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  • 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
• • 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
  • 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
  • B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
  • B01J29/74—Noble metals
• • 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
  • B01J29/86—Borosilicates; Aluminoborosilicates
• • 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
  • C01B39/08—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 the aluminium atoms being wholly replaced
• • 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
  • C01B39/12—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 the replacing atoms being at least boron atoms
• • 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
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2002/00—Crystal-structural characteristics
  • C01P2002/30—Three-dimensional structures
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2002/00—Crystal-structural characteristics
  • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
  • C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2004/00—Particle morphology
  • C01P2004/01—Particle morphology depicted by an image
  • C01P2004/03—Particle morphology depicted by an image obtained by SEM

Definitions

• This disclosure relates to the synthesis of molecular sieve SSZ-109.
• Zeolitic materials are known to have utility as sorbent materials and to have catalytic properties for various types of hydrocarbon conversion reactions.
• Certain zeolitic materials are ordered, porous crystalline metallosilicates having a definite crystalline structure as determined by X-ray diffraction.
• Within the zeolitic material there are a large number of smaller cavities which may be interconnected by a number of still smaller channels or pores. These cavities and pores are uniform in size within a specific zeolitic material. Since the dimensions of these pores are such as to accept for sorption 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.
• a method of synthesizing a molecular sieve having the structure of SSZ-109 comprising: (a) providing a reaction mixture comprising: (1) a source of silicon oxide; (2) a source of an oxide of a trivalent element (X); (3) optionally, a source of a Group 1 or Group 2 metal (M); (4) a structure directing agent (Q) comprising N 1 ,N 6 -diisopropyl-N 1 ,N 1 ,N 6 ,N 6 - tetramethylhexane-1,6-diaminium cations; (5) a source of hydroxide ions; and (6) water; and (b) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve.
• a reaction mixture comprising: (1) a source of silicon oxide; (2) a source of an oxide of a trivalent element (X); (3) optionally, a source of a Group 1 or Group 2 metal (M); (4) a structure directing agent (Q
• a molecular sieve having the structure of SSZ-109 and, in its as-synthesized form, comprising N 1 ,N 6 -diisopropyl- N 1 ,N 1 ,N 6 ,N 6 -tetramethylhexane-1,6-diaminium cations in its pores.
• the molecular sieve can have, in its as-synthesized and anhydrous form, a chemical composition comprising the following molar relationship:
• X is a trivalent element (e.g., one or more of boron, aluminum, gallium, and iron); and Q comprises N 1 ,N 6 -diisopropyl-N 1 ,N 1 ,N 6 ,N 6 -tetramethylhexane-1,6- diaminium cations.
• FIG. 1 shows a powder X-ray diffraction (XRD) pattern of the as- synthesized molecular sieve prepared in Example 1.
• FIG. 2 shows a Scanning Electron Micrograph (SEM) image of the as- synthesized molecular sieve prepared in Example 1.
• the term "as-synthesized” is employed herein to refer to a molecular sieve in its form after crystallization, prior to removal of the structure directing agent.
• anhydrous is employed herein to refer to a molecular sieve substantially devoid of both physically adsorbed and chemically adsorbed water.
• a molecular sieve having the framework structure of SSZ- 109 may be synthesized by: (a) providing a reaction mixture comprising: (1) a source of silicon oxide; (2) a source of an oxide of a trivalent element (X); (3) optionally, a source of a Group 1 or Group 2 metal (M); (4) a structure directing agent (Q) comprising N 1 ,N 6 -diisopropyl-N 1 ,N 1 ,N 6 ,N 6 -tetramethylhexane-1,6-diaminium cations; (5) a source of hydroxide ions; and (6) water; and (b) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve.
• a reaction mixture comprising: (1) a source of silicon oxide; (2) a source of an oxide of a trivalent element (X); (3) optionally, a source of a Group 1 or Group 2 metal (M); (4) a structure directing agent (Q) comprising
• the reaction mixture may have a composition, in terms of molar ratios, within the ranges set forth in Table 1: TABLE 1
• compositional variables X, M and Q are as described herein above.
• Suitable sources of silicon oxide include fumed silica, colloidal silica, precipitated silica, alkali metal silicates and tetraalkyl orthosilicates.
• Suitable sources of trivalent element X depend on the element X that is selected (e.g., boron, aluminum, gallium, and iron).
• suitable sources of boron include boric acid, sodium tetraborate and potassium tetraborate.
• Combined sources of silicon and boron can additionally or alternatively be used and can include borosilicate zeolites (e.g., borosilicate beta zeolite).
• suitable sources of aluminum include hydrated alumina, aluminum hydroxide, alkali metal aluminates, aluminum alkoxides, and water-soluble aluminum salts (e.g., aluminum nitrate).
• Combined sources of silicon and aluminum can additionally or alternatively be used and can include aluminosilicate zeolites (e.g., zeolite Y) and clays or treated clays (e.g., metakaolin).
• Examples of suitable Group 1 or Group 2 metals (M) include sodium, potassium and calcium.
• the metal is generally present in the reaction mixture as the hydroxide.
• the structure directing agent (Q) comprises N 1 ,N 6 -diisopropyl- N 1 ,N 1 ,N 6 ,N 6 -tetramethylhexane-1,6-diaminium cations, represented by the following structure (1):
• Suitable sources of Q are the hydroxides and/or other salts of the diquaternary ammonium compound.
