wherein at least a portion of the primary particles are spherical, it is particularly preferred that 95% by weight or more of the spherical primary particles have a diameter of less than or equal to 1 ⁇ . More preferred are diameters of 900 nm or less, more preferably 800 nm or less, more preferably 700 nm or less, more preferably 600 nm or less, and more preferably 500 nm or less.
• the primary particles of the zeolitic material have a diameter in the range of 5 nm or more, more preferably 10 nm or more, more preferably 20 nm or more, more preferably 30 nm or more, particularly preferably 50 nm or more.
• the diameters are particularly preferably in the range of from 5 to 800 nm, preferably from 10 to 500 nm, more preferably from 20 to 400 nm, more preferably from 30 to 300 nm, more preferably from 40 to 250 nm, and more preferably from 50 to 200 nm.
• embodiments of the present invention are preferred, wherein 95% by weight or more of the primary particles have a diameter of from 5 to 800 nm, preferably from 10 to 500 nm, more preferably from 20 to 400 nm, more preferably from 30 to 300 nm, more preferably from 40 to 250 nm, and more preferably from 50 to 200 nm.
• embodiments of the present invention are preferred, wherein 90% or more of the primary particles are spherical, and wherein preferably 95% by weight or more of the spherical primary particles have a diameter of less than or equal to 1 ⁇ , and more preferably of from 5 to 800 nm, more preferably from 10 to 500 nm, more preferably from 20 to 400 nm, more preferably from 30 to 300 nm, more preferably from 40 to 250 nm, and more preferably from 50 to 200 nm.
• the diameters of the primary particles as described in the context of the present invention may be determined, for example, via the electron microscopic methods SEM (scanning electron microscopy) and TEM (transmission electron microscopy). The diameters described in the context of the present invention were determined by SEM.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure contains 3 wt.-% or less of one or more elements M based on 100 wt.-% of YO2.
• M stands for sodium.
• the zeolitic material contains 3 wt.-% or less of both sodium and potassium based on 100 wt.-% of YO2.
• said amount refers to the weight of said one or more elements calculated as the element as opposed to being calculated as the oxide or the like.
• the one or more elements M stands for the group of alkaline metals and in particular for Li, Na, K, Rb, and Cs.
• M stands for the group of both alkali and alkaline earth metals, wherein the alkaline earth metals wherein said alkaline earth metals refer in particular to the elements Mg, Ca, Sr, and Ba, wherein according to said particularly preferred embodiments of the present invention wherein the zeolitic material contains 3 wt.-% or less of one or more elements M including alkaline earth metals, said one or more alkaline earth metals M do not include the one or more elements further comprised in the zeolitic material according to any of the particular and preferred embodiments of the present invention.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure further comprises Mg as the one or more element selected from the group of alkaline earth metals
• Mg as the one or more element selected from the group of alkaline earth metals
• the zeolitic material contains 3 wt.-% or less of alkali and alkaline earth metals M, wherein M does not include Mg.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure contains 1 wt.-% or less of the one or more elements M based on 100 wt.-% of YO2, wherein preferably the zeolitic material contains 0.5 wt.-% or less thereof, more preferably 0.1 wt.-% or less, more preferably 0.05 wt.-% or less, more preferably 0.02 wt.-% or less, more preferably 0.01 wt.-% or less, more preferably 0.005 wt.-% or less, more preferably 0.001 wt.-% or less, more preferably 0.0005 wt.-% or less and more preferably 0.0003 wt.-% or less thereof.
• the zeolitic material is substantially free of the one or more elements M, wherein at most traces of said one or more elements M are contained therein, said traces constituting less than 0.0001 wt.-% based on 100 wt.-% of YO2 comprised in the zeolitic material.
• said one or more alkaline earth metals may stand for any alkaline earth metal or a combination of two or more alkaline earth metals, wherein preferably the one or more element selected from the group of alkaline earth metals is selected from the group consisting of Mg, Ca, Ba, Sr, and mixtures of two or more thereof, wherein more preferably the one or more elements comprise Mg and/or Ca.
• the one or more elements selected from the group of alkaline earth metals comprise Mg, wherein more preferably Mg is further comprised in the zeolitic material as the one or more elements selected from the group of alkaline earth metals.
• the one or more element selected from the group of alkaline earth metals may be contained in the zeolitic material having an MFI, MEL, and/or MWW-type framework structure, no particular restriction applies in this respect according to the present invention, such that in principle any conceivable amount thereof may be comprised therein.
• the one or more element selected from the group of alkaline earth metals further comprised in the zeolitic material may be contained therein in an amount ranging anywhere from 0.1 to 15 wt.-% based on the total weight of the zeolitic material, wherein preferably the one or more elements are further comprised therein in an amount ranging from 0.5 to 10 wt.-%, more preferably from 1 to 7 wt.-%, more preferably from 2 to 5 wt.-%, more preferably from 3 to 4.5 wt.-%, and more preferably from 3.5 to 4.3 wt.-%.
• the one or more element selected from the group of alkaline earth metals further comprised in the zeolitic material or contained therein in an amount ranging from 3.8 to 4.1 wt.-%.
• the one or more alkaline earth metals further comprised in the zeolitic material there is no particular restriction as to the manner in which said one or more element is contained in the zeolitic material.
• said one or more alkaline earth metal elements may be comprised on the outer surface of the particles of the zeolitic material and/or within the porous structure of said materials, wherein it is preferred that at least a portion of said one or more alkaline earth metal elements is contained in the porous structure of the zeolitic material, in particular as non- framework elements of the zeolitic material which do not constitute the one or more framework structures of the zeolitic material and are accordingly present in the pores and/or cavities formed by the respective framework structure and typical for zeolitic materials in general.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure may display a YO2 : X2O3 atomic ratio ranging anywhere from 10 to 1500, wherein preferably the atomic ratio ranges from 30 to 1200, more preferably from 50 to 900, more preferably from 70 to 700, more preferably from 80 to 500, and even more preferably from 90 to 300.
• the zeolitic material having an MFI, MEL, and/or MWW-type framework structure displays a YO2 : X2O3 atomic ratio in the range of from 100 to 250.
• the specific zeolitic material having an MFI, MEL, and/or MWW-type framework structure of the present invention there is no particular restriction as to the specific MFI and/or MEL and/or MWW-type material, such that any conceivable one or more zeolites having an MFI and/or MEL and/or MWW-type framework structure may be contained therein.
• the zeolitic material comprises one or more zeolites having an MWW-type framework structure
• said one or more zeolites having an MWW-type framework structure may include one or more zeolites selected from the group consisting of MCM-22, [Ga-Si-0]-MWW, [Ti-Si-0]-MWW, ERB-1 , ITQ-1 , PSH-3, SSZ-25, and mixtures of two or more thereof.
• the zeolitic material comprises one or more zeolites having an MWW-type framework structure which may be employed for the conversion of oxygenates to olefins, wherein more preferably the zeolitic material according to said particularly preferred embodiments comprises MCM-22 and/or MCM-36.
• the one or more zeolites having an MEL-type framework structure which may be comprised in the zeolitic material of the present invention may include one or more zeolites selected from the group consisting of ZSM-1 1 , [Si-B-0]-MEL, Bor-D (MFI/MEL-intergrowth), Boralite D, SSZ-46, Silicalite 2, TS-2, and mixtures of two or more thereof.
