WO2020109290A1 - Solvent-free mechanochemical activation in zeolite synthesis - Google Patents

Solvent-free mechanochemical activation in zeolite synthesis Download PDF

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Publication number
WO2020109290A1
WO2020109290A1 PCT/EP2019/082541 EP2019082541W WO2020109290A1 WO 2020109290 A1 WO2020109290 A1 WO 2020109290A1 EP 2019082541 W EP2019082541 W EP 2019082541W WO 2020109290 A1 WO2020109290 A1 WO 2020109290A1
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mixture
range
zeolitic material
group
framework structure
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PCT/EP2019/082541
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French (fr)
Inventor
Andrei-Nicolae PARVULESCU
Ulrich Mueller
Marion Winkelmann
Ralf Boehling
Christian Riemann
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Basf Se
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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B39/00Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
    • C01B39/02Crystalline 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
    • C01B39/46Other types characterised by their X-ray diffraction pattern and their defined composition
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B39/00Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
    • C01B39/02Crystalline 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
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B39/00Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
    • C01B39/02Crystalline 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
    • C01B39/04Crystalline 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
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B39/00Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
    • C01B39/02Crystalline 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
    • C01B39/46Other types characterised by their X-ray diffraction pattern and their defined composition
    • C01B39/48Other types characterised by their X-ray diffraction pattern and their defined composition using at least one organic template directing agent

Definitions

  • the present invention relates to a process for the preparation of a zeolitic material including the mechanochemical activation of the reaction mixture prior to crystallization, as well as to a cata lyst per se as obtainable or obtained according to said process. Furthermore, the present inven tion relates to the use of the inventive zeolitic material, in particular as a catalyst.
  • Molecular sieves are classified by the Structure Commission of the International Zeolite Associ ation according to the rules of the lUPAC Commission on Zeolite Nomenclature. According to this classification, framework-type zeolites and other crystalline microporous molecular sieves, for which a structure has been established, are assigned a three letter code and are described in the Atlas of Zeolite Framework Types, 6th edition, Elsevier, London, England (2007).
  • Chabazite is a well studied example, wherein it is the classical representative of the class of zeolitic materials having a CHA framework structure.
  • the class of zeolitic materials having a CHA framework structure comprises a large number of compounds further comprising phosphorous in the framework structure are known which are accordingly referred to as silicoaluminophosphates (SAPO).
  • SAPO silicoaluminophosphates
  • further molecular sieves of the CHA structure type are known which contain aluminum and phosphorous in their framework, yet contain little or no sili ca, and are accordingly referred to as aluminophosphates (APO).
  • Zeolitic materials belonging to the class of molecular sieves having the CHA-type framework structure are employed in a varie ty of applications, and in particular serve as heterogeneous catalysts in a wide range of reac tions such as in methanol to olefin catalysis and selective catalytic reduction of nitrogen oxides NO x to name some two of the most important applications.
  • Zeolitic materials of the CHA frame work type are characterized by three-dimensional 8-membered-ring (8MR) pore/channel sys tems containing double-six-rings (D6R) and cages.
  • Zeolitic materials having a CHA-type framework structure and in particular Chabazite with incor porated copper ions (Cu-CHA) are widely used as heterogeneous catalyst for the selective cata lytic reduction (SCR) of NO x fractions in automotive emissions.
  • SCR selective cata lytic reduction
  • these catalyst systems Based on the small pore open ings and the alignment of the copper ions in the CHA cages, these catalyst systems have a unique thermal stability, which tolerates temperatures higher than 700°C in presence of H2O.
  • high silica aluminosilicate zeolite chabazite (CHA), SSZ-13, has a three-dimensional pore system with ellipsoidal-shaped large cages (6.7 x 10 A) that are accessible via 8-membered ring windows (3.8 x 3.8 A), which have attracted great interest because they exhibit extraordinary catalytic properties not only in selective catalytic reduction of NO x with NH 3 (NH 3 -SCR) in recent years, but also in methanol to olefin (MTO) and in the conversion of syngas to olefins.
  • NH 3 -SCR NH 3 -SCR
  • MTO methanol to olefin
  • US 2016/01 15039 A1 relates to a method for the continuous production of a zeolite in a tubular reactor displaying a low ratio of the volume to the lateral surface area.
  • Liu et al. in Angew. Chem. Int. Ed. 2015, 54, 5683-5687 discloses a continuous syn thesis of high-silica zeolite SSZ-13 employing very short reaction times. Ju, J. et al. in Chemical Engineering Journal 2006, 1 16, 1 15-121 as well as Vandermeersch, T. et al.
  • 2001/0054549 A1 concerns a continuous process and apparatus for preparing inorganic mate rials employing microwaves.
  • DE 39 19 400 A1 describes a hydrothermal pre-treatment of a batch reaction mixture in a tubular reactor prior to crystallization thereof in a batch reactor for at least 40 h re action time at ambient pressure on an industrial scale.
  • WO 2017/216236 A1 relates to a continuous process for preparing a zeolitic ma terial comprising continuously feeding the reaction mixture prepared into a continuous flow reac tor.
  • said reaction method affords a highly improved methodology for attaining high space-time-yields, said process is still limited by the foregoing preparation step of a reaction mixture apt for continuous synthesis, in particular in view of the lengthy aging of the reaction mixture prior to its use in continuous synthesis.
  • WO 2005/039761 A2 relates to a method for making a molecular sieve catalyst involving the aging of the reaction mixture and its analysis via 27 AI NMR.
  • US 7,528,089 B2 on the other hand, relates to the processing of a high solids material for the formation of a microporous ma terial including a rotary calciner or rotary screw as a means of conveying the synthesis mixture continuously or semi-continuously.
  • WO 2016/153950 A1 describes methods for the syn thesis of zeolitic materials involving a step of subjecting the reaction mixture to high shear pro cessing conditions.
  • WO 2015/185625 A2 relates to the preparation of a zeolitic material having the CHA framework structure using trimethylcyclohexylammonium and tetramethylammonium hydroxide.
  • Preferred D50 values of the zeolitic material are disclosed as being in the range of from 1650 to 1850 nm or, alternatively, in the range of from 550 to 650 nm.
  • WO 03/020641 A1 relates to crystalline zeolite SSZ-62 that has the CHA crystal structure, a mole ratio greater than 10 of silicon oxide to aluminum oxide and has a crystallite size of 0.5 micron or less.
  • a method for preparing SSZ-62 using specific sources of silicon and aluminum, and a N,N,N-trimethyl-l-adamantylammonium cation templating agent is disclosed, processes employing SSZ-62 as a catalyst, and processes using SSZ-62 to separate gases are disclosed.
  • WO 2018/059316 A1 relates to a specific process for preparing a zeolitic material having a zeo- litic framework structure which exhibits a molar ratio (a AI2O3) : Si02 or a crystalline precursor thereof, wherein a is a number in the range of from 0 to 0.5.
  • WO 2012/072527 A2 discloses a process comprising (1 ) mixing a silicon source, an aluminum source and an optional template to obtain a synthesis gel, (2) grinding the synthesis gel, (3) hydrothermal treatment of the ground synthesis gel.
  • Preferred according to said document is the synthesis of zeolites having the BEA or MFI framework structure type.
  • K. Wantae et al. (“Effect of Dry Grinding of Pyrophyllite on the Hydrothermal Synthesis of Zeo lite Na-X and Na-A”, Materials Transactions 2014, vol. 55, p. 1488-1493) relates to a study of the effect of dry grinding of pyrophyllite on the hydrothermal synthesis of zeolite Na-X and Na-A, wherein a mechanochemical activation of said material is followed by hydrothermal reaction in sodium hydroxide solution.
  • DD 205 674 A1 relates to the preparation of crystalline zeolites having a silica to alumina molar ratio of S1O 2 to AI 2 O 3 of higher than 10.
  • the preparation process involves use of a ZSM- containing material activated by means of grinding.
  • V. Valtchev et al. (“Tribochemical activation of seeds for rapid crystallization of zeolite Y” in Zeo lites 1995, vol. 15, p. 193-197) relates to the influence of tribochemical activation of seeds on the crystallization of zeolite Y.
  • Y. Wu et al. (“Effect of microwave-assisted aging on the static hydrothermal synthesis of zeolite MCM-22”, Microporous and mesoporous Mat. 2008, vol. 1 16, p. 386-393) relates to a study on the synthesis of a zeolitic material having the MWW framework structure.
  • the specific mechanochemical treat ment of a mixture of reactants having a high solids content results in an activation of the zeolite precursor materials similar to the activation achieved by the conventional aging of reaction mix tures.
  • the mechanochemical activation route requires only a fraction of the time which conventional aging procedures necessitate, such that a tremendous increase in space-time-yields may be achieved compared to known ultrafast zeolite synthesis procedures.
  • the present invention relates to a process for preparing a zeolitic material comprising YO2 and X2O3 in its framework structure, wherein Y stands for a tetravalent element and X stands for a trivalent element, wherein said process comprises:
  • the mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, wherein the energy intake is preferably determined according to reference example 1.
  • the energy intake is determined via de termination of the torque with a given mill, preferably with a stirred media mill.
  • the torque has to be determined, first without the material of which the energy intake is to be determined and, second, with said material.
  • the torque determined for the experiment without the material of which the energy intake is to be determined is subtracted from the torque determined for the experiment with said material.
  • the specific energy input in kJ/kg is calculated. It is also possible to determine the torque with other devices.
  • the torque with and without material load can be determined and the energy intake calcu lated as described above or the power input with material (load value) and without material (no- load value) is determined. With regards to the latter, the no-load value is subtracted from the load value und the energy intake as introduced into the product can be calculated.
  • the energy intake is determined as described in reference exam ple 1 as disclosed herein.
  • the one or more peaks (PX) consists of one or two peaks (PX), more prefer ably of one peak (PX).
  • the 27 AI MAS NMR of the mix ture obtained in (ii) is determined as described in the experimental section of the present appli cation.
  • the amount of water added in (iii) to the ground mixture no particular restriction ap plies. It is preferred that water is added in (iii) to the ground mixture. In the case where water is added in (iii) to the ground mixture, it is preferred that the resulting mixture comprises an amount of water in the range of from 68 to 94 weight-%, more preferably in the range of from 70 to 92 weight-%, more preferably in the range of from 72 to 90 weight-%, more preferably in the range of from 74 to 88 weight-%, based on the total weight of the resulting mixture.
  • the mixture prepared in (i) has a density in the range of from 0.1 to 5 g/ml, more preferably in the range of from 0.5 to 3.5 g/ml, more preferably in the range of from 1 .0 to 2.75 g/ml.
  • homogenization in (iii) is achieved by grinding and/or mixing, preferably by mixing.
  • homogenization in (iii) is achieved according to any of the particular or preferred embodiments of the inventive process as described in the present application relative to the grinding and/or mixing of the mixture in (ii).
  • the energy intake of the mixture during the grinding and/or mixing procedure in (ii) is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 0.8 to 80 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg of the mixture, more preferably of from 3 to 30 kJ/kg of the mixture, more preferably of from 4 to 25 kJ/kg, more preferably of from 5 to 20 kJ/kg of the mixture, more preferably of from 7 to 17 kJ/kg, more preferably of from 8 to 15 kJ/kg of the mixture, more preferably of from 9 to 13 kJ/kg, and more preferably of from 10 to 12 kJ/kg. It is particularly preferred that the energy intake is determined as described in reference example 1 as disclosed herein.
  • the energy intake of the mixture during the grinding and/or mix ing procedure in (ii) is in the range of from 0.5 to 100 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg, more preferably of from 1 .5 to 20 kJ/kg of the mixture, more preferably of from 2 to 10 kJ/kg, more preferably of from 2.5 to 7 kJ/kg of the mixture, more preferably of from 3 to 5 kJ/kg, and more preferably of from 3.5 to 4.5 kJ/kg. It is particularly preferred that the en ergy intake is determined as described in reference example 1 as disclosed herein.
  • said mixture contains from 10 to 280 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, contained in the mixture prepared in (i) and heated in (iv), preferably of from 20 to 260 wt.-%, more preferably of from 30 to 240 wt.-%, more preferably of from 40 to 230 wt.-%, more preferably of from 60 to 220 wt.-%, more preferably of from 80 to 210 wt.-%, more preferably of from 100 to 200 wt.-%, more pref erably of from 120 to 190 wt.-%, more preferably of from 140 to 180 wt.-%, more preferably of from 150 to 170 wt.-%.
