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
  • B01J29/70—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
• • 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
  • B01J29/7049—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead
• • 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
  • B01J29/87—Gallosilicates; Aluminogallosilicates; Galloborosilicates
• • 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
  • C01B39/06—Preparation of isomorphous zeolites characterised by measures to replace the aluminium or silicon atoms in the lattice framework by atoms of other elements, i.e. by direct or secondary synthesis
  • C01B39/065—Galloaluminosilicates; Group IVB- metalloaluminosilicates; Ferroaluminosilicates
• • 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
  • C01B39/46—Other types characterised by their X-ray diffraction pattern and their defined composition
  • C01B39/48—Other types characterised by their X-ray diffraction pattern and their defined composition using at least one organic template directing agent
• • 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
  • B01J2229/26—After treatment, characterised by the effect to be obtained to stabilize the total catalyst structure
• • 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
  • B01J2229/36—Steaming
• • 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

Definitions

• This invention relates to a synthetic crystalline zeolite, to a method for its synthesis and to its use in catalytic conversion of organic compounds.
• Zeolitic materials both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion. Certain zeolitic materials are ordered, porous
• zeolitic material Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as "molecular sieves" and are utilized in a variety of ways to take advantage of these properties.
• Such molecular sieves both natural and synthetic, include a wide variety of positive ion-containing crystalline silicates. These silicates can be
• SiO 4 and Periodic Table Group IIIA element oxide e.g. AlO 4 , in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total Group IIIA element, e.g. aluminum, and silicon atoms to oxygen atoms is 1:2.
• a cation for example an alkali metal or an alkaline earth metal cation.
• This can be expressed wherein the ratio of the Group IIIA element, e.g. aluminum, to the number of various cations, such as Ca/2, Sr/2, Na, K or Li, is equal to unity.
• One type of cation may be exchanged either entirely or partially with another type of cation utilizing ion exchange techniques in a conventional manner. By means of such cation exchange, it has been possible to vary the properties of a given silicate by suitable selection of the cation. The spaces between the tetrahedra are occupied by molecules of water prior to dehydration.
• zeolites Many of these zeolites have come to be designated by letter or other convenient symbols, as illustrated by zeolite A (U.S. Patent 2,882,243); zeolite X (U.S.
• Patent 2,882,244 zeolite Y (U.S. Patent 3,130,007); zeolite ZK-5 (U.S. Patent 3,247,195); zeolite ZK-4 (U.S. Patent 3,314,752); zeolite ZSM-5 (U.S. Patent 3,702,886); zeolite ZSM-11 (U.S. Patent 3,709,979);
• zeolite ZSM-12 U.S. Patent 3,832,449
• zeolite ZSM-20 U.S. Patent 3,972,983
• ZSM-35 U.S. Patent
• zeolite MCM-22 U.S. Patent 4,954,325)
• zeolite MCM-35 U.S. Patent 4,981,663
• U.S. Patent 4,439,409 refers to a zeolite named PSH-3 and its synthesis from a reaction mixture
• Hexamethyleneimine is also used for synthesis of zeolite MCM-22 in U.S.
• the present invention is directed to a synthetic crystalline zeolite, referred to herein as MCM-49, which is structurally related to, but different from, MCM-22.
• the invention resides in a synthetic crystalline zeolite having, in its as-synthesized form, an X-ray diffraction pattern including values
• Figure 1a shows a segment of the X-ray diffraction pattern of the as-synthesized precursor of MCM-22 from a repeat of Example 1 of U.S. Patent 4,954,325,
• Figure 1b shows a segment of the X-ray diffraction pattern of the as-synthesized crystalline material product of Example 7 of the present invention
• Figure lc shows a segment of the X-ray diffraction pattern of the calcined MCM-22 from a repeat of Example 1 of U.S. Patent 4,954,325,
• Figures 2-7 are X-ray diffraction patterns of the as-synthesized crystalline material products of the present Examples 1, 3, 5, 7, 8, and 11, respectively, and,
• Figure 8 compares the 27AR MAS NMR spectra of calcined MCM-22 and calcined MCM-49.
• the zeolite of the present invention is characterized in its as-synthesized form by an X-ray diffraction pattern including the lines listed in Table
• the crystalline MCM-49 material of the invention transforms to a single crystal phase with little or no detectable impurity crystal phases having an X-ray diffraction pattern which is not readily distinguished from that of MCM-22 described in U.S.