• the one or more zeolites having an MEL-type framework structure may be employed for the conversion of oxygenates to olefins, wherein according to a particularly preferred embodiment thereof, the zeolitic material comprises ZSM-1 1 .
• the zeolitic material of the present invention comprises one or more zeolites having an MFI-type framework structure, and in particular one or more zeolites of the MFI-type framework structure which may be employed in the conversion of oxygenates to olefins.
• the zeolitic material may by way of example comprise one or more zeolites selected from the group consisting of ZSM-5, ZBM-10, [As-Si-0]-MFI, [Fe-Si-0]-MFI, [Ga-Si-0]-MFI, AMS-1 B, AZ-1 , Bor-C, Boralite C, Encilite, FZ-1 , LZ-105, monoclinic H-ZSM-5, Mutinaite, NU-4, NU-5, Silicalite, TS-1 , TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, and mixtures of two or more thereof.
• the zeolitic material comprises ZSM-5 and/or Z
• the BET surface area of the zeolitic materials as determined according to DIN 66131 , it may accordingly range anywhere from 200 to 900 m 2 /g, wherein preferably the BET surface area ranges from 250 to 700 m 2 /g, more preferably from 300 to 600 m 2 /g, more preferably from 350 to 550 m 2 /g, more preferably from 380 to 500 m 2 /g, more preferably from 400 to 470 m 2 /g, and more preferably from 420 to 450 m 2 /g.
• the BET surface area of the zeolitic material as determined according to DIN 66131 ranges from 425 to 440 m 2 /g.
• the zeolitic material displays a low water uptake, i.e. a high hydrophobicity, wherein by way of example the water uptake of the zeolitic material may be 10.0 wt.-% or less.
• the inventive zeolitic material displays a water uptake of 10.0 wt.-% or less, more preferably of 7.4 wt.-% or less, more preferably of 6.2 wt.-% or less, more preferably of 6.0 wt.-% or less, more preferably of 5.0 wt.- % or less, more preferably of 4.5 wt.-% or less, more preferably of 4.2 wt.-% or less, more preferably of 3 wt.-% or less, and more preferably of 2.2 wt.-% or less.
• the zeolitic material displays a water uptake of 2 wt.-% or less, and even more preferably of 1.5 wt.-% or less.
• the zeolitic materials of the present invention can be employed as such, like in the form of a powder, a spray powder or a spray granulate obtained from above-described separation techniques, e.g. decantation, filtration, centrifugation, or spraying.
• the zeolitic material in many industrial applications, it is often desired on the part of the user not to employ the zeolitic material as powder or sprayed material, i.e. the zeolitic material obtained by the separation of the material from its mother liquor, optionally including washing and drying, and subsequent calcination, but a zeolitic material which is further processed to give moldings.
• Such moldings are required particularly in many industrial processes, e.g. in many processes wherein the zeolitic material of the present invention is employed as catalyst or adsorbent.
• the present invention also relates to a molding comprising the inventive zeolitic material according to any of the particular and preferred embodiments thereof as defined in the present application.
• the present invention accordingly also relates to a molding containing a zeolitic material as described above.
• the molding may comprise any conceivable compounds in addition to the zeolitic material according to the present invention, provided that it is ensured that the resulting molding is suitable for the desired application.
• the present invention also describes a process for the production of a molding, containing a zeolitic material as described above, comprising the step of
• binder materials are in general all compounds which impart adhesion and/or cohesion between the particles of the zeolitic material which are to be bound, which adhesion and cohesion are over and above the physisorption which may be present without a binder material.
• binder materials are metal oxides, such as S1O2, AI2O3, ⁇ 2, Zr02 or MgO or clays or mixtures of two or more of these compounds.
• AI2O3 binder materials clay minerals and naturally occurring or synthetic aluminas, for example alpha-, beta-, gamma-, delta-, eta-, kappa-, chi- or theta-alumina and the inorganic or organometallic precursor compounds thereof, for example gibbsite, bayerite, boehmite, pseudoboehmite or trialkoxyaluminates, for example aluminum triisopropylate, are in particular suitable.
• Further preferred binder materials are amphiphilic compounds having a polar and a nonpolar moiety, and graphite.
• Further binder materials are, for example, clays, such as montmorillonites, kaolins, bentonites, halloysites, dickites, nacrites or anaxites.
• binder materials may be used as such. It is also possible in the context of the present invention to use compounds from which the binder is formed in at least one further step in the production of the moldings.
• binder material precursors are tetraalkoxysilanes, tetraalkoxytitanates, tetraalkoxyzirconates or a mixture of two or more different tetraalkoxysilanes or a mixture of two or more different tetraalkoxytitanates or a mixture of two or more different tetraalkoxyzirconates or a mixture of at least one tetraalkoxysilane and at least one tetraalkoxytitanate or of at least one tetraalkoxysilane and at least one tetraalkoxyzirconate or of at least one tetraalkoxytitanate and at least one tetraalkoxyzirconate or of at least one tetraalkoxyt
• binder materials which either completely or partly comprise S1O2 or are a precursor of S1O2 from which S1O2 is formed in at least one further step in the production of the moldings are very particularly preferred.
• colloidal silica and wet process silica and dry process silica can be used. These are very particularly preferably amorphous silica, wherein the size of the silica particles is in the range of from 5 to 100 nm and the surface area of the silica particles is in the range of from 50 to 500 m 2 /g.
• Colloidal silica preferably as an alkaline and/or ammoniacal solution, more preferably as an ammoniacal solution, is commercially available, inter alia, as Ludox ® , Syton ® , Nalco ® or Snowtex ® .
• Wet process silica is commercially available, inter alia, as Hi-Sil ® , Ultrasil ® , Vulcasil ® , Santocel ® , Valron-Estersil ® , Tokusil ® or Nipsil ® .
• Dry process silica is commercially available, inter alia, as Aerosil ® , Reolosil ® , Cab-O-Sil ® , Fransil ® or ArcSilica ® .
• an ammoniacal solution of colloidal silica is preferred in the context of the present invention.
• the present invention also relates to a molding as described above, additionally containing S1O2 as binder material.
• the present invention also relates to a process as described above, wherein the binder material employed according to (A) is Si02-containing or -forming binder material. Accordingly, the present invention also relates to a process as described above, wherein the binder material is a colloidal silica.
• the binder materials are preferably used in an amount which leads to the finally resulting moldings, whose binder content is up to 80, more preferably from 5 to 80, more preferably from 10 to 70, more preferably from 10 to 60, more preferably from 15 to 50, more preferably from 15 to 45, particularly preferably from 15 to 40, % by weight, based in each case on the total weight of the finally resulting molding.
• the mixture of binder material or precursor for a binder material and the zeolitic material can be mixed with at least one further compound for further processing and for forming a plastic mass.
• pore formers are preferred here. Pore formers which may be used in the process according to the present invention are all compounds which, with regard to the prepared molding, provide a certain pore size, a certain pore size distribution and/or a certain pore volume.
• Preferably used pore formers in the process according to the present invention are polymers which are dispersible, suspendable or emulsifiable in water or in aqueous solvent mixtures.