  • heating of the mixture obtained in (iii) in (iv) it is preferred according to the pre sent invention that said heating is conducted at a temperature in the range of from 100 to 280°C, preferably of from 120 to 270 °C, more preferably of from 140 to 260 °C, more preferably of from 160 to 255 °C, more preferably of from 180 to 250 °C, more preferably of from 200 to 245 °C, and more preferably of from 220 to 240 °C.
  • crystallization and in particular the heating in (iv) is conducted for a duration in the range of from 0.2 to 96 h, preferably of from 0.5 to 48 h, preferably from 0.75 to 24 h, more preferably from 1 to 12 h, more preferably from 1.25 to 8 h, more preferably from 1.5 to 5 h, more preferably from 1.75 to 4 h, and more preferably from 2 to 3 h.
  • a zeolitic material comprising YO2 and X2O3 in its framework structure may be crystallized from the mixture.
  • grinding and/or mixing in (ii) is carried out for a duration in the range of from 0.01 to 120 min, preferably of from 0.05 to 60 min, more preferably of from 0.1 to 30 min, more preferably of from 0.2 to 20 min, more preferably of from 0.3 to 10 min, more preferably of from 0.4 to 7 min, more preferably of from 0.5 to 5 min, more preferably of from 0.7 to 4 min, more preferably of from 1 to 3 min, more preferably of from 1.2 to 2.8 min, more preferably of from 1.4 to 2.6 min, and more preferably of from 1.5 to 2.5 min.
  • the rate of energy transfer to the mixture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg * h), preferably from 50 to 1 ,200 kJ/(kg * h), more preferably from 100 to 1 ,000 kJ/(kg * h), more preferably from 150 to 800 kJ/(kg * h), more preferably from 200 to 600 kJ/(kg * h), more preferably from 250 to 500 kJ/(kg * h), more preferably from 280 to 450 kJ/(kg * h), more preferably from 300 to 370 kJ/(kg * h), and more preferably from 320 to 340 kJ/(kg * h).
  • the energy intake of the mixture during the grinding and/or mixing can al ternatively be in the range of from 0.5 to 50 kJ/kg.
  • the rate of energy transfer to the mixture in (ii) is in the range of from 10 to 1 ,000 kJ/(kg * h), prefera bly from 25 to 800 kJ/(kg * h), more preferably from 50 to 600 kJ/(kg * h), more preferably from 75 to 400 kJ/(kg * h), more preferably from 90 to 200 kJ/(kg * h), more preferably from 100 to 175 kJ/(kg * h), more preferably from 110 to 150 kJ/(kg * h), more preferably from 120 to 140 kJ/(kg * h), and more preferably from 125 to 135 kJ/(kg * h).
  • the mixture obtained in (i) may have any suitable temperature prior to the grinding and/or mixing in (ii), wherein it is preferred according to the present invention that the mixture prepared in (i) has an initial temperature in the range of from 10 to 50°C when sub ject to grinding and/or mixing in (ii), preferably in the range of from 15 to 40°C, and more prefer ably in the range of from 20 to 30°C. Furthermore and independently thereof, it is preferred that in (i) and prior to (ii) the mixture prepared in (i) is not heated to a temperature of 40°C or great er, preferably of 35°C or greater, more preferably of 30°C or greater, wherein more preferably in
  • any suitable apparatus may be employed to said effect, provided that the energy intake of the mixture during the grinding and/or mixing proce dure is in the range of from 0.3 to 200 kJ/kg of the mixture.
  • grinding and/or mixing in (ii) is carried out in a mill selected from the group con sisting of a stirred media mill, a ball mill, a roller mill, a kneader and a high shear mixer, preferably from the group consisting of a stirred media mill, a planetary ball mill, a smooth wheel roller mill, a kneader with roller blades, a kneader with sigma blades, a high shear mixer equipped with a microgranulation tool, and a high shear mixer equipped with a pin mixing tool, wherein more preferably grinding and/or mixing in (ii) is carried out in a stirred media mill and/or in a roller mill, preferably in a stir
  • grinding and/or mixing in (ii) is car ried out in a stirred media mill using grinding beads made of a material selected from the group consisting of stainless steel, ceramic, and rubber, preferably from the group consisting of chrome steel, flint, zirconia, and lead antimony alloy, wherein more preferably the grinding beads for stirred media milling are made of chrome steel and/or zirconia, preferably of zirconia.
  • grinding and/or mixing in (ii) is car ried out in a stirred media mill using grinding beads with a diameter in the range of from 0.1 to 50 mm, preferably of from 0.8 to 20 mm, more preferably of from 1 to 10 mm, more preferably of from 1.2 to 7 mm, , more preferably of from 2 to 5 mm, more preferably of from 2.3 to 4 mm, more preferably of from 2.5 to 3.5 mm, more preferably of from 2.8 to 3.3 mm.
  • grinding and/or mixing in (ii) is carried out in a stirred media mill, wherein the filling degree of the grinding media in the stirred media mill is in the range of from 20 to 80%, preferably of from 25 to 75%, more preferably of from 30 to 70%, more preferably of from 35 to 65%, more preferably of from 40 to 60%, and more preferably of from 40 to 50%. Furthermore and independently thereof, it is preferred that grinding and/or mixing in
  • (ii) is carried out in a stirred media mill, wherein the tip speed of the ball mill is in the range of from 1 to 20 m/s, preferably of from 2 to 15 m/s, more preferably of from 3 to 12 m/s, more pref erably of from 4 to 8 m/s.
  • grind ing and/or mixing in (ii) is carried out in a ball mill, wherein the ball mill is operated at a speed in the range of from 10 to 250 rpm, preferably of from 30 to 220 rpm, more preferably of from 50 to 200 rpm, more preferably of from 60 to 180 rpm, more preferably of from 70 to 150 rpm, more preferably of from 80 to 120 rpm, and more preferably of from 90 to 100 rpm.
  • the ball mill comprises a volume having a cylindrical geometry, wherein the diameter of the volume having a cylindrical geometry is in the range of from 200 to 400 mm, more preferably in the range of from 250 to 350 mm, more preferably in the range of from 280 to 320 mm, more preferably in the range of from 290 to 310 mm, more preferably in the range of from 295 to 305 mm.
  • the ball mill is operated at a relative rotation speed of from 30 to 150 % of the critical rotation speed, more preferably of from 40 to 125 % of the critical rotation speed, more prefera bly of from 45 to 120 % of the critical rotation speed, more preferably of from 50 to 95 % of the critical rotation speed, more preferably of from 60 to 90 % of the critical rotation speed and more preferably of from 70 to 90 % of the critical rotation speed.
  • the critical rotation speed of the ball mill is in the range of from 40 to 80 rpm, more preferably in the range of from 50 to 70 rpm, more preferably in the range of from 55 to 65 rpm, more preferably in the range of from 58 to 62 rpm, more preferably in the range of from 59 to 61 rpm.
  • heating in (iv) may be conducted under any suitable condi tions, provided that a zeolitic material comprising YO2 and X2O3 in its framework structure is crystallized from the mixture. It is however preferred that in (iv) the mixture is heated under au togenous pressure, wherein preferably the pressure is in the range of from 0.1 to 9 MPa, more preferably in the range of from 0.5 to 7 MPa, more preferably from 0.8 to 5 MPa, more prefera bly from 1.2 to 4 MPa, more preferably from 1.6 to 3.5 MPa, more preferably from 1.8 to 3 MPa, more preferably from 2 to 2.7 MPa, and more preferably from 2.2 to 2.5 MPa.
  • the pressure is in the range of from 0.1 to 9 MPa, more preferably in the range of from 0.5 to 7 MPa, more preferably from 0.8 to 5 MPa, more prefera bly from 1.2 to 4 MPa, more preferably from 1.6 to 3.5 MPa, more preferably from 1.8 to 3
  • any conceivable zeolitic material may be obtained, wherein it is preferred that the zeolitic material crystallized in (iv) has a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR,
  • a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR,
  • MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI,
  • GME, MFI, MOR, and MWW including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, includ ing mixed structures of two or more thereof, wherein more preferably the zeolitic material crys tallized in (iv) has a CHA- and/or AEI-type framework structure, preferably a CHA-type frame work structure.
  • the zeolitic material crystallized in (iv) has a CHA-type framework structure, wherein preferably the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhender- sonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK- 14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • the mixture crystallized in (iv) is mechani cally agitated, wherein preferably mechanical agitation is achieved by stirring.
  • the inventive process and in particular the crystallization in (iv) is preferably con ducted as a batch process or as a continuous process.
  • crystallization in (iv) comprises continuously feeding the mixture ob tained in (iii) into a continuous flow reactor at a liquid hourly space velocity in the range of from 0.3 to 20 IT 1 for a duration of at least 1 h, and crystallizing the zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture in the continuous flow reactor, wherein the mixture is heated to a temperature in the range of from 80 to 300°C.
  • the volume of the continuous flow reactor is in the range of from 150 cm 3 to 75 m 3 , preferably from 50 cm 3 to 3 m 3 , preferably from 55 cm 3 to 1 m 3 , more preferably from 60 cm 3 to 0.7 m 3 , more preferably from 65 cm 3 to 0.3 m 3 , more preferably from 70 cm 3 to 0.1 m 3 , more preferably from 75 to 70,000 cm 3 , more preferably from 80 to 50,000 cm 3 , more preferably from 85 to 30,000 cm 3 , more preferably from 90 to 10,000 cm 3 , more pref erably from 95 to 7,000 cm 3 , more preferably from 100 to 5,000 cm 3 , more preferably from 105 to 3,000 cm 3 , more preferably from 1 10 to 1 ,000 cm 3 , more preferably from 1 15 to 700 cm 3 , more preferably from 120 to 500 cm 3 , more preferably from 125 to 350 cm 3 , more preferably from 130 to 250 cm 3 .
  • the continuous feeding is performed such that the liquid hourly space velocity is in the range of from 0.05 to 10 h 1 , more preferably from 0.1 to 5 h 1 , more preferably from 0.2 to 3 h 1 , more preferably from 0.4 to 2 h 1 , more preferably from 0.6 to 1.5 h 1 , more preferably from 0.8 to 1.2 h 1 , and more preferably from 0.9 to 1 h 1 .
  • the mixture obtained in (iii) is continuously fed into the continuous flow re actor for a duration ranging from 3 h to 360 d, more preferably from 6 h to 120 d, more prefera bly from 12 h to 90 d, more preferably from 18 h to 60 d, more preferably from 1 to 30 d, more preferably from 1 .5 to 25 d, more preferably from 2 to 20 d, more preferably from 2.5 to 15 d, more preferably from 3 to 12 d, more preferably from 3.5 to 8 d, and more preferably from 4 to 6 d.
  • the continuous flow reactor which may be employed according to the particular and preferred embodiments of the inventive process involving a continuous process, no particular restrictions apply, wherein it is preferred according to the present invention that the continuous flow reactor is selected among a tubular reactor, a ring reactor, and a continuously oscillating reactor, preferably among a plain tubular reactor, a tubular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, and a continuously oscillating baffled reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor.
  • At least a portion of the preferred tubular reactor is of a regular cylindrical form having a constant inner diameter perpendicular to the direction of flow, wherein the inner diameter is preferably in the range of from 2 to 1200 mm, more preferably from 3 to 800 mm, more preferably from 3 to 500 mm, more preferably from 4 to 200 mm, more preferably from 4 to 100 mm, more preferably from 4.5 to 50 mm, more preferably from 4.5 to 30 mm, more preferably from 5 to 15 mm, more preferably from 5 to 10 mm, more preferably from 5.5 to 8 mm, and more preferably from 5.5 to 6.5 mm.
  • the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 3 to 500 m more preferably from 3.5 to 200 m, more preferably from 3.5 to 100 m, more preferably from 4 to 50 m, more preferably from 4 to 30 m, more preferably from 4.5 to 20 m, more prefer ably from 4.5 to 15 m, more preferably from 5 to 10 m, and more preferably from 5 to 7 m.
  • the wall of the continuous flow reactor is made of a metallic material, wherein the metallic material comprises one or more metals select ed from the group consisting of Ta, Cr, Fe, Ni, Cu, Al, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Ta, Cr, Fe, Ni, Mo, and combina tions and/or alloys of two or more thereof, preferably from the group consisting of Cr, Fe, Ni,
  • the metallic mate rial comprises a nickel alloy, a nickel-molybdenum alloy, and more preferably a nickel- molybdenum-chromium alloy.
  • the surface of the inner wall of the continuous flow reactor is lined with an organic polymer material, wherein the organic polymer material preferably comprises one or more polymers selected from the group consisting of fluorinated polyalkylenes and mixtures of two or more thereof, preferably from the group consisting of (C2-C3)polyalkylenes and mixtures of two or more thereof, prefer ably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof, wherein more preferably the polymer material comprises poly(tetrafluoroethylene), wherein more preferably the inner wall of the continuous flow reactor is lined with
  • the contin uous flow reactor is straight and/or comprises one or more curves with respect to the direction of flow, wherein preferably the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow. Furthermore and independently thereof, it is preferred that the walls of the continuous flow reactor are subject to vibration during crystallization in (iv).