• Patent 4,954,325 but is distinguishable from the patterns of other known crystalline materials.
• MCM-49 includes the lines listed in Table II below:
• MCM-22 and PSH-3 are members of an unusual family of materials because, upon calcination, there are changes in the X-ray diffraction pattern that can be explained by a significant change in one axial
• the present as-synthesized MCM-49 has an axial dimension similar to those of the calcined members of the family and, hence, there are similarities in their X-ray diffraction patterns. Nevertheless, the MCM-49 axial dimension is different from that observed in the calcined materials. For example, the changes in axial dimensions in MCM-22 can be determined from the
• calcined MCM-49 and calcined MCM-22 can be
• the NMR spectra are obtained using a Bruker MSL-400 spectrometer at 104.25 MHz with 5.00 KHz spinning speed, 1.0 ⁇ s excitation pulses (solution
• the crystalline material of this invention has a composition comprising the molar relationship:
• X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum; Y is a tetravalent element such as silicon and/or germanium, preferably silicon; and n is less than 35, preferably from 11 to less than 20, most preferably from 15 to less than 20. More specifically, the crystalline material of this invention has a formula, on an
• M is an alkali or alkaline earth metal
• R is an organic directing agent
• the crystalline material of the invention is thermally stable and in the calcined form exhibits high surface area (greater than 400 m 2 /gm) and an
• the present crystalline material can be prepared from a reaction mixture containing sources of alkali or alkaline earth metal (M), e.g. sodium or potassium, cation, an oxide of trivalent element X, e.g. aluminum, an oxide of tetravalent element Y, e.g. silicon, organic directing agent (R), and water, said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges:
• M alkali or alkaline earth metal
• R organic directing agent
• the source of YO 2 should predominately be solid YO 2 , for example at least about 30 wt.% solid YO 2 , in order to obtain the crystal product of the invention.
• YO 2 is silica
• Ultrasil (a precipitated, spray dried silica containing about 90 wt.% silica) or HiSil (a precipitated hydrated SiO 2 containing about 87 wt.% silica, about 6 wt.% free H 2 O and about 4.5 wt.% bound H 2 O of hydration and having a particle size of about 0.02 micron) favors crystalline MCM-49 formation from the above mixture.
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica
• the YO 2 e.g. silica, source contains at least about 30 wt.% solid YO 2 , e.g. silic
• the directing agent R is selected from the group consisting of cycloalkylamine, azacycloalkane,
• R include cyclopentylamine
• the R/M ratio is also important in the synthesis of MCM-49 in preference to other crystalline phases, such as MCM-22, since it is found that MCM-49 is favored when the R/M ratio is less than 3 and
• a suitable reactor vessel such as for example, polypropylene jars or teflon lined or
• reaction mixture components can be supplied by more than one source.
• the reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time of the new crystalline material will vary with the nature of the reaction mixture employed and the
• Synthesis of the new crystals may be facilitated by the presence of at least 0.01 percent, preferably 0.10 percent and still more preferably 1 percent, seed crystals (based on total weight) of crystalline product.
• Useful seed crystals include MCM-22 and/or MCM-49.
• the original sodium cations of the as-synthesized material can be replaced in accordance with techniques well known in the art, at least in part, by ion exchange with other cations.
• Preferred replacing cations include metal ions
• hydrogen ions hydrogen precursor, e.g. ammonium, ions and mixtures thereof.
• Particularly preferred cations are those which tailor the catalytic activity for certain hydrocarbon conversion reactions. These include hydrogen, rare earth metals and metals of
• the crystalline material of the invention When used as a catalyst, the crystalline material of the invention may be subjected to treatment to remove part or all of any organic constituent.
• this treatment involves heating at a
• the crystalline material can also be used as a catalyst in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenating component such as tungsten, vanadium, molybdenum,
• Such component can be in the composition by way of cocrystallization, exchanged into the
• composition to the extent a Group IIIA element, e.g. aluminum, is in the structure, impregnated therein or intimately physically admixed therewith.
• a Group IIIA element e.g. aluminum
• platinum component can be impregnated in or on to it such as, for example, by, in the case of platinum, treating the silicate with a solution containing a platinum metal-containing ion.
• suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing the platinum amine complex.
• the crystalline material of this invention can be used to catalyze a wide variety of chemical conversion processes including many of present
• catalysts include those requiring a catalyst with acid activity. Specific examples include:
• benzene with long chain olefins, e.g. C 14 olefin, with reaction conditions including a temperature of 340°C to 500°C, a pressure of 100 to 20000 kPa (1 to 200 atmospheres), a weight hourly space velocity of 2 hr -1 to 2000 hr -1 and an aromatic hydrocarbon/olefin mole ratio of 1/1 to 20/1, to provide long chain alkyl aromatics which can be subsequently sulfonated to provide synthetic detergents;
• reaction conditions including a temperature of 340°C to 500°C, a pressure of 100 to 20000 kPa (1 to 200 atmospheres), a weight hourly space velocity of 2 hr -1 to 2000 hr -1 and an aromatic hydrocarbon/olefin mole ratio of 1/1 to 20/1, to provide long chain alkyl aromatics which can be subsequently sulfonated to provide synthetic detergents;
• alkylation of aromatic hydrocarbons with gaseous olefins to provide short chain alkyl aromatic compounds e.g. the alkylation of benzene with propylene to provide cumene, with reaction conditions including a temperature of 10 °C to 125oC, a pressure of 100 to 3000 kPa (1 to 30 atmospheres), and an aromatic hydrocarbon weight hourly space velocity (WHSV) of from 5 hr to 50 hr -1 ;
• alkylation of aromatic hydrocarbons e.g. benzene, toluene, xylene and naphthalene
• long chain olefins e.g. C olefin
• composition of the invention When used as a catalyst, it may be desirable to incorporate the composition of the invention with another material resistant to the temperatures and other conditions employed in organic conversion
• Such materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and/or metal oxides such as alumina.
• the latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides.
• Use of a material in conjunction with the new crystal, i.e. combined therewith or present during synthesis of the new crystal, which is active, tends to change the conversion and/or selectivity of the catalyst in certain organic conversion processes.
• Inactive materials suitably serve as diluents to control the amount of conversion in a given process so that products can be obtained economically and orderly without employing other means for controlling the rate of reaction.
• These materials may be incorporated into naturally occurring clays, e.g. bentonite and kaolin, to improve the crush strength of the catalyst under commercial operating conditions.
• Said materials i.e. clays, oxides, etc., function as binders for the catalyst. It is desirable to provide a catalyst having good crush strength because in commercial use it is desirable to prevent the catalyst from breaking down into powder-like materials.
• These clay and/or oxide binders have been employed normally only for the purpose of improving the crush strength of the
• Naturally occurring clays which can be composited with the new crystal include the montmorillonite and kaolin family, which families include the
• Binders useful for compositing with the present crystal also include inorganic oxides, notably alumina.
• the new crystal can be composited with a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia, silica-silica-alumina-magnesia and silica-magnesia-zirconia.
• a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia, silica-silica-alumina-magnesia and silica-magnesia-zirconia.
• crystalline material and inorganic oxide matrix vary widely, with the crystal content ranging from 1 to 90 percent by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of 2 to 80 weight percent of the composite.
• a weighed sample of the calcined adsorbant was contacted with the desired pure adsorbate vapor in an adsorption chamber, evacuated to less than 133 kPa (1 mmHg) and contacted with 1.6 kPa (12 Torr) of water vapor and 5.3 kPa (40 Torr) of n-hexane or cyclohexane vapor, pressures less than the vapor-liquid equilibrium pressure of the respective adsorbate at 90°C.
• the pressure was kept constant (within about ⁇ 0.5 mm) by addition of adsorbate vapor controlled by a manostat during the adsorption period, which did not. exceed about 8 hours.
• the decrease in pressure caused the manostat to open a valve which admitted more adsorbate vapor to the chamber to restore the above control pressures.
• experimental conditions of the test used herein include a constant temperature of 538°C and a variable flow rate as described in detail in the Journal of
• HMI hexamethyleneimine
• the reaction mixture had the following composition in mole ratios:
• the mixture was crystallized in a stirred reactor at 150°C for 4 days.
• the crystals were filtered, washed with water and dried at 120°C.
• a portion of the product was submitted for X-ray analysis and identified as the new crystalline material MCM-49.