• Preferred polymers here are polymeric vinyl compounds, for example polyalkylene oxides, such as polyethylene oxides, polystyrene, polyacrylates, polymethacrylates, polyolefins, polyamides and polyesters, carbohydrates, such as cellulose or cellulose derivatives, for example methylcellulose, or sugar or natural fibers.
• Further suitable pore formers are, for example, pulp or graphite.
• the polymer content of the mixture according to (A) is preferably in the range of from 5 to 90, more preferably from 15 to 75, particularly preferably from 25 to 55, % by weight, based in each case on the amount of zeolitic material in the mixture according to (A). If it is desirable for the pore size distribution to be achieved, a mixture of two or more pore formers may also be used.
• the pore formers are removed in a step (E) by calcination to give the porous molding.
• moldings which have pores in the range of at least 0.6, preferably from 0.6 to 0.8, particularly preferably from more than 0.6 to 0.8, ml/g, determined according to DIN 66134, are obtained.
• the specific surface area of the molding according to the present invention is in general at least 250 m 2 /g, preferably at least 290 m 2 /g, particularly preferably at least 300 m 2 /g.
• the specific surface area may be from 250 to 400 m 2 /g or from 290 to 450 m 2 /g or from 300 to 500 m 2 /g.
• the present invention also relates to a molding as described above, having a specific surface area of at least 250 m 2 /g, containing pores having a pore volume of at least 0.6 ml/g.
• at least one pasting agent is added in a likewise preferred embodiment of the process according to the present invention.
• Pasting agents which may be used are all compounds suitable for this purpose.
• these are preferably organic, in particular hydrophilic, polymers, for example cellulose, cellulose derivatives, such as methylcellulose, starch, such as potato starch, wallpaper paste, polyacrylates, polymethacrylates, polyvinyl alcohol, polyvinylpyrrolidone, polyisobutene, polyethyleneglycol or polytetrahydrofuran.
• compounds which also act as pore formers can accordingly be used as pasting agents.
• these pasting agents are removed in a step (E) by calcination to give the porous molding.
• At least one acidic additive is introduced during the preparation of the mixture according to (A).
• Organic acidic compounds can be removed by calcination in the preferred step (E), as described below, are very particularly preferred.
• Carboxylic acids for example formic acid, oxalic acid and/or citric acid, are particularly preferred. It is also possible to use two or more of these acidic compounds.
• the order of addition of the components of the mixture according to (A) which contains the zeolitic material is not critical. It is possible both first to add the at least one binder material, subsequently the at least one pore former, the at least one acidic compound and finally the at least one pasting agent and it is possible to interchange the sequence with regard to the at least one binder material, the at least one pore former, the at least one acidic compound and the at least one pasting agent.
• the mixture according to (A) is as a rule homogenized for from 10 to 180 min.
• kneaders, edge mills or extruders are particularly preferably used for the homogenization.
• the mixture is preferably kneaded. On an industrial scale, treatment in an edge mill is preferred for homogenization.
• the present invention also describes a process as described above, comprising the steps
• the homogenization as a rule temperatures of from about 10 °C to the boiling point of the pasting agent and atmospheric or slightly superatmospheric pressure are employed. Subsequently at least one of the compounds described above can be optionally added.
• the mixture thus obtained is homogenized, preferably kneaded, until an extrudable plastic mass has formed.
• the homogenized mixture is molded according to a more preferred embodiment of the present invention.
• preferred shaping methods are those in which the molding is effected by extrusion in conventional extruders, for example to give extrudates having a diameter of, preferably, from 1 to 10 mm, particularly preferably from 2 to 5 mm.
• extrusion apparatuses are described, for example, in Ullmann's Enzyklopadie der Technischen Chemie, 4th Edition, Vol. 2, page 295 et seq., 1972.
• a ram extruder may likewise preferably be used for the molding.
• the shaping can be selected from the following group, wherein the combination of at least two of these methods is explicitly included: bricketting by means of a ram press, roll press, ring-roll press, bricketting without binder; pelleting, melting, spinning techniques, deposition, foaming, spray-drying; combustion in a shaft furnace, convection furnace, travelling grate, rotary kiln, edge mill.
• the compacting may take place at ambient pressure or at superatmospheric pressure, for example at from 1 to several hundred bar. Furthermore, the compacting may take place at ambient temperature or at a temperature higher than the ambient temperature, for example at from 20 to 300 °C. If drying and/or combustion are part of the shaping step, temperatures of up to 1 ,500 °C are conceivable. Finally, the compacting may take place in the ambient atmosphere or in a controlled atmosphere. Controlled atmospheres are, for example, inert gas atmospheres or reducing and/or oxidizing atmospheres. Accordingly, the present invention also describes a process for the production of a molding as described above, comprising the steps
• the shape of the moldings produced according to the invention can be chosen as desired. In particular, inter alia spheres, oval shapes, cylinders or tablets are possible.
• the molding is particularly preferably carried out by extrusion of the kneaded mixture obtained according to (B), more preferably substantially cylindrical extrudates having a diameter in the range of from 1 to 20 mm, preferably from 1 to 10 mm, more preferably from 2 to 10 mm, and particularly preferably from 2 to 5 mm, being obtained as extrudates.
• step (C) is preferably followed by at least one drying step.
• This at least one drying step is effected at temperatures in general in the range of from 80 to 160 °C, preferably from 90 to 145 °C, particularly preferably from 100 to 130 °C, wherein the duration of drying generally is 6 hours or more, for example in the range of from 6 to 24 hours.
• shorter drying times for example about 1 , 2, 3, 4 or 5 hours, are also possible.
• the preferably obtained extrudate can, for example, be milled.
• the present invention also describes a process for the production of a molding as described above, comprising the steps
• step (D) drying of the at least one molding.
• step (D) is preferably followed by at least one calcination step.
• the calcination is carried out at a temperature in general in the range of from 350 to 750 °C, preferably from 450 to 600 °C.
• the calcination can be effected under any suitable gas atmosphere, air and/or lean air being preferred.
• the calcination is preferably carried out in a muffle furnace, a rotary kiln and/or a belt calcination furnace, wherein the duration of calcination generally is 1 hour or more, for example in the range of from 1 to 24 or from 3 to 12 h.
• the process according to the present invention for example, to calcine the moldings once, twice or more often for in each case at least one hour, for example in each case in the range of from 3 to 12 h, wherein the temperatures during the calcination step can remain the same or can be changed continuously or discontinuously. If calcination is effected twice or more often, the calcination temperatures in the individual steps may be different or identical.
• the present invention also relates to a process for the production of moldings as described above, comprising the steps
• the calcined material can, for example, be comminuted.
• the at least one molding can be treated with a concentrated or dilute Broenstedt acid or with a mixture of two or more Broenstedt acids.
• Suitable acids are, for example, hydrochloric acid, sulfuric acid, phosphoric acid, nitric acid or carboxylic acids, dicarboxylic acids or oligo- or polycarboxylic acids, such as nitrilotriacetic acid, sulfosalicylic acid or ethylenediaminotetraacetic acid.
• this at least one treatment with at least one Broenstedt acid is followed by at least one drying step and/or at least one calcination step, which in each case is carried out under the conditions described above.
• the catalyst extrudates can be subjected to a steam treatment for better hardening, after which once again preferably drying is effected at least once and/or calcination is effected at least once.
• a steam treatment for better hardening, after which once again preferably drying is effected at least once and/or calcination is effected at least once.