  • the continuous flow reactor consists of a single stage.
  • no matter is added to and/or removed from the reaction mixture during its passage through the continuous flow reactor in (iv), wherein preferably no matter is added, wherein more preferably no matter is added and no matter is removed from the reaction mixture during its passage through the con tinuous flow reactor in (iv).
  • the mix ture prepared in (iii) is directly fed to the continuous flow reactor in (iv), wherein while being fed to the continuous flow reactor in (iv), the mixture prepared in (iii) is pre-heated, preferably to a temperature in the range of from 100 to 300°C, more preferably of from 100 to 280°C, more preferably of from 140 to 260°C, more preferably of from 160 to 250°C, more preferably of from 180 to 240°C, more preferably of from 190 to 230°C, and more preferably of from 200 to 220°C.
  • the mixture crystallized in (iv) in the continuous flow reactor is mechanically agitated, wherein preferably mechanical agitation is achieved by movable parts contained in the continuous flow reactor, wherein more preferably the movable parts are provided such as to continually or periodically, preferably to continually free the walls of the continuous flow reactor from zeolitic materials and/or solid residue attached thereto, wherein more preferably the movable parts comprise a scraper, more preferably a screw, and more preferably a rotating screw.
  • the liquid comprises one or more solvents selected from the group consisting of polar protic solvents and mixtures thereof, preferably from the group consisting of n-butanol, isopropanol, propanol, ethanol, methanol, water, and mixtures thereof, more preferably from the group consisting of ethanol, methanol, water, and mixtures thereof, wherein more preferably the liquid comprises water, and wherein more preferably water is used as the liquid, preferably deionized water.
  • solvents selected from the group consisting of polar protic solvents and mixtures thereof, preferably from the group consisting of n-butanol, isopropanol, propanol, ethanol, methanol, water, and mixtures thereof, more preferably from the group consisting of ethanol, methanol, water, and mixtures thereof, wherein more preferably the liquid comprises water, and wherein more preferably water is used as the liquid, preferably deionized water.
  • the weight ratio of the liquid comprising one or more solvents to the reaction product effluent continuously exiting the reactor in the range of from 0.5 to 30, preferably from 1 to 25, more preferably from 2 to 20, more preferably from 3 to 18, more preferably from 4 to 15, more preferably from 5 to 12, more preferably from 6 to 10, more preferably from 6.5 to 9, more pref erably from 7 to 8.5, and more preferably from 7.5 to 8.
  • drying in (viii) is effected at a temperature in the range from 50 to 220°C, preferably from 70 to 180°C, more preferably from 80 to 150°C, more preferably from 90 to 130°C, more preferably from 100 to 125°C, and more preferably from 1 10 to 120°C.
  • calcining in (ix) is effected at a temperature in the range from 300 to 900 °C, preferably of from 400 to 700 °C, more preferably of from 450 to 650 °C, and more preferably of from 500 to 600 °C.
  • calcining in (ix) is effected for a duration in the range of from 0.5 to 12 h, pref erably in the range of from 1 to 9 h, more preferably in the range of from 2 to 6 h.
  • the supernatant obtained from the isolation of the zeolitic material in (vi), and/or a feed having the same composition as said supernatant is not at any point recycled to the reaction mixture during its passage through the continuous flow reac tor.
  • in (vi) isolating the zeolitic mate rial includes a step of spray-drying the zeolitic material obtained in (iv) or (v),
  • drying of the zeolitic material includes a step of spray-drying the zeolitic material obtained in (iv), (v), (vi), or (vii).
  • inventive process further comprises
  • the process further comprises
  • Y may stand for any conceivable tetravalent element where in it is preferred that Y is selected from the group consisting of Si, Sn, Ti, Zr, Ge, and combina tions of two or more thereof, Y preferably being Si.
  • the one or more sources for YO2 are one or more solid sources for YO2, wherein preferably the one or more sources for YO2 comprises one or more compounds select ed from the group consisting of silicas, silicates, silicic acid and combinations of two or more thereof, preferably selected from the group consisting of silicas, alkali metal silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, colloidal silica, reactive amorphous solid silica, silica gel, pyrogenic silica, lithium silicates, sodium silicates, potassium silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na 2 Si0 3 , silicic acid, and combinations of two or more thereof, more preferably selected from
  • the silica gel preferably used as the one or more sources for YO2 according to particular and preferred embodiments of the inventive process, it is preferred that the silica gel has the formula S1O2 x H2O, wherein x is in the range of from 0.1 to 1.165, preferably from 0.3 to 1.155, more preferably from 0.5 to 1.15, more preferably from 0.8 to 1.13, and more preferably from 1 to 1.1.
  • X may stand for any conceivable trivalent element wherein it is preferred that X is selected from the group consisting of Al, B, In, Ga, and combinations of two or more thereof, X preferably being Al.
  • any conceivable source may be employed where in it is preferred that the one or more sources for X2O3 are one or more solid sources for X2O3, wherein preferably the one or more sources for X2O3 comprises one or more compounds se lected from the group consisting of aluminum sulfates, sodium aluminates, and boehmite, wherein preferably the one or more sources for X2O3 comprises Al 2 (S0 4 ) 3 and/or NaAI0 2 , pref erably AI 2 (S0 4 )3, wherein more preferably the one or more sources for X2O3 is Al2(S04)3 and/or NaAI02, preferably Al2(S04)3.
  • YO2 X2O3 molar ratio of the one or more sources of YO2, calculated as YO2, to the one or more sources for X2O3, calculated as X2O3, in the mixture prepared in (i), it is pre ferred that it is in the range of from 1 to 100, preferably of from 2 to 70, more preferably of from 4 to 50, more preferably of from 6 to 40, more preferably of from 8 to 35, more preferably of from 12 to 30, more preferably of from 15 to 25, more preferably of from 17 to 22, and more preferably of from 19 to 20.
  • the mixture prepared in (i) and crystallized in (iv) further comprises one or more structure directing agents, wherein preferably one or more organotemplates are employed as the one or more structure directing agents.
  • SDA structure directing agents
  • the molar ratio SDA : YO2 of the one or more structure directing agents (SDA) to the one or more sources of YO2, calculated as YO2, in the mixture prepared in (i) and heated in (iv) it is preferred that it ranges from 0.01 to 0.5, wherein the one or more structure directing agents do not include structure directing agents optionally contained in seed crystals optionally con tained in the mixture prepared in (i), and more preferably from 0.03 to 0.2, more preferably from 0.06 to 0.15, more preferably from 0.09 to 0.13, and more preferably from 0.1 1 to 0.12.
  • the one or more structure directing agents comprise one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 independently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl, preferably for 1 -adamantyl.
  • R 1 , R 2 , and R 3 independently from one another stand for optionally substituted and/or op tionally branched (Ci-C 6 )alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more pref erably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 1 , R 2 , and R 3 independently from one another stand for optionally substituted me thyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more preferably R 1 , R 2 , and R 3 independently from one another stand for optionally substituted methyl, preferably unsubstituted methyl.
  • R 4 stands for optionally het erocyclic and/or optionally substituted adamantyl and/or benzyl, preferably for optionally hetero cyclic and/or optionally substituted 1 -adamantyl, more preferably for optionally substituted ada mantyl and/or benzyl, more preferably for optionally substituted 1 -adamantyl, more preferably for unsubstituted adamantyl and/or benzyl, and more preferably for unsubstituted 1 -adamantyl.
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more /V,/V/V-tri(Ci-C 4 )alkyl-1 -adamantylammonium compounds, preferably one or more /V,/V,/V-tri(Ci-C 3 )alkyl-1 -adamantylammonium compounds, more preferably one or more N,N,N- tri(Ci-C 2 )alkyl-1 -adamantylammonium compounds, more preferably one or more N,N,N- tri(Ci- C 2 )alkyl-1 -adamantylammonium and/or one or more /V,/V,/V-tri(C-i-C 2 )alkyl-1 - adamantylammonium compounds, more preferably one or more compounds selected from /V,/V
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are salts, pref erably one or more salts selected from the group consisting of halides, sulfate, nitrate, phos phate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of bromide, chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammonium hy droxides.
  • the one or more structure directing agents comprise one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 independently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl.
  • R 1 and R 2 independently from one another stand for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci- C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 1 and R 2 independently from one another stand for optionally substituted methyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more preferably R 1 and R 2 independently from one another stand for optionally substituted methyl, preferably un substituted methyl.
  • R 3 stands for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substi tuted methyl or ethyl, wherein more preferably R 3 stands for optionally substituted ethyl, prefer ably unsubstituted ethyl.
  • R 4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cycloalkyl, preferably for 5- to 7-membered cycloalkyl, more preferably for 5- or 6-membered cycloalkyl, wherein more preferably R 4 stands for optionally heterocyclic and/or optionally substituted 6-membered cyclo alkyl, preferably optionally substituted cyclohexyl, and more preferably unsubstituted cyclohexyl.
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more /V,/V/V-tri(Ci-C4)alkyl-(C5-C7)cycloalkylammonium compounds, preferably one or more /V,/V,/V-tri(Ci-C3)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-cyclopentylammonium and/or one or more /V,/V,/V-tri(Ci-C2)alkyl- cyclohexylammonium compounds, more preferably one or more compounds selected from
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + - containing compounds are salts, preferably one or more salts selected from the group consist ing of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of bromide, chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammonium hydroxides.
  • the one or more structure directing agents are se lected from the group consisting of tetra(C1 -C3)alkylammonium comounds, dibenzylme- thylammonium compounds, dibenzyl-1 ,4-diazabicyclo[2, 2, 2]octane, and mixture of two or more thereof, preferably from the group consisting of tetra(C1 -C2)alkylammonium comounds, diben- zylmethylammonium compounds, dibenzyl-1 ,4-diazabicyclo[2, 2, 2]octane, and mixture of two or more thereof, more preferably from the group consisting of tetraethylammonium comounds, triethylmethylammonium comounds, diethyldimethylammonium comounds, ethyltrimethylammo- nium comounds,
  • the tetraalkylammonium compounds are salts, preferably one or more salts selected from the group consisting of halides, preferably chloride and/or bromide, more preferably chlo ride, hydroxide, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium compounds are tetraalkylammonium hydroxides and/or chlorides, and even more preferably tetraalkylammoni um hydroxides.
  • the mixture pre pared in (i) and crystallized in (iv) does not comprise an organotemplate and preferably does not comprise a structure directing agent.
  • the mixture prepared in (i) and crystallized in (iv) further comprises seed crystals, wherein the amount of seed crystals in the mixture pre pared in (i) preferably ranges from 0.5 to 25 wt.-% based on 100 wt.-% of the one or more sources of YO2 contained in the mixture, calculated as YO2, preferably from 3 to 25 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 18 wt.-%, more preferably from 10 to 16 wt.-%, and more preferably from 12 to 14 wt.-%.
  • the seed crystals comprise one or more zeolitic materials having a framework structure type select ed from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX,
  • zeolitic materials having a framework structure type select ed from the group consisting of AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX,
  • the one or more zeolitic materials having a CHA-type framework structure are comprised in the seed crystals
  • the one or more zeolitic materials having a CHA-type framework structure com prised in the seed crystals is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • the seed crystal preferably contained in the mixture prepared in (i) may be obtained according to any suitable procedure. It is preferred according to the inventive process that the seed crystals contained in the mixture prepared in (i) and heated in (iv) comprise one or more zeolitic materials having the framework structure of the zeolitic material comprising YO 2 and X 2 O 3 in its framework structure obtained according to any of the particular and preferred embodiments of the inventive process as described in the present application, wherein prefera bly the one or more zeolitic materials of the seed crystals is obtainable and/or obtained accord ing to any of the particular and preferred embodiments of the inventive process as described in the present application.
  • the mixture prepared in (iii) and constituting the feed crystallized in (iv) consists of a single liquid phase and a solid phase com prising the seed crystals. Furthermore and independently thereof, it is preferred that the mixture constituting the feed crystallized in (iv) consists of two liquid phases and a solid phase compris ing the seed crystals, wherein the first liquid phase comprises H2O, and the second liquid phase comprises a lubricating agent.
  • the lubricating agent it is preferred that it comprises one or more fluorinated compounds, preferably one or more fluorinated polymers, more prefer ably one or more fluorinated polyethers, and more preferably one or more perfluorinated poly ethers.