• the reaction mixture may also contain seeds of a crystalline molecular sieve material, such as SSZ-109 from a previous synthesis, desirably in an amount of from 0.01 to 15,000 ppm by weight (e.g., from 100 to 10,000 ppm by weight) of the reaction mixture. Seeding can be advantageous in decreasing the amount of time necessary for complete crystallization to occur. In addition, seeding can lead to an increased purity of the product obtained by promoting the nucleation and/or formation of SSZ-109 over any undesired phases.
• a crystalline molecular sieve material such as SSZ-109 from a previous synthesis
• 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.
• reaction mixture can be prepared either batch wise or
• 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.
• Crystallization of the molecular sieve from the above reaction mixture can be carried out under either static, tumbled or stirred conditions in a suitable reactor vessel, such as for example polypropylene jars or Teflon-lined or stainless- steel autoclaves, at a temperature of from 125°C to 200°C for a time sufficient for crystallization to occur at the temperature used, e.g., from about 50 to 500 hours. Crystallization is usually carried out in an autoclave so that the reaction mixture is subject to autogenous pressure. [025] Once the molecular sieve crystals have formed, the solid product is separated from the reaction mixture by standard mechanical separation techniques such as centrifugation or filtration. The crystals are water-washed and then dried to obtain the as-synthesized molecular sieve crystals. The drying step is typically performed at a temperature of less than 200°C.
• the recovered crystalline molecular sieve product contains within its pores at least a portion of the structure directing agent used in the synthesis.
• the molecular sieve described herein may be subjected to treatment to remove part or all of the structure directing agent (Q) used in its synthesis.
• This can be conveniently effected by thermal treatment in which the as-synthesized material is heated at a temperature of at least about 370°C for at least 1 minute and generally not longer than 20 hours.
• the thermal treatment can be performed at a temperature up to 925°C. While sub-atmospheric pressure can be employed for the thermal treatment, atmospheric pressure is desired for reasons of convenience.
• the structure directing agent can be removed by treatment with ozone (see, e.g., A.N. Parikh et ai, Micropor. Mesopor. Mater. 2004, 76, 17-22).
• any Group 1 or 2 metal cations in the as- synthesized molecular sieve can be replaced in accordance with techniques well known in the art by ion exchange with other cations.
• Preferred replacing cations include metal ions (e.g., rare earth metals and metals of Groups 2 to 15 of the Periodic Table), hydrogen ions, hydrogen precursor ions (e.g., ammonium ions), and combinations thereof.
• SSZ-109 can be formulated into a catalyst composition by combination with other materials, such as binders and/or matrix materials, which provide additional hardness or catalytic activity to the finished catalyst.
• other materials such as binders and/or matrix materials, which provide additional hardness or catalytic activity to the finished catalyst.
• the relative proportions of SSZ-109 and matrix may vary widely with the SSZ-109 content ranging from 1 to 90 wt. % (e.g., from 2 to 80 wt. %) of the total catalyst. Characterization of the Molecular Sieve
• the present molecular sieve in its as-synthesized and anhydrous form, can have a chemical composition comprising the molar relationship set forth in Table
• the present molecular sieve may be an aluminosilicate or a borosilicate.
• the as-synthesized form of the present molecular sieve may have molar ratios different from the molar ratios of reactants of the reaction mixture used to prepare the as-synthesized form. This result may occur due to incomplete incorporation of 100% of the reactants of the reaction mixture into the crystals formed (from the reaction mixture).
• molecular sieve SSZ-109 has an X-ray diffraction pattern which, in its as-synthesized form, includes at least the peaks set forth in Table 3 below and which, in its calcined form, includes at least the peaks set forth in Table 4.
• the resulting product was analyzed by powder XRD and SEM.
• the powder XRD pattern of the product is shown FIG. 1 and is consistent with the product being SSZ-109.
• a SEM image of the product is shown in FIG. 2 and indicates a uniform field of crystals.
• the product had a SiO z /Al 2 O 3 molar ratio of 86.9, as determined by ICP elemental analysis.
• the product had a SiO z /Al 2 O 3 mole ratio of 152.9, as determined by ICP elemental analysis.
• the product had a SiO z /Al 2 O 3 molar ratio of 498.9, as determined by ICP elemental analysis.
• the product had a SiO 2 /B 2 O 3 molar ratio of 145.6, as determined by ICP elemental analysis.
• the calcined material of Example 9 had a micropore volume of 0.08 cm 3 /g based on argon adsorption isotherm at 87.50 K (-186°C) recorded on ASAP 2010 equipment from Micromeritics.
• the sample is first degassed at 400°C for 16 hours prior to argon adsorption.
• the low-pressure dose is 2.00 cm 3 /g (STP).
• STP standard temperature
• a maximum of one hour equilibration time per dose is used and the total run time is 37 hours.
• the argon adsorption isotherm is analyzed using the density function theory (DFT) formalism and parameters developed for activated carbon slits by J.P. Olivier (J. Porous Mater.
• DFT density function theory
• the catalyst was tested at about 450°F initially to determine the temperature range for the next set of measurements.
• the overall temperature range will provide a wide range of hexadecane conversion with the maximum conversion just below and greater than 96%.
• At least five on-line GC injections were collected at each temperature. Conversion was defined as the amount of hexadecane reacted to produce other products (including iso-Cie isomers). Yields were expressed as weight percent of products other than n-C 16 and included iso-Cie as a yield product. The results are included in Table 5.

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• 2019
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