• the calcined molding is subjected to steam treatment and then once again dried at least once and/or calcined at least once.
• the moldings obtained according to the invention have hardnesses which are in general in the range of from 2 to 40 N, preferably in the range of from 5 to 40 N, particularly preferably from 10 to 40 N.
• the present invention accordingly also relates to a molding as described above, having a cutting hardness of from 2 to 40 N.
• the hardness described above was determined on an apparatus from Zwick, type BZ2.5/TS1 S with a preliminary force of 0.5 N, a feed velocity under the preliminary force of 10 mm/min and a subsequent test velocity of 1 .6 mm/min.
• the apparatus had a fixed turntable and a freely movable punch with built-in blade of 0.3 mm thickness.
• the movable punch with the blade was connected to a load cell for force pick-up and, during the measurement, moved toward the fixed turntable on which the catalyst molding to be investigated was present.
• the test apparatus was controlled by means of a computer which registered and evaluated the measured results.
• the value obtained is the mean value of the measurements for 10 catalyst moldings in each case.
• the catalyst moldings had a cylindrical geometry, wherein their average length corresponds to about twice to three times the diameter, and were loaded with the blade of 0.3 mm thickness with increasing force until the molding had been cut through.
• the blade was applied to the molding perpendicularly to the longitudinal axis of the molding.
• the force required for this purpose is the cutting hardness (unit N).
• the present invention accordingly also relates to a molding, obtainable by a process according any one of the above mentioned embodiments.
• the at least one molding according to the invention and/or the molding produced according to the invention can generally be used in all processes or operations in which the properties of the molding and in particular of the zeolitic material according to the present invention contained in the molding or a zeolitic material prepared according to the invention are desired.
• the at least one molding according to the invention or the molding produced according to the invention is used as a catalyst in chemical reactions.
• the present invention accordingly relates to the use of a molding as described above, or of a molding obtainable by a process as described above, as catalyst.
• the zeolitic material having an MFI , MEL, and/or MWW-type framework structure as described in the present application and in particular according to the particular and preferred embodiments described herein can be used in any suitable application, wherein said zeolitic material is preferably used as a molecular sieve, catalyst, catalyst support, and/or as an absorbent.
• the inventive zeolitic material can be used as molecular sieve to dry gases or liquids, for selective molecular separation, e.g. for the separation of hydrocarbons or amines; as ion exchanger; as chemical carrier; as adsorbent, in particular as adsorbent for the separation of hydrocarbons or amines; or as a catalyst.
• the zeolitic material according to the present invention is used as a catalyst and/or as a catalyst support.
• the zeolitic material is used in a catalytic process, preferably as a catalyst and/or catalyst support, and more preferably as a catalyst.
• the zeolitic material of the invention can be used in any conceivable catalytic process, wherein processes involving the conversion of at least one organic compound are preferred, more preferably of organic compounds comprising at least one carbon-carbon and/or carbon-oxygen and/or carbon-nitrogen bond, more preferably of organic compounds comprising at least one carbon-carbon and/or carbon-oxygen bond, and even more preferably of organic compounds comprising at least one carbon-oxygen bond.
• the inventive zeolitic material is used as a catalyst in the conversion of oxygenates to olefins, in a methanol to gasoline (MTG) process, in a biomass to olefins and/or biomass to aromatics process, in a methane to benzene process, in a process for the alkylation of aromatics, or in a fluid catalytic cracking (FCC) process.
• MMG methanol to gasoline
• FCC fluid catalytic cracking
• the zeolitic material is employed in a process for the conversion of oxygenates to olefins, wherein more preferably the zeolitic material is used as a catalyst in a dimethylether to olefin process (DTO), methanol to olefin (MTO) process, in a methanol to propylene (MTP) process, and/or in a methanol to propylene/butylene (MT3/4) process.
• DTO dimethylether to olefin process
• MTO methanol to olefin
• MTP methanol to propylene
• MT3/4 methanol to propylene/butylene
• the present invention further relates to a process for the conversion of oxygenates to olefins.
• the present invention further concerns a process for the conversion of oxygenates to olefins comprising
• the catalyst which is used in the inventive process no particular restriction applies in its respect provided that it comprises a zeolitic material according to the present invention and that it is suited for the conversion of at least one oxygenate to at least one olefin. Again, this applies in particular relative to the particular and preferred embodiments according to the present invention as defined in the present application. According to particularly preferred embodiments of the inventive process for the conversion of oxygenates to olefins, however, the catalyst comprises a molding according to any of the particular and preferred embodiments of the present invention, wherein the molding accordingly comprises a zeolitic material according to any of the particular and preferred embodiments of the present invention.
• the one or more oxygenates contained in the gas stream provided in step (I) comprise one or more oxygenates selected from the group consisting of aliphatic alcohols, ethers, carbonyl compounds, and mixtures of two or more thereof.
• the one or more oxygenates comprised in the gas stream is selected from the group consisting of Ci-C6-alcohols, di-Ci-C3- alkyl ethers, Ci-C6-aldehydes, C2-C6-ketones, and mixtures of two or more thereof, more preferably from the group consisting of Ci-C4-alcohols, di-Ci-C2-alkyl ethers, Ci-C4-aldehydes, C2-C 4 -ketones, and mixtures of two or more thereof.
• the gas stream provided in step (I) comprises one or more oxygenates selected from the group consisting of methanol, ethanol, n-propanol, isopropanol, butanol, dimethyl ether, diethyl ether, ethyl methyl ether, diisopropyl ether, di-n- propyl ether, formaldehyde, dimethyl ketone, and mixtures of two or more thereof
• the one or more oxygenates comprised in the gas stream according to (I) is selected from the group consisting of methanol, ethanol, n-propanol, isopropanol, butanol, dimethyl ether, diethyl, ethyl methyl ether, diisopropyl ether, di-n-propyl ether, formaldehyde, dimethyl ketone, and mixtures of two or more thereof, and more preferably from the group consisting of methanol, ethanol, n-propanol, isopropano
• the gas stream provided in step (I) comprises methanol and/or dimethyl ether, wherein it is particularly preferred that dimethyl ether is comprised as the one or more oxygenates in the gas stream according to (I).
• the content of oxygenates in the gas stream according to (I) lies in the range of from 30 to 100 vol.-% based on the total volume of the gas stream, wherein the content refers in particular to a gas stream at a temperature in the range of from 200 to 700 °C and at a pressure of 101 .3 kPa, preferably at a temperature in the range of from 250 to 650 °C, more preferably at a temperature of from 300 to 600 °C, more preferably at a temperature of 350 to 560 °C, more preferably at a temperature in the range of from 400 to 540 °C, more preferably at a temperature in the range of from 430 to 520 °C, and more preferably at a temperature in the range of from 450 to 500 °C at a pressure of 101.3 kPa.
• the content of oxygenates in the gas stream according to (I) is comprised in the range of from 30 to 99.9 vol.- % based on the total volume of the gas stream, and more preferably in the range of from 30 to 99 vol.-%, more preferably from 30 to 95 vol.-%, more preferably from 30 to 90 vol.-%, more preferably from 30 to 80 vol.-%, more preferably from 30 to 70 vol.-%, more preferably from 30 to 60 vol.-%, and more preferably from 30 to 50 vol.-%.