  • the H 2 O : YO 2 molar ratio of water to YO 2 from the one or more sources of YO 2 , calculated as YO 2 , in the mixture obtained in (iii) ranges from 1 to 200, preferably from 3 to 100, more preferably from 5 to 50, more preferably from 6 to 30, more preferably from 7 to 20, more preferably from 8 to 15, more preferably from 9 to 13, and more preferably from 10 to 1 1.
  • the mixture prepared in (i) comprises one or more alkali metals M, wherein the molar ratio M : YO 2 of the one or more alkali metals M to the one or more sources of YO 2 , calculated as YO 2 , ranges from 0.05 to 3, preferably of from 0.1 to 2, more preferably of from 0.2 to 1.5, more pref erably of from 0.3 to 1 , more preferably of from 0.35 to 0.8, and more preferably of from 0.4 to 0.5.
  • the one or more alkali metals M it is preferred that they comprise one or more alkali metals selected from the group consisting of Li, Na, K, Rb, Cs, and combinations of two or more thereof, more preferably from the group consisting of Li, Na, Rb and combinations of two or more thereof, wherein more preferably the one or more alkali metals M are Li and/or Na, more preferably Na, wherein more preferably the one or more alkali metals M is sodium.
  • sodium is comprised in the mixture pre- pared in (i) in a compound selected from the group consisting of sodium hydroxide, sodium aluminates, and sodium silicates, wherein preferably sodium is comprised in the mixture pre pared in (i) as Na2SiC>3 and/or NaAIC>2, preferably as Na2SiC>3, and more preferably as Na2SiC>3 x 9 H2O.
  • the crystallinity of the zeolitic material obtained in (ix) is in the range of from 45 to 99%, preferably from 50 to 95%, more preferably from 55 to 90%, more preferably from 60 to 85%, more preferably from 65 to 80%, and more preferably from 70 to 75%.
  • the mixture prepared in (i) and ground in (ii) contains substantially no phosphorous and/or phosphorous containing compounds.
  • the framework of the zeolitic material crystallized in (iv) contains substan tially no phosphorous, wherein preferably the zeolitic material crystallized in (iv) contains sub stantially no phosphorous and/or phosphorous containing compounds.
  • the present invention further relates to a zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable and/or obtained according to according to any of the particular and preferred embodiments of the inventive process as de scribed in the present application.
  • the zeolitic material of the present invention has a CHA-type framework structure, wherein it is further preferred that the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • SSZ-13 more preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ- 218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ- 62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34, SSZ-13, and SSZ-62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof, wherein more preferably the zeolitic material comprises chaba zite and/or SSZ-13, preferably SSZ-13, and wherein more preferably the zeolitic material is chabazite and/or SSZ-13, preferably SS
  • the mean particle size D50 by volume of the zeolitic material as determined accord ing to ISO 13320:2009 is in the range of from 0.1 to 10 pm, and is preferably in the range of from 0.3 to 6.0 pm, more preferably in the range of from 1.5 to 4.5 pm, and more preferably in the range of from 2.5 to 3.6 pm.
  • the zeolitic materials obtained according to the inventive process it is also conceivable to blend the zeolitic materials obtained according to the inventive process with at least one other catalytically active material or a material being active with respect to the intend ed purpose.
  • the one or more transition metal comprises Cu and/or Fe, more preferably Cu. It is also possible to blend at least two different inventive materials with at least one other catalytically active material or a material being active with respect to the intend ed purpose.
  • the catalyst may be disposed on a substrate.
  • the substrate may be any of those materials typically used for preparing catalysts, and will usually comprise a ceramic or metal honeycomb structure. Any suitable substrate may be employed, such as a monolithic substrate of the type having fine, parallel gas flow passages extending there through from an inlet or an outlet face of the substrate, such that passages are open to fluid flow there through (referred to as honey comb flow through substrates).
  • honey comb flow through substrates honey comb flow through substrates.
  • the passages which are essentially straight paths from their fluid inlet to their fluid outlet, are defined by walls on which the catalytic material is disposed as a washcoat so that the gases flowing through the passages contact the catalytic material.
  • the flow passages of the monolithic substrate are thin-walled channels, which can be of any suitable cross-sectional shape and size such as trapezoidal, rectangular, square, sinusoidal, hexagonal, oval, circular, etc.
  • Such structures may contain from about 60 to about 400 or more gas inlet openings (i.e., cells) per square inch (2.54 cm x 2.54 cm) of cross section.
  • the substrate can also be a wall-flow filter substrate, where the channels are alternately blocked, allowing a gaseous stream entering the channels from one direction (inlet direction), to flow through the channel walls and exit from the channels from the other direction (outlet direc tion).
  • the catalyst composition can be coated on the flow through or wall-flow filter. If a wall flow substrate is utilized, the resulting system will be able to remove particulate matter along with gaseous pollutants.
  • the wall-flow filter substrate can be made from materials commonly known in the art, such as cordierite, aluminum titanate or silicon carbide. It will be understood that the loading of the catalytic composition on a wall flow substrate will depend on substrate properties such as porosity and wall thickness, and typically will be lower than loading on a flow through substrate.
  • the ceramic substrate may be made of any suitable refractory material, e.g., cordierite, cordier- ite-alumina, silicon nitride, zircon mullite, spodumene, alumina-silica magnesia, zircon silicate, sillimanite, a magnesium silicate, zircon, petalite, alpha-alumina, an aluminosilicate, and the like.
  • suitable refractory material e.g., cordierite, cordier- ite-alumina, silicon nitride, zircon mullite, spodumene, alumina-silica magnesia, zircon silicate, sillimanite, a magnesium silicate, zircon, petalite, alpha-alumina, an aluminosilicate, and the like.
  • the substrates useful for the catalysts may also be metallic in nature and be composed of one or more metals or metal alloys.
  • the metallic substrates may be employed in various shapes such as corrugated sheet or monolithic form.
  • Suitable metallic supports include the heat re sistant metals and metal alloys such as titanium and stainless steel as well as other alloys in which iron is a substantial or major component.
  • Such alloys may contain one or more of nickel, chromium and/or aluminum, and the total amount of these metals may advantageously com prise at least 15 wt. % of the alloy, e.g., 10-25 wt. % of chromium, 3-8 wt. % of aluminum and up to 20 wt. % of nickel.
  • the alloys may also contain small or trace amounts of one or more other metals such as manganese, copper, vanadium, titanium, and the like.
  • the surface or the metal substrates may be oxidized at high temperatures, e.g., 1000 °C and higher, to improve the resistance to corrosion of the alloys by forming an oxide layer on the surfaces of the sub strates. Such high temperature-induced oxidation may enhance the adherence of the refractory metal oxide support and catalytically promoting metal components to the substrate.
  • zeolitic material obtained according to the inventive process may be deposited on an open cell foam substrate.
  • substrates are well known in the art, and are typically formed of refractory ceramic or metallic materials.
  • a catalyst containing the zeolitic material obtained according to the inventive process for removal of nitrogen oxides NO x from exhaust gases of internal com bustion engines, in particular diesel engines, which operate at combustion conditions with air in excess of that required for stoichiometric combustion, i.e., lean.
  • inventive zeolitic material according to any of the particular and pre ferred embodiments as described in the present application as a molecular sieve, as an adsor bent, for ion-exchange, as a catalyst or a precursor thereof, and/or as a catalyst support or a precursor thereof, preferably as a catalyst or a precursor thereof and/or as a catalyst support or a precursor thereof, more preferably as a catalyst or a precursor thereof, more preferably as a catalyst for the selective catalytic reduction (SCR) of nitrogen oxides NO x ; for the storage and/or adsorption of CO 2 ; for the oxidation of NH 3 , in particular for the oxidation of NH 3 slip in diesel systems; for the decomposition of N 2 O; as an additive in fluid catalytic cracking (FCC) process es; and/or as a catalyst in organic conversion reactions, preferably in the conversion of alcohols to
  • a process for preparing a zeolitic material comprising YO 2 and X 2 O 3 in its framework
  • mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2,
  • peaks in the range of from -20 to 15 ppm, preferably of from -10 to 12 ppm, more preferably of from -5 to 10 ppm, more preferably of from -3 to 8 ppm, more preferably of from -2 to 7 ppm, more preferably of from -1.5 to 6.5 ppm, more preferably of from -1 to 6 ppm, more preferably of from -0.5 to 5.5 ppm, and more preferably of from 0.5 to 5.0 ppm;
  • the relative 27 AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) and within the range of 15 to -20 ppm (h) of the zeolitic material offer a ratio of the integration values h : (h + h) comprised in the range of from 0.5 to 50%, preferably of from 1 to 35%, more preferably of from 3 to 25%, more preferably of from 5 to 18%, more preferably of from 8 to 15%, more preferably of from 9 to 14%, more preferably of from 10 to 13%, and more preferably of from 11 to 12%,
  • the one or more peaks (PX) consists of one or two peaks (PX), more preferably of one peak (PX).
  • the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 0.8 to 80 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg of the mixture, more preferably of from 3 to 30 kJ/kg of the mixture, more preferably of from 4 to 25 kJ/kg, more preferably of from 5 to 20 kJ/kg of the mixture, more preferably of from 7 to 17 kJ/kg, more preferably of from 8 to 15 kJ/kg of the mixture, more preferably of from 9 to 13 kJ/kg, and more preferably of from 10 to 12 kJ/kg.
  • the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 1 to 50 kJ/kg, more preferably of from 1.5 to 20 kJ/kg of the mixture, more preferably of from 2 to 10 kJ/kg, more preferably of from 2.5 to 7 kJ/kg of the mixture, more preferably of from 3 to 5 kJ/kg, and more preferably of from 3.5 to 4.5 kJ/kg.
  • the mixture prepared in (i) and ground in (ii) contains from 10 to 280 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, contained in the mixture prepared in (i) and heated in (iv), preferably of from 20 to 260 wt.-%, more preferably of from 30 to 240 wt.-%, more preferably of from 40 to 230 wt.-%, more preferably of from 60 to 220 wt.-%, more prefer ably of from 80 to 210 wt.-%, more preferably of from 100 to 200 wt.-%, more preferably of from 120 to 190 wt.-%, more preferably of from 140 to 180 wt.-%, more preferably of from 150 to 170 wt.-%.
  • the rate of energy transfer to the mix ture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg * h), preferably from 50 to 1 ,200 kJ/(kg * h), more preferably from 100 to 1 ,000 kJ/(kg * h), more preferably from 150 to 800 kJ/(kg * h), more preferably from 200 to 600 kJ/(kg * h), more preferably from 250 to 500 kJ/(kg * h), more preferably from 280 to 450 kJ/(kg * h), more preferably from 300 to 370 kJ/(kg * h), and more preferably from 320 to 340 kJ/(kg * h).
  • a stirred media mill preferably from the group consisting of a stirred media mill, a planetary ball mill, a smooth wheel roller mill, a kneader with roller blades, a kneader with sigma blades, a high shear mixer equipped with a microgranulation tool, and a high shear mixer equipped with a pin mixing tool,
  • the ball mill comprises a volume having a cylindrical geometry, wherein the diameter of the volume having a cylindrical geometry is in the range of from 200 to 400 mm, preferably in the range of from 250 to 350 mm, more preferably in the range of from 280 to 320 mm, more preferably in the range of from 290 to 310 mm, more preferably in the range of from 295 to 305 mm.
  • crystallization in (iv) comprises continuously feeding the mixture obtained in (iii) into a continuous flow reactor at a liquid hourly space velocity in the range of from 0.3 to 20 tv 1 for a duration of at least 1 h, and crystallizing the zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture in the continuous flow reactor, wherein the mixture is heated to a temperature in the range of from 80 to 300°C.
  • the volume of the continuous flow reactor is in the range of from 150 cm 3 to 75 m 3 , preferably from 50 cm 3 to 3 m 3 , preferably from 55 cm 3 to 1 m 3 , more preferably from 60 cm 3 to 0.7 m 3 , more preferably from 65 cm 3 to 0.3 m 3 , more preferably from 70 cm 3 to 0.1 m 3 , more preferably from 75 to 70,000 cm 3 , more preferably from 80 to 50,000 cm 3 , more preferably from 85 to 30,000 cm 3 , more preferably from 90 to 10,000 cm 3 , more preferably from 95 to 7,000 cm 3 , more preferably from 100 to 5,000 cm 3 , more preferably from 105 to 3,000 cm 3 , more preferably from 110 to 1 ,000 cm 3 , more preferably from 1 15 to 700 cm 3 , more preferably from 120 to 500 cm 3 , more preferably from 125 to 350 cm 3 , more preferably from 130 to 250 cm 3 , more preferably from 135 to 200
  • any of embodiments 28 to 32 wherein the continuous flow reactor is se lected among a tubular reactor, a ring reactor, and a continuously oscillating reactor, pref erably among a plain tubular reactor, a tubular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, and a continuously oscillating baffled reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor.