• the material exhibited the X-ray powder diffraction pattern as shown in Table III and Figure 2.
• the chemical composition of the product was, in wt.%:
• the SiO 2 /Al 2 O 3 molar ratio of this product was 17.4.
• Example 1 The calcined portion of the product of Example 1 was ammonium exchanged and calcined at 538oC in air for 16 hours to provide the hydrogen form transformation product of the crystalline MCM-49.
• the Alpha Test proved this material to have an Alpha Value of 291.
• a 1.45 part quantity of sodium aluminate was added to a solution containing 1 part of 50% NaOH solution and 53.1 parts H 2 O.
• a 5.4 part quantity of HMI was added, followed by 10.3 parts of Ultrasil, a
• the reaction mixture was thoroughly mixed and transferred to a stainless steel autoclave equipped with a stirrer.
• the reaction mixture had the following composition in mole ratios:
• the mixture was crystallized with stirring at 150°C for 8 days.
• the product was identified as poorly crystalline MCM-49 and had the X-ray pattern which appears in Table V and Figure 3.
• the chemical composition of the product was, in wt.%:
• the silica/alumina mole ratio of the product was 19.2.
• the sorption capacities, after calcining for 16 hours at 538°C were, in wt.%:
• Example 3 The calcined portion of the product of Example 3 was ammonium exchanged and calcined at 538°C in air for 16 hours to provide the hydrogen form transformation product of the crystalline MCM-49.
• the Alpha Test proved this material to have an Alpha Value of 286.
• a 10.5 part quantity of gallium oxide was added to a solution containing 1.0 part sodium aluminate, 3.05 parts 50% NaOH solution and 280 parts H 2 O.
• a 25.6 part quantity of HMI was added followed by 56.6 parts of Ultrasil and 1.7 parts of MCM-22 seeds. The slurry was thoroughly mixed.
• the mixture was crystallized with stirring at 150°C for 10 days.
• the product was identified as poorly crystalline MCM-49 and had the X-ray pattern which appears in Table VII and Figure 4.
• the chemical composition of the product was, in wt.%:
• Example 5 The calcined portion of the product of Example 5 was ammonium exchanged and calcined at 538°C in air for 16 hours to provide the hydrogen form transformation product of the crystalline MCM-49.
• the Alpha Test proved this material to have an Alpha Value of 64.
• the mixture was crystallized for 5 days at 143oC.
• the product was washed, dried at 120°C and identified by X-ray analysis as MCM-49. It exhibited an X-ray pattern as shown in Table IX and Figure 5.
• the chemical composition of the product was, in wt.%:
• the silica/alumina mole ratio of the product was 18.4.
• the surface area of this material was measured to be 459 m 2 /g.
• a 2.24 part quantity of 45% sodium aluminate was added to a solution containing 1.0 part of 50% NaOH solution and 43.0 parts H 2 O in an autoclave.
• An 8.57 part quantity of Ultrasil precipitated silica was added with agitation, followed by 4.51 parts of HMI.
• the reaction mixture had the following composition, in mole ratios:
• the mixture was crystallized at 150oC for 84 hours with stirring.
• the product was identified as MCM-49 and had the X-ray pattern which appears in Table XI and Figure 6.
• the chemical composition of the product was, in wt.%:
• the silica/alumina mole ratio of the product was 17.3.
• Example 8 The calcined portion of the product of Example 8 was ammonium exchanged and calcined at 538oC in air for 3 hours to provide the hydrogen form transformation product of the crystalline MCM-49.
• the Alpha Test proved this material to have an Alpha Value of 308.
• Example 12 4,954,325 (hereinafter Example 12).
• the catalyst of the second experiment was the Example 6 product. After 20 minutes on stream, the product distribution, in weight percent, was determined to be as shown in Table XIII. Significant propylene aromatization selectivity to benzene is observed for the Example 6 catalyst compared to MCM-22. The benzene yield over the Example 6 catalyst was 7.16 wt.%, compared to 2.64 wt.% for MCM-22.
• This mixture had the following composition, in mole ratios:
• the mixture was crystallized at 143°C for 192 hours with stirring.
• the product was identified as
• the chemical composition of the product was, in wt.%:
• the silica/alumina mole ratio of the product was 27.4.

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• 1991
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