• the content of the one or more oxygenates in the gas stream according to (I) lies in the range of from 30 to 45 vol.-%.
• step (I) contains from 30 to 100 vol.-% of oxygenates based on the total volume of the gas stream.
• the further components which may be contained in the gas stream according to (I) of the inventive process, in principle there is no restriction neither with respect to the number nor with respect to the amount of said one or more further components to the one or more oxygenates, provided that when bringing said gas stream into contact with a zeolitic material according to the present invention in step (II), at least one of the one or more oxygenates may be converted to at least one olefin.
• one or more inert gases may for example be contained in the gas stream according to (I) in addition to the one or more oxygenates such as for example one or more noble gases, nitrogen gas, carbon monoxide, carbon dioxide, water, and mixtures of two or more thereof.
• the one or more inert gases may comprise unwanted side-products which are recycled such as paraffins, olefinic products with 5 or more carbon atoms, aromatics, or mixtures of two or more thereof, which are produced according to any of the particular and preferred embodiments of the inventive process for the conversion of oxygenates to olefins.
• the gas stream according to (I) of the inventive process further comprises water in addition to the one or more oxygenates.
• the gas stream provided in step (I) may contain 60 vol.-% water or less based on the total volume of the gas stream, wherein according to particular embodiments which are preferred the water content in the gas stream ranges from 5 to 60 vol.-% based on the total volume of the gas stream, wherein it is preferred that the water content ranges from 10 to 55 vol.%, and more preferably from 20 to 50 vol.-%.
• water is contained in the gas stream according to (I) in an amount of 30 to 45 vol.-% in addition to the one or more oxygenates.
• the water content in the gas stream is 5 vol.-% or less, more preferably 3 vol.-% or less, more preferably 1 vol.-% or less, more preferably 0.5 vol.-% or less, more preferably 0.1 vol.-% or less, more preferably 0.05 vol.-% or less, more preferably 0.01 vol.-% or less, more preferably 0.005 vol.-% or less, and more preferably 0.001 vol.-% or less.
• the gas stream provided in step (I) contains 60 vol.-% or less of water based on the total volume of the gas stream.
• the gas stream according to (I) originates from a pre-reaction, preferably from the conversion of one or more alcohols to one or more ethers, and in particular from the conversion of one or more alcohols selected from the group consisting of methanol, ethanol, n- propanol, isopropanol, and mixtures of two or more thereof, more preferably from the group consisting of methanol, ethanol, n-propanol, and mixtures of two or more thereof, wherein it is particularly preferred that the gas stream provided in (I) originates from a pre-reaction of methanol and/or ethanol and preferably from methanol which at least in part is converted to one or more di-Ci-C2-alkyl ethers, preferably to
• the gas stream provided in step (I) originates from a pre-reaction, wherein methanol is at least in part converted to dimethylether.
• the gas stream provided in step (I) originates from a pre-reaction of one or more alcohols
• the pre-reaction for the conversion of at least one alcohol leads to at least one ether and in particular to at least one dialkyl ether, wherein it is particularly preferred that the pre-reaction is a dehydration reaction, wherein water is produced as a secondary product from the condensation reaction to one or more dialkyl ethers.
• the gas stream provided in step (I) originates from a pre-reaction
• a gas stream resulting from such a pre-reaction is directly provided in step (I) of the inventive process without having been subject to any type of workup.
• step (II) As regards the particular conditions under which the gas stream is contacted with a catalyst according to the present invention in step (II), no particular restriction applies in this respect provided that the conversion of at least one oxygenate to at least one olefin may be realized. This, for example, applies to the temperature at which the contacting in step (II) takes place.
• said contacting of the gas stream in step (II) may be conducted according to the inventive process at a temperature in the range of from 200 to 700 °C, wherein it is preferred that the contacting is conducted at a temperature in the range of from 250 to 650 °C, more preferably of from 300 to 600 °C, more preferably of from 350 to 560 °C, more preferably of from 400 to 540 °C, and more preferably of from 430 to 520 °C.
• the contacting of the gas stream in step (II) is conducted at a temperature in the range of from 450 to 500 °C.
• contacting of the gas stream with the zeolitic material in step (II) is performed at a temperature in the range of 200 to 700°C. Same applies accordingly relative to the pressure under which the gas stream is contacted with a catalyst according to the present invention in step (II) of the inventive process.
• said contacting may be conducted at any conceivable pressure, provided that at least one oxygenate may be converted to at least one olefin upon contacting of the gas stream with the catalyst.
• the contacting in step (II) may be conducted at a pressure in the range of from 0.1 to 10 bar, wherein the pressure as defined in the present application designates the absolute pressure such that a pressure of 1 bar upon contacting of the gas stream with the catalyst corresponds to the normal pressure of 1 .03 kPa.
• contacting in step (II) is preferably performed at a pressure of from 0.3 to 7 bar, more preferably of from 0.5 to 5 bar, more preferably of from 0.7 to 3 bar, more preferably of from 0.8 to 2.5 bar, and more preferably of from 0.9 to 2.2 bar.
• contacting of the gas stream in step (II) is conducted at a pressure of from 1 to 2 bar.
• step (II) contacting of the gas stream with the zeolitic material in step (II) is performed at a pressure in the range of 0.1 to 10 bar.
• the inventive process for the conversion of oxygenates to olefins is conducted, such that both a non- continuous mode as well as a continuous mode may be applied to the inventive process, wherein the non-continuous process may for example be conducted as a batch-process.
• the inventive process for the conversion of oxygenates to olefins is at least in part performed in a continuous mode.
• WHSV weight hourly space velocity
• weight hourly space velocities may be chosen for the contacting in step (II) which lie in the range of from 0.5 to 50 per hour, wherein preferably weight hourly space velocities of from 1 to 30 per hour are chosen, more preferably of from 2 to 20 per hour, more preferably of from 3 to 15 per hour, and more preferably of from 4 to 10 per hour.
• weight hourly space velocities ranging from 5 to 7 per hour are chosen for the contacting of the gas stream in step (II) with a catalyst according to the present invention.
• said weight hourly space velocities are preferably adjusted in function of the conversion of the one or more oxygenates comprised in the gas stream provided in step (I) of the inventive process, and in particular adjusted such that a certain level of conversion comprised in a specific range is achieved.
• the weight hourly space velocities may be adjusted such that the conversion of the one or more oxygenates lies in the range of from 50 to 99.9%.
• weight hourly space velocities are preferred according to the particular and preferred embodiments of the inventive process wherein the conversion of the oxygenates lies in the range of from 70 to 99.5%, more preferably from 90 to 99%, more preferably from 95 to 98.5%, more preferably from 96 to 98%, and even more preferably from 96.5 to 97.5%.
• the weight hourly space velocity under which the gas stream in step (II) is contacted with a catalyst according to the present invention is adjusted to assure full conversion of the one or more oxygenates, i.e.
• a conversion of from 96.5 to 99.9% or more thereof more preferably a conversion of the one or more oxygenates of from 97.5 to 99.9% or more thereof, more preferably of from 98 to 99.9% or more thereof, more preferably of from 99 to 99.9% or more thereof, and more preferably of from 99.5 to 99.9% or more relative to the conversion of the one or more oxygenates.