  • any of embodiments 28 to 33 wherein at least a portion of the tubular re actor is of a regular cylindrical form having a constant inner diameter perpendicular to the direction of flow, wherein the inner diameter is preferably in the range of from 2 to 1200 mm, more preferably from 3 to 800 mm, more preferably from 3 to 500 mm, more prefera bly from 4 to 200 mm, more preferably from 4 to 100 mm, more preferably from 4.5 to 50 mm, more preferably from 4.5 to 30 mm, more preferably from 5 to 15 mm, more prefera bly from 5 to 10 mm, more preferably from 5.5 to 8 mm, and more preferably from 5.5 to 6.5 mm. 35.
  • any of embodiments 28 to 34, wherein the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 3 to 500 m more preferably from 3.5 to 200 m, more preferably from 3.5 to 100 m, more preferably from 4 to 50 m, more preferably from 4 to 30 m, more preferably from 4.5 to 20 m, more preferably from 4.5 to 15 m, more pref erably from 5 to 10 m, and more preferably from 5 to 7 m.
  • the wall of the continuous flow re actor is made of a metallic material
  • the metallic material comprises one or more metals selected from the group consisting of Ta, Cr, Fe, Ni, Cu, Al, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Ta, Cr, Fe, Ni, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Cr, Fe, Ni, Mo, and combinations and/or alloys of two or more thereof where in preferably the metallic material comprises a nickel alloy, a nickel-molybdenum alloy, and more preferably a nickel-molybdenum-chromium alloy.
  • the organic pol ymer material preferably comprises one or more polymers selected from the group con sisting of fluorinated polyalkylenes and mixtures of two or more thereof, preferably from the group consisting of (C2-C3)polyalkylenes and mixtures of two or more thereof, prefer ably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof, wherein more preferably the polymer material comprises
  • the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow.
  • the liquid comprises one or more solvents selected from the group consisting of polar protic solvents and mixtures thereof, preferably from the group consisting of n-butanol, isopropanol, propanol, ethanol, metha nol, water, and mixtures thereof,
  • ethanol more preferably from the group consisting of ethanol, methanol, water, and mixtures thereof,
  • the liquid comprises water, and wherein more preferably water is used as the liquid, preferably deionized water.
  • the weight ratio of the liquid comprising one or more solvents to the reaction product effluent continuously exiting the reactor in the range of from 0.5 to 30, preferably from 1 to 25, more preferably from 2 to 20, more preferably from 3 to 18, more preferably from 4 to 15, more preferably from 5 to 12, more preferably from 6 to 10, more preferably from 6.5 to 9, more preferably from 7 to 8.5, and more preferably from 7.5 to 8.
  • drying in (viii) is effected at a tem perature in the range from 50 to 220°C, preferably from 70 to 180°C, more preferably from 80 to 150°C, more preferably from 90 to 130°C, more preferably from 100 to 125°C, and more preferably from 110 to 120°C.
  • drying of the zeolitic material includes a step of spray-drying the zeolitic material obtained in (iv), (v), (vi), or (vii).
  • the process of any of embodiments 1 to 51 wherein the process further comprises
  • the one or more structure directing agents comprise one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 independently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl, preferably for 1-adamantyl.
  • R 4 stands for optionally heterocyclic and/or optionally substituted adamantyl and/or benzyl, preferably for optionally heterocyclic and/or optionally substituted 1-adamantyl, more preferably for optionally substituted ada mantyl and/or benzyl, more preferably for optionally substituted 1-adamantyl, more prefer ably for unsubstituted adamantyl and/or benzyl, and more preferably for unsubstituted 1- adamantyl.
  • R 4 stands for optionally heterocyclic and/or optionally substituted adamantyl and/or benzyl, preferably for optionally heterocyclic and/or optionally substituted 1-adamantyl, more preferably for optionally substituted ada mantyl and/or benzyl, more preferably for optionally substituted 1-adamantyl, more prefer ably for unsubstituted adamantyl and/or benzyl, and
  • any of embodiments 56 to 58, wherein the one or more tetraalkylammoni- um cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more /V,/V,/V-tri(Ci- C 4 )alkyl-1-adamantylammonium compounds, preferably one or more /V,/V,/V-tri(Ci- C 3 )alkyl-1-adamantylammonium compounds, more preferably one or more /V/V,/V-tri(Ci- C 2 )alkyl-1-adamantylammonium compounds, more preferably one or more /V/V,/V-tri(Ci- C 2 )alkyl-1-adamantylammonium and/or one or more /V,/V,/V-tri(Ci-C 2 )alkyl-1- adamantylammonium compounds, more preferably one or more compounds selected from /V,/V,/
  • the one or more tetraalkylammoni um cation R 1 R 2 R 3 R 4 N + -containing compounds are salts, preferably one or more salts se lected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mix tures of two or more thereof, more preferably from the group consisting of bromide, chlo ride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammoni um hydroxides.
  • the one or more structure directing agents comprise one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 independently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl.
  • R 3 stands for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 3 stands for optionally substituted ethyl, preferably un substituted ethyl. 64.
  • R 4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cycloalkyl, preferably for 5- to 7-membered cycloalkyl, more preferably for 5- or 6-membered cycloalkyl, wherein more preferably R 4 stands for optionally heterocyclic and/or optionally substituted 6-membered cycloalkyl, preferably optionally substituted cyclohexyl, and more preferably unsubstituted cyclohexyl.
  • any of embodiments 61 to 64, wherein the one or more tetraalkylammoni- um cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more /V,/V,/V-tri(Ci- C4)alkyl-(C5-C7)cycloalkylammonium compounds, preferably one or more /V,/V,/V-tri(Ci- C3)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more N,N,N- tri(Ci-C2)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-cyclopentylammonium and/or one or more /V,/V/V-tri(Ci-C2)alkyl- cyclohexylammonium compounds, more preferably one or more compounds selected from /V
  • the one or more tetraalkylammoni um cation R 1 R 2 R 3 R 4 N + -containing compounds are salts, preferably one or more salts se lected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mix tures of two or more thereof, more preferably from the group consisting of bromide, chlo ride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammoni um hydroxides.
  • tetraalkylammonium compounds are salts, preferably one or more salts selected from the group consisting of halides, preferably chloride and/or bromide, more preferably chloride, hydroxide, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium compounds are tetraalkylammonium hydroxides and/or chlorides, and even more preferably tetraalkylammonium hydroxides.
  • the one or more sources for YO2 are one or more solid sources for YO2, wherein preferably the one or more sources for YO2 comprises one or more compounds selected from the group consisting of silicas, silicates, silicic acid and combinations of two or more thereof, preferably selected from the group consisting of silicas, alkali metal silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, colloidal silica, reactive amorphous solid silica, silica gel, pyrogenic silica, lithium silicates, sodium sili cates, potassium silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na 2 Si0 3 , silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel
  • silica gel has the formula S1O2 x H2O, wherein x is in the range of from 0.1 to 1.165, preferably from 0.3 to 1.155, more prefera bly from 0.5 to 1.15, more preferably from 0.8 to 1.13, and more preferably from 1 to 1.1.
  • X is selected from the group consist ing of Al, B, In, Ga, and combinations of two or more thereof, X preferably being Al. 74.
  • the one or more sources for X2O3 are one or more solid sources for X2O3, wherein preferably the one or more sources for X2O3 comprises one or more compounds selected from the group consisting of aluminum sulfates, sodium aluminates, and boehmite, wherein preferably the one or more sources for X2O3 comprises Al2(S04)3 and/or NaAI02, preferably A ⁇ SC H wherein more prefera bly the one or more sources for X2O3 is Al2(S04)3 and/or NaAI02, preferably Al2(S04)3.
  • the mixture prepared in (i) and crys tallized in (iv) further comprises seed crystals, wherein the amount of seed crystals in the mixture prepared in (i) preferably ranges from 0.5 to 25 wt.-% based on 100 wt.-% of the one or more sources of YO2 contained in the mixture, calculated as YO2, preferably from 3 to 25 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 18 wt.-%, more preferably from 10 to 16 wt.-%, and more preferably from 12 to 14 wt.-%.
  • the seed crystals comprise one or more zeolitic materials having a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX, SFW, BEA, CHA, FAU, FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, FAU, FER, HEU
  • zeolitic materials having a CHA- type framework structure comprised in the seed crystals is selected from the group con sisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • the one or more zeolitic materials having a CHA-type framework structure comprised in the seed crystals is chabazite and/or SSZ-13, preferably SSZ-13.
  • the seed crystals comprised in the mixture prepared in (i) and heated in (iv) comprise one or more zeolitic materials having the framework structure of the zeolitic material comprising YO2 and X2O3 in its framework structure obtained according to the process of any of embodiments 1 to 78, wherein pref erably the one or more zeolitic materials of the seed crystals is obtainable and/or obtained according to the process of any of embodiments 1 to 78.
  • the lubricating agent comprises one or more fluorinated compounds, preferably one or more fluorinated polymers, more preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyeth ers.
  • the mixture prepared in (i) comprises one or more alkali metals M, wherein the molar ratio M : YO2 of the one or more alkali metals M to the one or more sources of YO2, calculated as YO2, ranges from 0.05 to 3, preferably of from 0.1 to 2, more preferably of from 0.2 to 1.5, more preferably of from 0.3 to 1 , more preferably of from 0.35 to 0.8, and more preferably of from 0.4 to 0.5.
  • the one or more alkali metals M comprise one or more alkali metals selected from the group consisting of Li, Na, K, Rb, Cs, and combina tions of two or more thereof, more preferably from the group consisting of Li, Na, Rb and combinations of two or more thereof, wherein more preferably the one or more alkali met als M are Li and/or Na, more preferably Na, wherein more preferably the one or more al kali metals M is sodium.
  • any of embodiments 1 to 86, wherein the crystallinity of the zeolitic materi al obtained in (ix) is in the range of from 45 to 99%, preferably from 50 to 95%, more pref erably from 55 to 90%, more preferably from 60 to 85%, more preferably from 65 to 80%, and more preferably from 70 to 75%.
  • the process of any of embodiments 1 to 87, wherein the zeolitic material crystallized in (iv) has a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI,
  • LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX, SFW, BEA, CHA, FAU,
  • FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, FAU, FER, GME, LEV, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, GME, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, including mixed structures of two or more thereof, wherein more preferably the zeolitic material crystallized in (iv) has a CHA- and/or AEI-type framework structure, preferably a CHA-type framework structure.
  • the zeolitic material crystallized in (iv) has a CHA-type framework structure, wherein preferably the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • the zeolitic material crystallized in (iv) comprises chabazite and/or SSZ-13, preferably chabazite, and wherein more preferably the zeolitic material crystallized in (iv) is chabazite and/or SSZ-13, preferably SSZ-13.
  • a zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable
  • the zeolitic material is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 ,
  • the zeolitic material comprises chabazite and/or SSZ-13, prefer ably SSZ-13, and wherein more preferably the zeolitic material is chabazite and/or SSZ- 13, preferably SSZ-13.
  • the zeolitic material of claim 92 or 903, wherein the mean particle size D50 by volume of the zeolitic material as determined according to ISO 13320:2009 is in the range of from 0.1 to 10 pm, and is preferably in the range of from 0.3 to 6.0 pm, more preferably in the range of from 1.5 to 4.5 pm, and more preferably in the range of from 2.5 to 3.6 pm.
  • a zeolitic material according to any of embodiments 92 to 94 as a molecular sieve, as an adsorbent, for ion-exchange, as a catalyst or a precursor thereof, and/or as a cata lyst support or a precursor thereof, preferably as a catalyst or a precursor thereof and/or as a catalyst support or a precursor thereof, more preferably as a catalyst or a precursor thereof, more preferably as a catalyst for the selective catalytic reduction (SCR) of nitro gen oxides NO x ; for the storage and/or adsorption of CO 2 ; for the oxidation of NH 3 , in par ticular for the oxidation of NH 3 slip in diesel systems; for the decomposition of N 2 O; as an additive in fluid catalytic cracking (FCC) processes; and/or as a catalyst in organic con version reactions, preferably in the conversion of alcohols to olefins, and more preferably in methanol to o
  • Figure 1 displays the 27 AI MAS NMR of the mechanochemically activated reaction mixture of example 1 , wherein the chemical shift in ppm is plotted along the abscissa and the relative intensity in arbitrary units is shown along the ordinate. Furthermore, the in tegration values for the relative intensity integral within the range of 80 to 20 ppm and within the range of 15 to -20 ppm are respectively indicated along the ordinate.
