Classifications

• • 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
• • 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
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
  • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
  • B01J20/16—Alumino-silicates
  • B01J20/18—Synthetic zeolitic molecular sieves
• • 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
• • 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
• • 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
  • C01B39/04—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 using at least one organic template directing agent, e.g. an ionic quaternary ammonium compound or an aminated compound
• • 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

Definitions

• This disclosure relates to a new crystalline molecular sieve designated SSZ- 101, a method for preparing SSZ-101, and uses for SSZ-101.
• aluminophosphates, and mesoporous materials are ordered, porous crystalline materials having a definite crystalline structure as determined by X-ray diffraction (XRD).
• XRD X-ray diffraction
• New molecular sieves can contain novel internal pore architectures, providing enhanced selectivities in these processes.
• the present disclosure is directed to a new family of molecular sieves with unique properties, referred to herein as "molecular sieve SSZ-101" or simply “SSZ-101.”
• a molecular sieve having a mole ratio of at least 5 of (1) at least one oxide of at least one tetravalent element to (2) optionally, one or more oxides selected from the group consisting of oxides of trivalent elements, pentavalent elements, and mixtures thereof, and having, in its as-synthesized form, the X-ray diffraction lines of Table 5.
• the phrase "mole ratio of at least 5" includes the case where there is no oxide (2), i.e., the mole ratio of oxide (1) to oxide (2) is infinity. In that case, the molecular sieve is comprised of essentially all of the oxide of the one or more tetravalent elements.
• a method of preparing a crystalline molecular sieve by contacting under crystallization conditions (1) at least one source of an oxide of at least one tetravalent element; (2) optionally, one or more sources of one or more oxides selected from the group consisting of oxides of trivalent elements, pentavalent elements, and mixtures thereof; (3) at least one source of an element selected from Groups 1 and 2 of the Periodic Table; (4) hydroxide ions; and (5) a N-cyclohexylmethyl-N- ethylpiperidinium cation.
• the present disclosure also provides a novel molecular sieve designated SSZ- 101 having a composition, as-synthesized and in the anhydrous state, in terms of mole ratios, as follows:
• T is selected from the group consisting of tetravalent elements from Groups 4-14 of the Periodic Table, and mixtures thereof;
• X is selected from the group consisting of trivalent and pentavalent elements from Groups 3-13 of the Periodic Table, and mixtures thereof;
• Q is a N- cyclohexylmethyl-N-ethylpiperidinium cation; and
• M is selected from the group consisting of elements from Groups 1 and 2 of the Periodic Table;
• FIG. 1 is a powder X-ray diffraction (XRD) pattern of the as-synthesized molecular sieve prepared in Example 2.
• FIG. 2 is a powder XRD pattern of the calcined molecular sieve prepared in Example 3.
• molecular sieve includes (a) intermediate and (b) final or target molecular sieves and molecular sieves produced by (1) direct synthesis or (2) post- crystallization treatment (secondary synthesis). Secondary synthesis techniques allow for the synthesis of a target material from an intermediate material by heteroatom lattice substitution or other techniques.
• SDA structure directing agent
• the SDA cation is associated with anions which can be any anion that is not detrimental to the formation of SSZ-101.
• Representative anions include elements from Group 17 of the Periodic Table (e.g., fluoride, chloride, bromide and iodide), hydroxide, acetate, sulfate, tetrafluoroborate, carboxylate, and the like.
• molecular sieve SSZ-101 is prepared by: (a) preparing a reaction mixture containing (1) at least one source of an oxide of at least one tetravalent element; (2) optionally, one or more sources of one or more oxides selected from the group consisting of oxides of trivalent elements, pentavalent elements, and mixtures thereof; (3) at least one source of an element selected from Groups 1 and 2 of the Periodic Table; (4) hydroxide ions; (5) a N-cyclohexylmethyl-N-ethylpiperidinium cation and (6) water; and (b) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve.
• compositional variables T, X, M, and Q and stoichiometric variable b are as described herein above.
• composition of the reaction mixture from which SSZ-101 is formed in terms of mole ratios, is identified in Table 2 below:
• compositional variables M and Q and stoichiometric variable b are as described herein above.
• T is selected from the group consisting of tetravalent elements from Groups 4-14 of the Periodic Table.
• T is selected from the group consisting of silicon (Si), germanium (Ge), titanium (Ti), and mixtures thereof.
• T is selected from the group consisting of Si, Ge, and mixtures thereof.
• T is Si.
• Sources of elements selected for compositional variable T include oxides, hydroxides, acetates, oxalates, ammonium salts and sulfates of the element(s) selected for T.