• WHSV weight hourly space velocity
• FIGS. 1A, 2A, 3A, and 4A show the X-ray diffraction patterns (measured using Cu K alpha-1 radiation) of the crystalline material obtained according to Reference Examples 1 -4, respectively.
• the angle 2 theta in ° is shown along the abscissa and the intensity in counts is plotted along the ordinate.
• Figures 1 B, 2B, 3B, and 4B respectively show a scanning electron micrograph (SEM) of the
• ZSM-5 powder which was obtained according to Reference Examples 1 -4, respectively, using a magnification of 75,000 : 1 as indicated at the lower left hand corner of the image.
• a unit length corresponding to 0.5 ⁇ in the image is indicated as a checkered bar with 5 subunits of 0.1 ⁇ , respectively.
• Figures 1 C, 2C, and 4C respectively show the IR spectra of the crystalline material obtained according to Reference Examples 1 , 2, and 4.
• the wavenumbers in cm- 1 is plotted along the abscissa and the absorbance in arbitrary units is plotted along the ordinate.
• the crystallinity of the zeolitic materials in the present examples was determined by XRD analysis, wherein the crystallinity of a given material is expressed relative to a reference zeolitic material wherein the reflecting surfaces of the two zeolitic materials are compared.
• the reference zeolitic materials were commercial H-ZSM-5 at an S1O2/AI2O3 ratio of 100 or 250.
• the determination of the crystallinities was performed on a D8 Advance series 2 diffracto meter from Bruker AXS.
• the diffractometer was configured with an opening of the divergence aperture of 0.1 0 and a Lynxeye detector.
• the samples as well as the reference zeolitic material were measured in the range from 21 0 to 25 0 (2 Theta).
• the reflecting surfaces were determined by making use of the evaluation software EVA (from Bruker AXS). The ratios of the reflecting surfaces are given as percentage values.
• the IR measurements in the present examples were performed on a Nicolet 6700 spectrometer.
• the zeolitic materials were pressed into a self-supporting pellet without the use of any additives.
• the pellet was introduced into a high vacuum cell placed into the IR instrument. Prior to the measurement the sample was pretreated in high vacuum (10-5 mbar) for 3 h at 300 °C.
• the spectra were collected after cooling the cell to 50 °C.
• the spectra were recorded in the range of 4000 cm- 1 to 1400 cm- 1 at a resolution of 2 cm- 1 .
• the obtained spectra were represented by a plot having on the x axis the wavenumber (cm- 1 ) and on the y axis the absorbance (arbitrary units).
• a baseline correction was carried out. Changes in the 3000 to 3900 cm- 1 region were analyzed and for comparing multiple samples, the band at 1880 ⁇ 5 cm- 1 was taken as reference.
• Water adsorption/desorption isotherms in the present examples were performed on a VTI SA instrument from TA Instruments following a step-isotherm program.
• the experiment consisted of a run or a series of runs performed on a sample material that has been placed on the microbalance pan inside of the instrument.
• the residual moisture of the sample was removed by heating the sample to 100 °C (heating ramp of 5 °C/min) and holding it for 6 h under a nitrogen flow.
• the temperature in the cell was decreased to 25 °C and kept constant during the measurement.
• the microbalance was calibrated, and the weight of the dried sample was balanced (maximum mass deviation 0.01 wt.-%).
• Water uptake of a sample was measured as the increase in weight compared to the dry sample.
• an adsorption curve was measured by increasing the relative humidity (RH) (expressed as weight-% water in the atmosphere inside of the cell) to which the sample was exposed and measuring the water uptake by the sample as equilibrium.
• the RH was increased with a step of 10 % from 5 % to 85 % and at each step the system controlled the RH and monitored the weight of the sample until reaching the equilibrium conditions after the sample and recording the weight uptake.
• the total adsorbed water of the sample was taken after the sample was exposed to the 85 weight-% RH.
• the RH was decreased from 85 weight-% to 5 weight-% with a step of 10 % and the change in the weight of the sample (water uptake) was monitored and recorded.
• the crush strength in the present examples is to be understood as determined via a crush strength test machine Z2.5/TS1 S, supplier Zwick GmbH & Co., D.89070 Ulm, Germany.
• a crush strength test machine Z2.5/TS1 S supplier Zwick GmbH & Co., D.89070 Ulm, Germany.
• Register 1 Carbonan effet /buthandbuch fur die Material- Prufmaschine Z2.5/TS1 S
• Technische August-Nagel-Strasse 1 1 , D-89079 Ulm, Germany.
• a given (final) strand as prepared in Examples 5 to 1 1 having a diameter of 2.5 mm, is subjected to an increasing force via a plunger having a diameter of 3 mm until the strand is crushed.
• the force at which the strand crushes is referred to as the crushing strength of the strand.
• the machine is equipped with a fixed horizontal table on which the strand is positioned.
• a plunger which is freely movable in vertical direction actuates the strand against the fixed bed table.
• the apparatus was operated with a preliminary force of 0.5 N, a shear rate under preliminary force of 10 mm/min and a subsequent testing rate of 1 .6 mm/min.
• the vertically movable plunger was connected to a load cell for force pick-up and, during the measurement, moved toward the fixed turntable on which the molding (strand) to be investigated is positioned, thus actuating the strand against the table.
• the plunger was applied to the strands perpendicularly to their longitudinal axis. Controlling the experiment was carried out by means of a computer which registered and evaluated the results of the measurements. The values obtained are the mean value of the measurements for 25 strands in each case.
• Reference Example 1 Synthesis of ZSM-5 zeolite at an Si0 2 : Al 2 0 3 molar ratio of 100
• Tetraethylorthosilicate (757 g) was stirred in a four-necked flask. Water (470 g) and tetrapropylammonium hydroxide (40 wt% in water, 366 g) were added. The mixture was stirred for 60 minutes during which the temperature rose to 60 °C. This was due to the hydrolysis of tetraethylorthosilicate resulting in the formation of ethanol. The ethanol was removed via distillation until a sump temperature of 95 °C was reached. Thereby 817 g of ethanol were removed from the mixture. The mixture was then allowed to cool to 40 °C while stirring, 817 g of water were added and the resulting gel was filled into an autoclave. A solution of aluminum sulfate octadeca hydrate (24.2 g) and water (40 g) were added to the autoclave. The autoclave was closed and heated to 170 °C.
• the calcined material displayed an S1O2 : AI2O3 molar ratio of 96.
• Figure 1A shows the XRD of the crystalline product obtained from the synthesis of Reference Example 1 , displaying the line pattern typical for the MFI framework structure.
• the crystallinity as determined according to Reference Example 1 was 98%.
• Figure 1 B shows the electron micrograph of the product as obtained from SEM at a magnification of 75 x 10 4 . As may be taken from the micrograph, practically only spherical primary particles are observed even at this high degree of magnification, wherein the size of the primary particles was determined to lie in the range of from 100-170 nm.
• the material displayed a BET surface area of 426 m 2 /g.
• the total intrusion volume determined according to Hg porosimetry according to DIN 66133 was 1 .24 ml/g (milliliter/gram), the respective total pore area 40.5 m 2 /g.
• Temperature programmed desorption of ammonia afforded values of 0.43 mmol/g when conducted at 152 °C and of 0.24 mmol/g when conducted at 378 °C.
• the material had a water uptake of 6.3 wt.% at a relative humidity of 85 %.