  • Figure 2 displays the 27 AI MAS NMR of the mechanochemically activated reaction mixture of reference example 4, wherein the chemical shift in ppm is plotted along the abscissa and the relative intensity in arbitrary units is shown along the ordinate. Furthermore, the integration values for the relative intensity integral within the range of 80 to 20 ppm and within the range of 15 to -20 ppm are respectively indicated along the ordi nate.
  • the energy intake can be determined via determination of the torque with the stirred media mill.
  • the torque has to be determined, first without the material of which the energy intake is to be determined and, second, with said material.
  • the torque determined for the experiment without the material of which the energy intake is to be determined is subtracted from the torque deter mined for the experiment with said material. Based on the result from said calculation, the spe cific energy input in kJ/kg can be calculated. It is also possible to determine the torque with oth er devices.
  • the torque with and without material load is determined and the energy intake is calculated as described above or the power input with material (load value) and without material (no-load value) is determined. With regards to the latter, the no-load value is subtracted from the load value und the energy intake as introduced into the product can be calculated.
  • the energy intake was determined via determination of the torque using a torque- determination apparatus IC3001-Ex (German:“Drehmoment-Mess worn IC3001-Ex”; Dr. Staiger, Mohilo & Co. GmbH, Schorndorf) and a torque-rotation speed determination apparatus IC3001-Ex-n (German:“Drehmoment-Drehiere-Mess responded IC3001-Ex-n”; Dr. Staiger, Mo hilo & Co. GmbH, Schorndorf), whereby manual no. 1294 dated May 13, 1993 (German:
  • samples were 27 AI solid-state nuclear magnetic reso nance (NMR) was performed using the following devices, procedures and parameters: Storage of samples at 62% relative humidity for at least 60 hours prior to packing, packing of samples into 4mm Zr0 2 rotors with Kel-F caps, Bruker Avance III spectrometer with 9.4 Tesla magnet, 10 kHz (w/2tt) magic angle spinning, one-pulse radiofrequency excitation corresponding to a 0.83ps 15°-pulse on AlC -solution (1 % in H2O), 10 ms acquisition of the free induction decay, no heteronuclear 1 H radiofrequency decoupling, averaging of at least 5120 scans with a recycle delay of 0.5s, Fourier transform with 10 Hz exponential line broadening for noise suppression, manual phasing and baseline correction in Bruker Topspin 3.0.
  • Powder X-ray diffraction (PXRD) data was collected using a diffractometer (D8 Advance Series II, Bruker AXS GmbH) equipped with a LYNXEYE detector operated with a Copper anode X-ray tube running at 40kV and 40mA.
  • the geometry was Bragg-Brentano, and air scattering was reduced using an air scatter shield.
  • the crystallinity was determined using DIFFRAC.EVA soft ware (User Manual for DIFFRAC.EVA, Bruker AXS GmbH, Düsseldorf).
  • Example 1 Synthesis of a zeolitic material having a CHA-type framework structure via mecha- nochemical activation
  • the 27 AI MAS NMR of the mechanochemically activated reaction mixture is displayed in figure 1 and shows a relative 27 AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) of 82.7 and within the range of 15 to -20 ppm (I2) of 17.3 such as to afford a ratio of the integra tion values I2 : (h + I2) of 17.3.
  • the filling degree of the grinding media was 50 %. 44 g of 47.8 % N,N,N-trimethyl-1 -adamantanammonium hydroxide (TMAdAOH) were introduced into the mill. Afterwards the mill was closed and operated in batch mode. The tip speed was set to 5 m/s. The mixture was ground for 2 minutes for affording a mechanochemi cally activated reaction mixture (approximately 5.5 kJ/kg).
  • TMAdAOH N,N,N-trimethyl-1 -adamantanammonium hydroxide
  • the 27 AI MAS NMR of the mechanochemically activated reaction mixture is displayed in figure 2 and shows a relative 27 AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) of 91.2 and within the range of 15 to -20 ppm (I2) of 8.8 such as to afford a ratio of the integra tion values I2 : (h + I2) of 8.8.
  • Example 2 Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture
  • Example 3 Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture
  • Example 4 Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture 5.01 g of the sample obtained according to Reference Example 4 was diluted with 18.65 g of distilled water, thus affording a dilution rate of S1O2 : H2O of 1 : 1 1. The mixture was then stirred, and 7.5 g of the mixture were removed from with a pipette and placed in an autoclave. The au toclave was then sealed and subsequently heated at 230 °C for 3 h.
  • the solid reaction product was then washed with 3 I of distilled water, filtered dry over a suction filter, after which it was dried for 2 h at 120 °C and then calcined for 5 h at 550 °C. As determined by x-ray diffraction, the product displayed a crystallinity of 65% and consisted of 15% ZSM-39, 85% chabazite, ⁇ 0.5% dodecasil.
  • Comparative Example Synthesis of a zeolitic material having a CHA-type framework structure according to a conventional synthesis method
  • the mechanochemical activation of the reactants in the inventive Example prior to crystallization leads to a considerably increased crystallization rate of the reaction mixture, the product of the Comparative Example displaying only a fraction of the crystallinity of the inventive Example after crystallization under the same conditions.
  • the surprising technical effect is even more pronounced than would appear to be the case since mixture in the Comparative Ex ample was placed in two autoclaves, such that the surface to volume ratio in the Comparative Example was higher than in the inventive examples, as a result of which a faster rate of heating was achieved in the Comparative Example.

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Abstract

The present invention relates to a process for preparing a zeolitic material comprising YO2 and X2O3 in its framework structure, wherein Y stands for a tetravalent element and X stands for a trivalent element, wherein said process comprises: (i) preparing a mixture comprising one or more sources of YO2, one or more sources of X2O3, and H2O; (ii) grinding and/or mixing the mixture prepared in (i), wherein the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.3 to 200 kJ/kg of the mixture; (iii) adding water, preferably distilled water, to the ground mixture obtained in (ii) and preferably homogenizing the resulting mixture; and (iv)crystallizing a zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture obtained in (iii), wherein the mixture is heated to a temperature in the range of from 80 to 300°C; wherein the mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2. Furthermore, the invention relates to a zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable and/or obtained according to the inventive process as well as to the use of said material.

Description

Solvent-Free Mechanochemical Activation in Zeolite Synthesis
TECHNICAL FIELD
The present invention relates to a process for the preparation of a zeolitic material including the mechanochemical activation of the reaction mixture prior to crystallization, as well as to a cata lyst per se as obtainable or obtained according to said process. Furthermore, the present inven tion relates to the use of the inventive zeolitic material, in particular as a catalyst.
INTRODUCTION
Molecular sieves are classified by the Structure Commission of the International Zeolite Associ ation according to the rules of the lUPAC Commission on Zeolite Nomenclature. According to this classification, framework-type zeolites and other crystalline microporous molecular sieves, for which a structure has been established, are assigned a three letter code and are described in the Atlas of Zeolite Framework Types, 6th edition, Elsevier, London, England (2007).
Among said zeolitic materials, Chabazite is a well studied example, wherein it is the classical representative of the class of zeolitic materials having a CHA framework structure. Besides aluminosilicates such as Chabazite, the class of zeolitic materials having a CHA framework structure comprises a large number of compounds further comprising phosphorous in the framework structure are known which are accordingly referred to as silicoaluminophosphates (SAPO). In addition to said compounds, further molecular sieves of the CHA structure type are known which contain aluminum and phosphorous in their framework, yet contain little or no sili ca, and are accordingly referred to as aluminophosphates (APO). Zeolitic materials belonging to the class of molecular sieves having the CHA-type framework structure are employed in a varie ty of applications, and in particular serve as heterogeneous catalysts in a wide range of reac tions such as in methanol to olefin catalysis and selective catalytic reduction of nitrogen oxides NOx to name some two of the most important applications. Zeolitic materials of the CHA frame work type are characterized by three-dimensional 8-membered-ring (8MR) pore/channel sys tems containing double-six-rings (D6R) and cages.
Zeolitic materials having a CHA-type framework structure and in particular Chabazite with incor porated copper ions (Cu-CHA) are widely used as heterogeneous catalyst for the selective cata lytic reduction (SCR) of NOx fractions in automotive emissions. Based on the small pore open ings and the alignment of the copper ions in the CHA cages, these catalyst systems have a unique thermal stability, which tolerates temperatures higher than 700°C in presence of H2O.
Among zeolitic materials having the CHA-type framework structure, high silica aluminosilicate zeolite chabazite (CHA), SSZ-13, has a three-dimensional pore system with ellipsoidal-shaped large cages (6.7 x 10 A) that are accessible via 8-membered ring windows (3.8 x 3.8 A), which have attracted great interest because they exhibit extraordinary catalytic properties not only in selective catalytic reduction of NOx with NH3 (NH3-SCR) in recent years, but also in methanol to olefin (MTO) and in the conversion of syngas to olefins.
The synthesis of zeolitic materials from simple starting compounds involves a complex process of self organization which often necessitates special conditions such as elevated temperatures and/or pressure, wherein such reactions typically require the heating of starting materials under autogenous pressure for obtaining the zeolitic material after lengthy reaction times ranging from days to several weeks. Accordingly, due to the often harsh reaction conditions and the long re action times, batch synthesis has long been the method of choice for synthesizing zeolitic mate rials. Batch reactions however present numerous limitations, in particular relative to the levels of space-time-yield which may be attained.
Efforts have accordingly been invested in finding improved batch reaction procedures as well as alternative methodologies which offer advantages to the classical batch synthetic procedures employed for the synthesis of zeolitic materials. One method which has been investigated in this respect involves the use of continuous stirred-tank reactors wherein the fluid reagents are con tinuously introduced at the top of a tank reactor, and the effluent containing the solid reaction product is continuously removed from the bottom of the tank reactor. Although said methodolo gies eliminate the need to empty the reaction vessel between batch runs under non-continuous conditions, the reaction times necessary for crystallization remain lengthy.
For increasing the efficiency of continuous stirred-tank reactors, these are often employed in series, wherein each stage contributes to a given incremental progress of the reaction to com pletion. The higher the number of stages which are employed, the higher the efficiency which may be attained, maximum efficiency being theoretically realized by an infinite number of infi nitely small reaction stages. Besides in continuous stirred-tank reactors, the concept of multiple stages has also been realized e.g. in multiple stage cylindrical reactors such as disclosed in US 5,989,518 for the synthesis of a 4A zeolite.
Along these lines, reactor geometries have been conceived which allow for a rapid synthesis of zeolitic materials. Thus, US 2016/01 15039 A1 relates to a method for the continuous production of a zeolite in a tubular reactor displaying a low ratio of the volume to the lateral surface area. Similarly, Liu et al. in Angew. Chem. Int. Ed. 2015, 54, 5683-5687 discloses a continuous syn thesis of high-silica zeolite SSZ-13 employing very short reaction times. Ju, J. et al. in Chemical Engineering Journal 2006, 1 16, 1 15-121 as well as Vandermeersch, T. et al. in Microporous and Mesoporous Materials 2016, 226, 133-139, on the other hand, respectively disclose the rapid synthesis of micron sized NaA zeolite in a continuous flow reactor setup. Liu, Z. et al. in Chemistry of Materials 2014, 26, 2327-2331 concerns an ultrafast continuous-flow synthesis of crystalline microporous aluminophophate AIPO4-5. Slangen et al.“Continuous Synthesis of Zeo lites using a Tubular Reactor”, 12th International Zeolite Conference, Materials Research Society 1999 relates to the continuous syntheses of NaA zeolite, NaY zeolite, and silicalite-1 in a tubular reactor of 6 mm outer diameter (~3 mm inner diameter) and variable length.
For reactions which do not necessitate high pressure, microwave-assisted procedures have been investigated such as Bonaccorsi, L. et al. in Microporous and Mesoporous Materials 2008,
1 12, 481 -493 which relates to the continuous synthesis of zeolite LTA. Similarly, US
2001/0054549 A1 concerns a continuous process and apparatus for preparing inorganic mate rials employing microwaves.
Although considerable progress has been made relative to the reaction efficiency in view of the use of continuous stirred-tank and multiple stage reactors, progress made in view of the reduc tion of the reaction times has been limited to reactor geometries applied on a lab-scale level. Furthermore, although in principle continuous, efforts made with respect to the reduction of re action times remain limited with respect to economically viable durations of operation due to the clogging of the reactor, in particular in applications employing plug flow methodologies.