• each source(s) of the element(s) selected for composition variable T is an oxide.
• T is Si
• sources useful for silicon include fumed silica, precipitated silicates, silica hydrogel, silicic acid, colloidal silica, tetra-alkyl orthosilicates (e.g., tetraethyl orthosilicate), and silica hydroxides.
• Sources useful herein for Ge include germanium oxide and germanium ethoxide.
• X is selected from the group consisting of trivalent and pentavalent elements from Groups 3-13 of the Periodic Table.
• X is selected from the group consisting of boron (B), aluminum (Al), gallium (Ga), indium (In), iron (Fe), and mixtures thereof.
• B aluminum
• Ga gallium
• In iron
• X is selected from the group consisting of B, Al, Ga, In, and mixtures thereof.
• X is Al.
• Sources of elements selected for compositional variable X include oxides, hydroxides, acetates, oxalates, ammonium salts and sulfates of the element(s) selected for X.
• sources useful for aluminum include aluminates, alumina, and aluminum compounds such as A1C1 3 , A1 2 (S04)3, Al(OH) 3 , kaolin clays, and other zeolites.
• An example of the source of aluminum oxide is zeolite Y. Boron, gallium, indium, titanium, and iron can be added in forms corresponding to their aluminum and silicon counterparts.
• the reaction mixture can be formed using at least one source of an element selected from Groups 1 and 2 of the Periodic Table (referred to herein as M).
• the reaction mixture is formed using a source of an element from Group 1 of the Periodic Table.
• the reaction mixture is formed using a source of sodium (Na). Any M- containing compound which is not detrimental to the crystallization process is suitable. Sources for such Groups 1 and 2 elements include oxides, hydroxides, nitrates, sulfates, halides, oxalates, citrates and acetates thereof.
• the molecular sieve reaction mixture can be supplied by more than one source. Also, two or more reaction components can be provided by one source.
• the reaction mixture can be prepared either batch wise or continuously. Crystal size, morphology and crystallization time of the molecular sieve described herein can vary with the nature of the reaction mixture and the crystallization conditions.
• the molecular sieve is prepared by: (a) preparing a reaction mixture as described herein above; and (b) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve (see, e.g., H. Robson, "Verified Syntheses ofZeolitic Materials,” Second Revised Edition, Elsevier, 2001).
• the reaction mixture is maintained at an elevated temperature until the crystals of the molecular sieve are formed.
• the hydrothermal crystallization is usually conducted under pressure, and usually in an autoclave so that the reaction mixture is subject to autogenous pressure, at a temperature between 125°C and 200°C.
• the reaction mixture can be subjected to mild stirring or agitation during the crystallization step.
• the molecular sieves described herein can contain impurities, such as amorphous materials, unit cells having framework topologies which do not coincide with the molecular sieve, and/or other impurities (e.g., organic hydrocarbons).
• the molecular sieve crystals can be allowed to nucleate spontaneously from the reaction mixture.
• the use of crystals of the molecular sieve as seed material can be advantageous in decreasing the time necessary for complete crystallization to occur.
• seeding can lead to an increased purity of the product obtained by promoting the nucleation and/or formation of the molecular sieve over any undesired phases.
• seed crystals are added in an amount between 1% and 10% of the weight of the source for compositional variable T used in the reaction mixture.
• the solid product is separated from the reaction mixture by standard mechanical separation techniques such as filtration.
• the crystals are water-washed and then dried to obtain the as-synthesized molecular sieve crystals.
• the drying step can be performed at atmospheric pressure or under vacuum.
• the molecular sieve can be used as-synthesized, but typically will be thermally treated (calcined).
• the term "as-synthesized” refers to the molecular sieve in its form after crystallization, prior to removal of the SDA cation.
• the SDA can be removed by thermal treatment (e.g., calcination), preferably in an oxidative atmosphere (e.g., air, gas with an oxygen partial pressure of greater than 0 kPa) at a temperature readily determinable by the skilled artisan sufficient to remove the SDA from the molecular sieve.
• an oxidative atmosphere e.g., air, gas with an oxygen partial pressure of greater than 0 kPa
• the SDA can also be removed by photolysis techniques (e.g., exposing the SDA-containing molecular sieve product to light or electromagnetic radiation that has a wavelength shorter than visible light under conditions sufficient to selectively remove the organic compound from the molecular sieve) as described in U.S. Patent. No. 6,960,327.