• Figure 1 C shows the IR-OH bands of the sample obtained according to Reference Example 1.
• the band regions along with the band heights are as follows:
• the IR-band ratio of the absorbance intensity for the silanol nests to the surface silanol amounts to 1 .45.
• Reference Example 2 Synthesis of ZSM-5 zeolite at an Si0 2 : Al 2 0 3 molar ratio of 250
• Tetraethylorthosilicate (757 kg) was stirred in a vessel.
• Water (470 kg) and tetrapropylammonium hydroxide (40 wt% in water, 333 kg) were added.
• the mixture was stirred for 60 minutes during which the temperature rose to 60 °C. This was due to the hydrolysis of tetraethylorthosilicate resulting in the formation of ethanol.
• the ethanol was removed via distillation until a sump temperature of 95 °C was reached. Thereby 832 kg of ethanol were removed from the mixture.
• 832 kg of water and a solution of aluminum sulfate octadecahydrate (9.4 kg) and water (20 kg) were added to the vessel.
• the vessel was closed and heated to 150 °C. After stirring the gel at 150 °C for 24 h the autoclave was cooled to ambient temperature and the mixture was removed. It was treated with nitric acid (10 wt% in water) until a pH value of 7.1 was reached. The resulting suspension was filtered. The filter cake was washed with water and dried (120 °C). The dry powder was ground and subsequently calcined (5 h, 500 °C). Elemental analysis:
• the calcined material displayed an S1O2 : AI2O3 molar ratio of 233.
• Figure 2A shows the XRD of the crystalline product obtained from the synthesis of Reference Example 2, displaying the line pattern typical for the MFI framework structure. The crystallinity as determined according to Reference Example 1 was 96%.
• Figure 2B shows the electron micrograph of the product as obtained from SEM at a magnification of 75 x 10 4 . As may be taken from the micrograph, practically only spherical primary particles are observed even at this high degree of magnification, wherein the size of the primary particles was determined to lie in the range of from 50-150 nm.
• the material displayed a BET surface area of 441 m 2 /g.
• the total intrusion volume determined according to Hg porosimetry according to DIN 66133 was 1 .45 ml/g (milliliter/gram), the respective total pore area 71 .3 m 2 /g.
• Temperature programmed desorption of ammonia (NH3-TPD) afforded values of 0.24 mmol/g when conducted at 107 °C and of 0.12 mmol/g when conducted at 343 °C.
• the material had a water uptake of 7.1 wt.% at a relative humidity of 85 %.
• Figure 2C shows the IR-OH bands of the sample obtained according to Reference Example 2.
• the band regions along with the band heights are as follows:
• the IR-band ratio of the absorbance intensity for the silanol nests to the surface silanol amounts to 1 .36.
• Tetraethylorthosilicate (757 g) was stirred in a four-necked flask. Water (470 g) and tetrapropylammonium hydroxide (40 wt% in water, 333 g) were added. The mixture was stirred for 60 minutes during which the temperature rose to 60 °C. This was due to the hydrolysis of tetraethylorthosilicate resulting in the formation of ethanol. The ethanol was removed via distillation until a sump temperature of 95 °C was reached. Thereby 805 g of ethanol were removed from the mixture. The mixture was then allowed to cool to 40 °C while stirring, 805 g of water were added and the resulting gel was filled into an autoclave. A solution of aluminum sulfate octadeca hydrate (7.6 g) and water (25 g) were added to the autoclave. The autoclave was closed and heated to 170 °C.
• the calcined material displayed an S1O2 : AI2O3 molar ratio of 325.
• Figure 3A shows the XRD of the crystalline product obtained from the synthesis of Example 1 , displaying the line pattern typical for the MFI framework structure.
• Figure 3B shows the electron micrograph of the product as obtained from SEM at a magnification of 75 x 10 4 . As may be taken from the micrograph, practically only spherical primary particles are observed even at this high degree of magnification, wherein the size of the primary particles was determined to lie in the range of from 100-200 nm.
• the material displayed a BET surface area of 442 m 2 /g.
• Temperature programmed desorption of ammonia (NH3-TPD) afforded values of 0.19 mmol/g when conducted at 108 °C and of 0.067 mmol/g when conducted at 340 °C.
• Reference Example 4 Water-treatment of ZSM-5 zeolite at an Si0 2 : AI2O3 molar ratio of 100
• a post-treatment stage was performed as follows: 100 g of the calcined zeolitic powder obtained according to Reference Example 1 were suspended in 2000 g of deionized water. The mixture was filled in a vessel and the vessel was closed (pressure-tight). Then, the mixture was heated to a temperature of 145 °C within 1 .5 h and kept at this temperature under autogenous pressure (about 4 bar) for 8 h. The water- treated powder was subjected to filtration and washed with deionized water. The obtained filter cake was dried at 120 °C for 4 h. Subsequently, the dried material was heated under air to a temperature of 500 °C within 4 h and kept at this temperature for 5 h. The yield thereafter was 85 g.
• the thus obtained water-treated zeolitic powder had a Si content of 45 wt.%, an Al content of 0.87 wt.% which correspond to an S1O2 : AI2O3 molar ratio of 99.
• the degree of crystallization determined via XRD was 101 -1 14%.
• the XRD of the material is shown in Figure 4A.
• the inventive water treatment caused an increase from a value of 98% (cf. Reference Example 1 ) to a value of 101 -1 14%.
• Figure 4B shows the electron micrograph of the product as obtained from SEM at a magnification of 50 x 10 4 . As may be taken from the micrograph, practically only spherical primary particles are observed even at this high degree of magnification, wherein the size of the primary particles was determined to lie in the range of from 70-150 nm.
• the powder had a multipoint BET specific area determined via nitrogen adsorption at 77 K according to DIN 66133 of 427 m 2 /g.
• the total intrusion volume determined according to Hg porosimetry according to DIN 66133 was 1 .1 1 ml/g (milliliter/gram), the respective total pore area 40.7 m 2 /g.
• the total amount of adsorbed water as determined was 3.8-4.1 wt.% (compared to 6.3 wt.% of the starting material as described in Reference Example 1 ). Therefore, it is clearly shown that the inventive water treatment increases the hydrophobicity of the powder.
• the IR spectrum of the powder obtained according to Reference Example 4 is shown in Fig. 4C.
• the band regions of the powder according to Reference Example 4 along with the band heights are as follows:
• the IR-band ratio of the absorbance intensity for the silanol nests to the surface silanol amounts to 1.00.
• ZSM-5 powder (100 g) obtained from Reference Example 1 was mixed with Pural SB (86.5 g), formic acid (2.6 g in 20 mL water) and Walocel (5 g). The masses of the raw materials were chosen in a way as to yield a zeolite-to-binder ratio of 60:40 in the resulting calcined shaped bodies.
• the mixture was homogenized in a kneading machine by the addition of water (100 g).
• the obtained plastic mixture was formed to strands (0 2.5 mm) using a strand press (pressure -100 bar). The strands were dried (16 h, 120°C) and calcined (4 h, 500°C), thus obtaining extrudates having a cutting hardness of 1 1.1 N.
• the BET surface area of the extrudates was determined to 362 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.46 cm 3 /g, the respective total pore area 1 17.0 m 2 /g.