In this respect, DE 39 19 400 A1 describes a hydrothermal pre-treatment of a batch reaction mixture in a tubular reactor prior to crystallization thereof in a batch reactor for at least 40 h re action time at ambient pressure on an industrial scale. There however remains the need to em ploy such flow reactor techniques not only as part of batch methodologies but to continuous processes wherein the crystallization takes place within the flow reactor without being limited to short operation periods in view of clogging issues.
In this regard, WO 2017/216236 A1 relates to a continuous process for preparing a zeolitic ma terial comprising continuously feeding the reaction mixture prepared into a continuous flow reac tor. Although said reaction method affords a highly improved methodology for attaining high space-time-yields, said process is still limited by the foregoing preparation step of a reaction mixture apt for continuous synthesis, in particular in view of the lengthy aging of the reaction mixture prior to its use in continuous synthesis.
WO 2005/039761 A2 relates to a method for making a molecular sieve catalyst involving the aging of the reaction mixture and its analysis via 27AI NMR. US 7,528,089 B2, on the other hand, relates to the processing of a high solids material for the formation of a microporous ma terial including a rotary calciner or rotary screw as a means of conveying the synthesis mixture continuously or semi-continuously. Finally, WO 2016/153950 A1 describes methods for the syn thesis of zeolitic materials involving a step of subjecting the reaction mixture to high shear pro cessing conditions.
WO 2015/185625 A2 relates to the preparation of a zeolitic material having the CHA framework structure using trimethylcyclohexylammonium and tetramethylammonium hydroxide. Preferred D50 values of the zeolitic material are disclosed as being in the range of from 1650 to 1850 nm or, alternatively, in the range of from 550 to 650 nm. WO 03/020641 A1 relates to crystalline zeolite SSZ-62 that has the CHA crystal structure, a mole ratio greater than 10 of silicon oxide to aluminum oxide and has a crystallite size of 0.5 micron or less. Further, a method for preparing SSZ-62 using specific sources of silicon and aluminum, and a N,N,N-trimethyl-l-adamantylammonium cation templating agent is disclosed, processes employing SSZ-62 as a catalyst, and processes using SSZ-62 to separate gases are disclosed.
WO 2018/059316 A1 relates to a specific process for preparing a zeolitic material having a zeo- litic framework structure which exhibits a molar ratio (a AI2O3) : Si02 or a crystalline precursor thereof, wherein a is a number in the range of from 0 to 0.5.
WO 2012/072527 A2 discloses a process comprising (1 ) mixing a silicon source, an aluminum source and an optional template to obtain a synthesis gel, (2) grinding the synthesis gel, (3) hydrothermal treatment of the ground synthesis gel. Preferred according to said document is the synthesis of zeolites having the BEA or MFI framework structure type.
N. E. Gordina et al. (“Use of Mechanochemical Activation and Ultrasonic Treatment for the Syn thesis of LTA Zeolite”, Russ. J. Gen. Chem. 2018, M A I K Nauka-lnterperiodica, vol. 88, p. 1981 -1989) relates to a study on the use of mechanochemical activation and ultrasonic treat ment for the synthesis of LTA zeolite.
K. Wantae et al. (“Effect of Dry Grinding of Pyrophyllite on the Hydrothermal Synthesis of Zeo lite Na-X and Na-A”, Materials Transactions 2014, vol. 55, p. 1488-1493) relates to a study of the effect of dry grinding of pyrophyllite on the hydrothermal synthesis of zeolite Na-X and Na-A, wherein a mechanochemical activation of said material is followed by hydrothermal reaction in sodium hydroxide solution.
N. E. Gordina et al. (“Synthesis of NaA Zeolite by Mechanochemical Methods”, Russ. J. Appl. Chem. 2003, vol. 76, p. 661 -662) relates to a study on the synthesis of Na-A zeolite by mecha nochemical methods, wherein the starting materials are mechanochemically treated.
DD 205 674 A1 relates to the preparation of crystalline zeolites having a silica to alumina molar ratio of S1O2 to AI2O3 of higher than 10. The preparation process involves use of a ZSM- containing material activated by means of grinding.
V. Valtchev et al. (“Tribochemical activation of seeds for rapid crystallization of zeolite Y” in Zeo lites 1995, vol. 15, p. 193-197) relates to the influence of tribochemical activation of seeds on the crystallization of zeolite Y.
R. Limin et al. (“Solvent-Free Synthesis of Zeolites from Solid Raw Materials”, J. Am. Chem Soc. 2012, vol. 134, p. 15173-15176) disclose a solvent-free route for synthesizing various zeo lites from mixing, grinding, and heating solid raw materials. G. Majano et al. (“Rediscovering zeolite mechanochemistry - A pathway beyond current synthe sis and modification boundaries”, Microporous and Mesoporous Mat. 2014, vol. 194, p. 106- 1 14) discloses a study on zeolite mechanochemistry, in particular with respect to the prepara tion process of specific zeolites.
Y. Wu et al. (“Effect of microwave-assisted aging on the static hydrothermal synthesis of zeolite MCM-22”, Microporous and mesoporous Mat. 2008, vol. 1 16, p. 386-393) relates to a study on the synthesis of a zeolitic material having the MWW framework structure.
DETAILED DESCRIPTION
It was therefore an object of the present invention to provide an improved process for preparing a zeolitic material which may afford increased space-time-yields for both batch and continuous processes. Thus, it has surprisingly been found that that the specific mechanochemical treat ment of a mixture of reactants having a high solids content results in an activation of the zeolite precursor materials similar to the activation achieved by the conventional aging of reaction mix tures. Furthermore, it has quite unexpectedly been found that the mechanochemical activation route requires only a fraction of the time which conventional aging procedures necessitate, such that a tremendous increase in space-time-yields may be achieved compared to known ultrafast zeolite synthesis procedures. In addition to the aforementioned, it has surprisingly been found that the advantages of mechanochemical activation in zeolite synthesis are not restricted to methodologies which necessitate an aging procedure, but are also observed in classical batch reaction processes which do not include a separate aging step. In particular, it has quite unex pectedly been found that mechanochemical activation of a reaction mixture according to the inventive process leads to a greatly increased rate of crystallization in conventional batch syn thesis, such that zeolites displaying a high crystallinity may be obtained in high yields after only a fraction of the time required in conventional batch synthesis.
Therefore, the present invention relates to a process for preparing a zeolitic material comprising YO2 and X2O3 in its framework structure, wherein Y stands for a tetravalent element and X stands for a trivalent element, wherein said process comprises:
(i) preparing a mixture comprising one or more sources of YO2, one or more sources of X2O3, and H2O;
(ii) grinding and/or mixing the mixture prepared in (i), wherein the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.3 to 200 kJ/kg of the mix ture;
(iii) adding water, preferably distilled water, to the ground mixture obtained in (ii) and prefera bly homogenizing the resulting mixture; and
(iv) crystallizing a zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture obtained in (iii), wherein the mixture is heated to a temperature in the range of from 80 to 300°C;
wherein the mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, wherein the energy intake is preferably determined according to reference example 1.
According to the present invention, it is preferred that the energy intake is determined via de termination of the torque with a given mill, preferably with a stirred media mill. The torque has to be determined, first without the material of which the energy intake is to be determined and, second, with said material. The torque determined for the experiment without the material of which the energy intake is to be determined is subtracted from the torque determined for the experiment with said material. Based on the result from said calculation, the specific energy input in kJ/kg is calculated. It is also possible to determine the torque with other devices. Thus, either the torque with and without material load can be determined and the energy intake calcu lated as described above or the power input with material (load value) and without material (no- load value) is determined. With regards to the latter, the no-load value is subtracted from the load value und the energy intake as introduced into the product can be calculated.
It is particularly preferred that the energy intake is determined as described in reference exam ple 1 as disclosed herein.
No particular restriction applies according to the present invention regarding the mixture ob tained in (ii), provided that it has been subject to a grinding and or mixing treatment according to any of the particular or preferred embodiments of the inventive process. It is, however, preferred that the 27AI MAS NMR of the mixture obtained in (ii) comprises:
a first peak (P1) in the range of from 20 to 80 ppm, preferably of from 45 to 65 ppm, pref erably of from 50 to 60 ppm, more preferably of from 52 to 58 ppm, more preferably of from 53 to 57 ppm, more preferably of from 53.5 to 56.5 ppm, more preferably of from 54 to 56 ppm, more preferably of from 54.5 to 55.5 ppm, and more preferably of from 55.0 to 55.5 ppm; and one or more peaks (PX) in the range of from -20 to 15 ppm, preferably of from -10 to 12 ppm, more preferably of from -5 to 10 ppm, more preferably of from -3 to 8 ppm, more prefera bly of from -2 to 7 ppm, more preferably of from -1.5 to 6.5 ppm, more preferably of from -1 to 6 ppm, more preferably of from -0.5 to 5.5 ppm, and more preferably of from 0.5 to 5.0 ppm; wherein the relative 27AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) and within the range of 15 to -20 ppm (I2) of the zeolitic material offer a ratio of the inte gration values I2 : (h + I2) comprised in the range of from 0.5 to 50%, preferably of from 1 to 35%, more preferably of from 3 to 25%, more preferably of from 5 to 18%, more preferably of from 8 to 15%, more preferably of from 9 to 14%, more preferably of from 10 to 13%, and more preferably of from 1 1 to 12%,
wherein preferably the relative 27AI solid-state NMR intensity integral ratio is measured at 9.4 Tesla and 10 kHz Magic Angle Spinning, and
wherein preferably the one or more peaks (PX) consists of one or two peaks (PX), more prefer ably of one peak (PX). According to the present invention, it is particularly preferred that the 27AI MAS NMR of the mix ture obtained in (ii) is determined as described in the experimental section of the present appli cation.
As regards the amount of water added in (iii) to the ground mixture, no particular restriction ap plies. It is preferred that water is added in (iii) to the ground mixture. In the case where water is added in (iii) to the ground mixture, it is preferred that the resulting mixture comprises an amount of water in the range of from 68 to 94 weight-%, more preferably in the range of from 70 to 92 weight-%, more preferably in the range of from 72 to 90 weight-%, more preferably in the range of from 74 to 88 weight-%, based on the total weight of the resulting mixture.
It is preferred that the mixture prepared in (i) has a density in the range of from 0.1 to 5 g/ml, more preferably in the range of from 0.5 to 3.5 g/ml, more preferably in the range of from 1 .0 to 2.75 g/ml.
As regards the preferred homogenization of the mixture in (iii), no particular restrictions apply provided that a homogenous mixture is obtained in (iii) for crystallization in (iv). It is, however, preferred according to the present invention that homogenization in (iii) is achieved by grinding and/or mixing, preferably by mixing. As regards the preferred grinding and/or mixing, it is yet further preferred that it is achieved according to any of the particular or preferred embodiments of the inventive process as described in the present application relative to the grinding and/or mixing of the mixture in (ii).
As concerns the energy intake of the mixture during the grinding and/or mixing procedure in (ii), it is preferred according to the present invention that it is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 0.8 to 80 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg of the mixture, more preferably of from 3 to 30 kJ/kg of the mixture, more preferably of from 4 to 25 kJ/kg, more preferably of from 5 to 20 kJ/kg of the mixture, more preferably of from 7 to 17 kJ/kg, more preferably of from 8 to 15 kJ/kg of the mixture, more preferably of from 9 to 13 kJ/kg, and more preferably of from 10 to 12 kJ/kg. It is particularly preferred that the energy intake is determined as described in reference example 1 as disclosed herein.
Alternatively, it is preferred that the energy intake of the mixture during the grinding and/or mix ing procedure in (ii) is in the range of from 0.5 to 100 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg, more preferably of from 1 .5 to 20 kJ/kg of the mixture, more preferably of from 2 to 10 kJ/kg, more preferably of from 2.5 to 7 kJ/kg of the mixture, more preferably of from 3 to 5 kJ/kg, and more preferably of from 3.5 to 4.5 kJ/kg. It is particularly preferred that the en ergy intake is determined as described in reference example 1 as disclosed herein.
With respect to the hhO content of the mixture prepared in (i) and ground in (ii), it is preferred according to the present invention that said mixture contains from 10 to 280 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, contained in the mixture prepared in (i) and heated in (iv), preferably of from 20 to 260 wt.-%, more preferably of from 30 to 240 wt.-%, more preferably of from 40 to 230 wt.-%, more preferably of from 60 to 220 wt.-%, more preferably of from 80 to 210 wt.-%, more preferably of from 100 to 200 wt.-%, more pref erably of from 120 to 190 wt.-%, more preferably of from 140 to 180 wt.-%, more preferably of from 150 to 170 wt.-%.