• photolysis techniques e.g., exposing the SDA-containing molecular sieve product to light or electromagnetic radiation that has a wavelength shorter than visible light under conditions sufficient to selectively remove the organic compound from the molecular sieve
• the molecular sieve can subsequently be calcined in steam, air or inert gas at temperatures ranging from 200°C to 800°C for periods of time ranging from 1 to 48 hours, or more.
• the target molecular sieve formed is an intermediate material
• the target molecular sieve can be achieved using post-synthesis techniques such as heteroatom lattice substitution techniques.
• the target molecular sieve can also be achieved by removing heteroatoms from the lattice by known techniques such as acid leaching.
• the molecular sieve made from the process disclosed herein can be formed into a wide variety of physical shapes.
• the molecular sieve can be in the form of a powder, a granule, or a molded product, such as extrudate having a particle size sufficient to pass through a 2-mesh (Tyler) screen and be retained on a 400-mesh (Tyler) screen.
• the molecular sieve can be extruded before drying or dried (or partially dried) and then extruded.
• the molecular sieve can be composited with other materials resistant to the temperatures and other conditions employed in organic conversion processes.
• matrix materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and metal oxides. Examples of such materials and the manner in which they can be used are disclosed in U.S. Patent Nos. 4,910,006 and 5,316,753.
• compositional variables T, X, Q and M and stoichiometric variable b are as described herein above.
• the molecular sieves made by the process disclosed herein have a composition (in terms of mole ratios), as-synthesized and in the anhydrous state, as described in Table 4 below:
• compositional variables Q and M are as described herein above:
• Molecular sieves synthesized by the process disclosed herein are characterized by their XRD pattern.
• the X-ray diffraction pattern lines of Table 5 are representative of as- synthesized SSZ-101 made in accordance with this disclosure.
• Minor variations in the diffraction pattern can result from variations in the mole ratios of the framework species of the particular sample due to changes in lattice constants.
• sufficiently small crystals will affect the shape and intensity of peaks, leading to significant peak broadening.
• Minor variations in the diffraction pattern can also result from variations in the organic compound used in the preparation. Calcination can also cause minor shifts in the XRD pattern. Notwithstanding these minor perturbations, the basic crystal lattice structure remains unchanged.
• the X-ray diffraction pattern lines of Table 6 are representative of calcined SSZ-101 made in accordance with this disclosure.
• SSZ-101 is useful as an adsorbent for gas separations.
• SSZ-101 can also be used as a catalyst for converting oxygenates (e.g., methanol) to olefins and for making small amines.
• SSZ-101 can be used to reduce oxides of nitrogen in a gas streams, such as automobile exhaust.
• SSZ-101 can also be used to as a cold start hydrocarbon trap in combustion engine pollution control systems.
• SSZ-101 is particularly useful for trapping C3 fragments.
• N-Cyclohexylmethylpiperidine 34.15 g was dissolved in 300 mL of methanol.
• An addition funnel was charged with a solution of 62 g of ethyl iodide in 100 mL of methanol.
• the ethyl iodide solution was added dropwise to the N- cyclohexylmethylpiperidine solution and then refluxed for 48 hours.
• the mixture was concentrated under vacuum to remove most of the ethyl iodide and methanol.
• N- cyclohexylmethyl-N-ethylpiperidinium iodide 49.9 g was recrystallized from hot acetone and diethyl ether.
• N-cyclohexylmethyl-N-ethylpiperidinium iodide was dissolved in deionized water (1 mL H 2 O/I mmol salt) and then 1.1 g of hydroxide-based ion exchange resin/1 mmol salt was added. The resulting slurry was left to stir gently for a few hours. The slurry was filtered and the filtrate was analyzed by titration of a small aliquot with dilute HCl. The exchange afforded N-cyclohexylmethyl-N-ethylpiperidinium hydroxide in nearly quantitative yield.
• the as -synthesized product had a S1O2/AI2O 3 mole ratio of 8, as determined by ICP elemental analysis.
• Example 2 The as-synthesized product of Example 2 was calcined inside a muffle furnace under a flow of air heated to 595°C at a rate of l°C/minute and held at 595°C for 5 hours, cooled and then analyzed by powder XRD.
• the powder XRD pattern of the resulting product is shown in FIG. 2.
• the powder XRD pattern indicates that the material remains stable after calcination to remove the organic SDA.
• Calcined SSZ-101 was subjected to a micropore volume analysis using 2 as adsorbate and via the BET method.
• the molecular sieve exhibited a micropore volume of 0.097 cm 3 /g.
• the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
• the term “comprising” means including elements or steps that are identified following that term, but any such elements or steps are not exhaustive, and an embodiment can include other elements or steps.

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