• Comparative Example 6 Shaping of ZSM-5 zeolite from Reference Example 2 ZSM-5 powder (100 g) obtained from Reference Example 2 was mixed with Pural SB (86.5 g), formic acid (2.6 g in 20 mL water) and Walocel (5 g). The masses of the raw materials were chosen in a way as to yield a zeolite-to-binder ratio of 60:40 in the resulting calcined shaped bodies. The mixture was homogenized in a kneading machine by the addition of water (83 g). The obtained plastic mixture was formed to strands (0 2.5 mm) using a strand press (pressure -100 bar). The strands were dried (16 h, 120°C) and calcined (4 h, 500°C), thus obtaining extrudates having a cutting hardness of 21.6 N.
• the BET surface area of the extrudates was determined to 374 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.36 cm 3 /g, the respective total pore area 1 19.5 m 2 /g.
• Example 7 Impregnation of ZSM-5 zeolite from Reference Example 1 with magnesium and shaping thereof
• ZSM-5 powder from Reference Example 1 was spray impregnated with a magnesium nitrate solution.
• the amount of magnesium nitrate was chosen in a way as to obtain a zeolite with 4 wt% of Mg after calcination.
• zeolite powder (98.2 g) obtained from Reference Example 1 was placed into a round-bottomed flask that was connected to a rotary evaporator.
• Magnesium nitrate (44.0 g) was solubilized in water to yield 77 mL of a solution. 68.9 mL of the solution were slowly sprayed on the rotating zeolite using a spray nozzle (1001/h N2 stream).
• the Mg-impregnated zeolite was shaped to extrudates exhibiting a zeolite-to-binder ratio of 60/40 in their calcined form.
• ZSM-5 powder 100 g was mixed with Pural SB (86.5 g), formic acid (2.6 g in 20 mL water) and Walocel (5 g). The mixture was homogenized in a kneading machine by the addition of water (95 g). The obtained plastic mixture was formed to strands (0 2.5 mm) using a strand press (pressure -150 bar). The strands were dried (16 h, 120°C) and calcined (4 h, 500°C), thus obtaining extrudates having a cutting hardness of 10.2 N.
• the BET surface area of the extrudates was determined to 309 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.84 cm 3 /g, the respective total pore area 102.9 m 2 /g.
• Example 8 Impregnation of ZSM-5 zeolite from Reference Example 2 with magnesium and shaping thereof
• ZSM-5 powder from Reference Example 2 was spray impregnated with a magnesium nitrate solution.
• the amount of magnesium nitrate was chosen in a way as to obtain a zeolite with 4 wt% of Mg after calcination.
• zeolite powder (120 g) obtained from Reference Example 2 was placed into a round-bottomed flask that was connected to a rotary evaporator.
• Magnesium nitrate (53.8 g) was solubilized in water to yield 82 ml. of a solution.
• 73 ml. of the solution were slowly sprayed on the rotating zeolite using a spray nozzle (100 l/h N2 stream).
• the Mg-impregnated zeolite was then shaped to extrudates exhibiting a zeolite-to-binder ratio of 60/40 in their calcined form.
• the impregnated ZSM-5 powder 100 g was mixed with Pural SB (86.5 g), formic acid (2.6 g in 20 ml. water) and Walocel (5 g).
• the mixture was homogenized in a kneading machine by the addition of water (85 g).
• the obtained plastic mixture was formed to strands (0 2.5 mm) using a strand press (pressure -130 bar).
• the strands were dried (16 h, 120°C) and calcined (4 h, 500°C), thus obtaining extrudates having a cutting hardness of 1 1 .0 N. Elemental analysis:
• the BET surface area of the extrudates was determined to 310 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.67 cm 3 /g.
• Example 9 Impregnation of water-treated ZSM-5 zeolite from Reference Example 4 with magnesium and shaping thereof
• ZSM-5 powder from Reference Example 4 was spray impregnated with a magnesium nitrate solution.
• the amount of magnesium nitrate was chosen in a way as to obtain a zeolite with 4 wt% of Mg after calcination.
• the zeolite powder 100 g was placed into a round- bottomed flask that was connected to a rotary evaporator.
• Magnesium nitrate (44.8 g) was solubilized in water. 61 .2 mL of the solution were slowly sprayed on the rotating zeolite using a spray nozzle (1 OOI/h N 2 stream). This corresponds to 90% of the maximum water uptake capacity of the zeolite.
• the complete solution was sprayed on the zeolite, the latter was allowed to rotate for 10 min.
• the treated powder was dried (16 h, 120°C), calcined (4 h, 500°C), milled and sieved (1 mm size).
• the obtained powder has an Mg content of 3.9 wt%.
• Mg-ZSM-5 powder (98.9 g) was mixed with Pural SB (90.3 g), formic acid (2.7 g in 20 mL water) and Walocel (5 g).
• the masses of the raw materials were chosen in a way as to yield a zeolite- to-binder ratio of 60:40 in the resulting calcined shaped bodies.
• the mixture was homogenized in a kneading machine by the addition of water (90 g).
• the obtained plastic mixture was formed to strands (0 2.5 mm) using a strand press (pressure -100 bar).
• the strands were dried (16 h, 120°C) and calcined (4 h, 500°C). They were split to 1 .6-2.0 mm fractions using a sieving machine equipped with two steel balls (0 2 cm, 258 g/ball) prior to application in the conversion of methanol to olefins.
• the obtained extrudates had a Si content of 23.7 wt.%, an Al content of 20.7 wt.%, an Mg content of 2.3 wt% and a multipoint BET specific area determined via nitrogen adsorption at 77 K according to DIN 66133 of 307 m 2 /g.
• the crush strength of the moldings as determined according to the method using a crush strength test machine Z2.5/TS1 S as described in Reference Example 4 was 8.7 N.
• the total intrusion volume determined according to Hg porosimetry according to DIN 66133 was 0.88 mL/g (milliliter/gram), the respective total pore area 124.7 m 2 /g.
• Temperature programmed desorption of ammonia afforded values of 0.41 mmol/g when conducted at 161 °C and of 0.25 mmol/g when conducted at 355 °C.
• the size of the primary particles of the commercial ZSM-5 zeolite as determined by SEM were shown to lie in the range of from 200-500 nm.
• the BET surface area of the extrudates was determined to 310 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.36 cm 3 /g.
• Example 7 For further comparison, the procedure of Example 7 was repeated using the commercial ZSM-5 zeolite employed in Comparative Example 10, thus obtaining extrudates having a cutting hardness of 10.5 N.
• the BET surface area of the extrudates was determined to 293 m 2 /g, and the pore volume as obtained by Hg-Porosimetry to 0.44 cm 3 /g.
• Methanol was evaporated, mixed with nitrogen to afford a gas stream containing 75 vol.-% methanol and 25 vol.-% nitrogen. Methanol in the gas stream was then converted to dimethylether in a heated pre-reactor (275 °C) charged with alumina split (34 ml_). The resulting stream was then converted in a continuously operated, electrically heated tubular reactor that was charged with the respective zeolite catalyst (2 g, diluted with 23 g of SiC) to be tested. The MTO reaction was conducted at a temperature of 450-500 °C at a pressure (absolute) of 1 -2 bar and at a weight hourly space velocity of 6 r 1 based on the volume of methanol in the initial gas stream.

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