As regards the heating of the mixture obtained in (iii) in (iv), it is preferred according to the pre sent invention that said heating is conducted at a temperature in the range of from 100 to 280°C, preferably of from 120 to 270 °C, more preferably of from 140 to 260 °C, more preferably of from 160 to 255 °C, more preferably of from 180 to 250 °C, more preferably of from 200 to 245 °C, and more preferably of from 220 to 240 °C.
Concerning the duration of the crystallization and in particular of the heating in (iv), no particular restrictions apply provided that a zeolitic material comprising YO2 and X2O3 in its framework structure may be crystallized from the mixture. According to the present invention it is however preferred that crystallization and in particular the heating in (iv) is conducted for a duration in the range of from 0.2 to 96 h, preferably of from 0.5 to 48 h, preferably from 0.75 to 24 h, more preferably from 1 to 12 h, more preferably from 1.25 to 8 h, more preferably from 1.5 to 5 h, more preferably from 1.75 to 4 h, and more preferably from 2 to 3 h.
With regard to the duration of the grinding and/or mixing in (ii), no particular restrictions apply provided that in (iv) a zeolitic material comprising YO2 and X2O3 in its framework structure may be crystallized from the mixture. According to the present invention it is however preferred that grinding and/or mixing in (ii) is carried out for a duration in the range of from 0.01 to 120 min, preferably of from 0.05 to 60 min, more preferably of from 0.1 to 30 min, more preferably of from 0.2 to 20 min, more preferably of from 0.3 to 10 min, more preferably of from 0.4 to 7 min, more preferably of from 0.5 to 5 min, more preferably of from 0.7 to 4 min, more preferably of from 1 to 3 min, more preferably of from 1.2 to 2.8 min, more preferably of from 1.4 to 2.6 min, and more preferably of from 1.5 to 2.5 min.
In principle, no particular restrictions apply according to the present invention relative to the grinding and/or mixing of the mixture in (ii), provided that the energy intake of the mixture during the grinding and/or mixing is in the range of from 0.3 to 200 kJ/kg of the mixture, or of any of the preferred ranges described in the present application. It is, however, preferred according to the present invention that the rate of energy transfer to the mixture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg*h), preferably from 50 to 1 ,200 kJ/(kg*h), more preferably from 100 to 1 ,000 kJ/(kg*h), more preferably from 150 to 800 kJ/(kg*h), more preferably from 200 to 600 kJ/(kg*h), more preferably from 250 to 500 kJ/(kg*h), more preferably from 280 to 450 kJ/(kg*h), more preferably from 300 to 370 kJ/(kg*h), and more preferably from 320 to 340 kJ/(kg*h).
As disclosed above, the energy intake of the mixture during the grinding and/or mixing can al ternatively be in the range of from 0.5 to 50 kJ/kg. Thus, it is preferred in an alternative, that the rate of energy transfer to the mixture in (ii) is in the range of from 10 to 1 ,000 kJ/(kg*h), prefera bly from 25 to 800 kJ/(kg*h), more preferably from 50 to 600 kJ/(kg*h), more preferably from 75 to 400 kJ/(kg*h), more preferably from 90 to 200 kJ/(kg*h), more preferably from 100 to 175 kJ/(kg*h), more preferably from 110 to 150 kJ/(kg*h), more preferably from 120 to 140 kJ/(kg*h), and more preferably from 125 to 135 kJ/(kg*h).
According to the invention, the mixture obtained in (i) may have any suitable temperature prior to the grinding and/or mixing in (ii), wherein it is preferred according to the present invention that the mixture prepared in (i) has an initial temperature in the range of from 10 to 50°C when sub ject to grinding and/or mixing in (ii), preferably in the range of from 15 to 40°C, and more prefer ably in the range of from 20 to 30°C. Furthermore and independently thereof, it is preferred that in (i) and prior to (ii) the mixture prepared in (i) is not heated to a temperature of 40°C or great er, preferably of 35°C or greater, more preferably of 30°C or greater, wherein more preferably in
(i) and prior to (ii) the mixture prepared in (i) is not subject to a heating step.
Concerning the grinding and/or mixing in (ii), any suitable apparatus may be employed to said effect, provided that the energy intake of the mixture during the grinding and/or mixing proce dure is in the range of from 0.3 to 200 kJ/kg of the mixture. According to the present invention it is preferred that grinding and/or mixing in (ii) is carried out in a mill selected from the group con sisting of a stirred media mill, a ball mill, a roller mill, a kneader and a high shear mixer, preferably from the group consisting of a stirred media mill, a planetary ball mill, a smooth wheel roller mill, a kneader with roller blades, a kneader with sigma blades, a high shear mixer equipped with a microgranulation tool, and a high shear mixer equipped with a pin mixing tool, wherein more preferably grinding and/or mixing in (ii) is carried out in a stirred media mill and/or in a roller mill, preferably in a stirred media mill.
It is further preferred according to the present invention that grinding and/or mixing in (ii) is car ried out in a stirred media mill using grinding beads made of a material selected from the group consisting of stainless steel, ceramic, and rubber, preferably from the group consisting of chrome steel, flint, zirconia, and lead antimony alloy, wherein more preferably the grinding beads for stirred media milling are made of chrome steel and/or zirconia, preferably of zirconia. Furthermore and independently thereof, it is preferred that grinding and/or mixing in (ii) is car ried out in a stirred media mill using grinding beads with a diameter in the range of from 0.1 to 50 mm, preferably of from 0.8 to 20 mm, more preferably of from 1 to 10 mm, more preferably of from 1.2 to 7 mm, , more preferably of from 2 to 5 mm, more preferably of from 2.3 to 4 mm, more preferably of from 2.5 to 3.5 mm, more preferably of from 2.8 to 3.3 mm. Furthermore and independently thereof, it is preferred that grinding and/or mixing in (ii) is carried out in a stirred media mill, wherein the filling degree of the grinding media in the stirred media mill is in the range of from 20 to 80%, preferably of from 25 to 75%, more preferably of from 30 to 70%, more preferably of from 35 to 65%, more preferably of from 40 to 60%, and more preferably of from 40 to 50%. Furthermore and independently thereof, it is preferred that grinding and/or mixing in
(ii) is carried out in a stirred media mill, wherein the tip speed of the ball mill is in the range of from 1 to 20 m/s, preferably of from 2 to 15 m/s, more preferably of from 3 to 12 m/s, more pref erably of from 4 to 8 m/s. In addition thereto and independently thereof, it is preferred that grind ing and/or mixing in (ii) is carried out in a ball mill, wherein the ball mill is operated at a speed in the range of from 10 to 250 rpm, preferably of from 30 to 220 rpm, more preferably of from 50 to 200 rpm, more preferably of from 60 to 180 rpm, more preferably of from 70 to 150 rpm, more preferably of from 80 to 120 rpm, and more preferably of from 90 to 100 rpm. Furthermore and independently thereof, it is preferred that the ball mill comprises a volume having a cylindrical geometry, wherein the diameter of the volume having a cylindrical geometry is in the range of from 200 to 400 mm, more preferably in the range of from 250 to 350 mm, more preferably in the range of from 280 to 320 mm, more preferably in the range of from 290 to 310 mm, more preferably in the range of from 295 to 305 mm. Furthermore and independently thereof, it is pre ferred that the ball mill is operated at a relative rotation speed of from 30 to 150 % of the critical rotation speed, more preferably of from 40 to 125 % of the critical rotation speed, more prefera bly of from 45 to 120 % of the critical rotation speed, more preferably of from 50 to 95 % of the critical rotation speed, more preferably of from 60 to 90 % of the critical rotation speed and more preferably of from 70 to 90 % of the critical rotation speed. Furthermore and independently thereof, it is preferred that the critical rotation speed of the ball mill is in the range of from 40 to 80 rpm, more preferably in the range of from 50 to 70 rpm, more preferably in the range of from 55 to 65 rpm, more preferably in the range of from 58 to 62 rpm, more preferably in the range of from 59 to 61 rpm.
According to the present invention, heating in (iv) may be conducted under any suitable condi tions, provided that a zeolitic material comprising YO2 and X2O3 in its framework structure is crystallized from the mixture. It is however preferred that in (iv) the mixture is heated under au togenous pressure, wherein preferably the pressure is in the range of from 0.1 to 9 MPa, more preferably in the range of from 0.5 to 7 MPa, more preferably from 0.8 to 5 MPa, more prefera bly from 1.2 to 4 MPa, more preferably from 1.6 to 3.5 MPa, more preferably from 1.8 to 3 MPa, more preferably from 2 to 2.7 MPa, and more preferably from 2.2 to 2.5 MPa.
As concerns the zeolitic material crystallized in (iv), any conceivable zeolitic material may be obtained, wherein it is preferred that the zeolitic material crystallized in (iv) has a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR,
MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI,
OFF, RTH, GME, AFX, SFW, BEA, CHA, FAU, FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group con sisting of AEI, BEA, CHA, FAU, FER, GME, LEV, MFI, MOR, and MWW, including mixed struc tures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA,
GME, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, includ ing mixed structures of two or more thereof, wherein more preferably the zeolitic material crys tallized in (iv) has a CHA- and/or AEI-type framework structure, preferably a CHA-type frame work structure. Furthermore and independently thereof, it is preferred that the zeolitic material crystallized in (iv) has a CHA-type framework structure, wherein preferably the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhender- sonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK- 14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [AI-Si-0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ-62, including mixtures of two or more thereof, more preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ-62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO- 34, SSZ-13, and SSZ-62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof, wherein more preferably the zeolitic material crystallized in (iv) comprises chabazite and/or SSZ-13, preferably chabazite, and wherein more preferably the zeolitic material crystallized in (iv) is chabazite and/or SSZ-13, preferably SSZ-13.
According to the inventive process, it is preferred that the mixture crystallized in (iv) is mechani cally agitated, wherein preferably mechanical agitation is achieved by stirring.
In principle, the inventive process and in particular the crystallization in (iv) is preferably con ducted as a batch process or as a continuous process. In instances wherein the inventive pro cess and in particular the crystallization in (iv) is preferably conducted as a continuous process, it is further preferred that crystallization in (iv) comprises continuously feeding the mixture ob tained in (iii) into a continuous flow reactor at a liquid hourly space velocity in the range of from 0.3 to 20 IT1 for a duration of at least 1 h, and crystallizing the zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture in the continuous flow reactor, wherein the mixture is heated to a temperature in the range of from 80 to 300°C. Furthermore and inde pendently thereof, it is preferred that the volume of the continuous flow reactor is in the range of from 150 cm3 to 75 m3, preferably from 50 cm3 to 3 m3, preferably from 55 cm3 to 1 m3, more preferably from 60 cm3 to 0.7 m3, more preferably from 65 cm3 to 0.3 m3, more preferably from 70 cm3 to 0.1 m3, more preferably from 75 to 70,000 cm3, more preferably from 80 to 50,000 cm3, more preferably from 85 to 30,000 cm3, more preferably from 90 to 10,000 cm3, more pref erably from 95 to 7,000 cm3, more preferably from 100 to 5,000 cm3, more preferably from 105 to 3,000 cm3, more preferably from 1 10 to 1 ,000 cm3, more preferably from 1 15 to 700 cm3, more preferably from 120 to 500 cm3, more preferably from 125 to 350 cm3, more preferably from 130 to 250 cm3, more preferably from 135 to 200 cm3, more preferably from 140 to 180 cm3, and more preferably from 145 to 160 cm3. Furthermore and independently thereof, it is preferred that the continuous feeding is performed such that the liquid hourly space velocity is in the range of from 0.05 to 10 h 1, more preferably from 0.1 to 5 h 1, more preferably from 0.2 to 3 h 1, more preferably from 0.4 to 2 h 1, more preferably from 0.6 to 1.5 h 1, more preferably from 0.8 to 1.2 h 1, and more preferably from 0.9 to 1 h 1. Furthermore and independently thereof, it is preferred that in (iv) the mixture obtained in (iii) is continuously fed into the continuous flow re actor for a duration ranging from 3 h to 360 d, more preferably from 6 h to 120 d, more prefera bly from 12 h to 90 d, more preferably from 18 h to 60 d, more preferably from 1 to 30 d, more preferably from 1 .5 to 25 d, more preferably from 2 to 20 d, more preferably from 2.5 to 15 d, more preferably from 3 to 12 d, more preferably from 3.5 to 8 d, and more preferably from 4 to 6 d.
As regards the continuous flow reactor which may be employed according to the particular and preferred embodiments of the inventive process involving a continuous process, no particular restrictions apply, wherein it is preferred according to the present invention that the continuous flow reactor is selected among a tubular reactor, a ring reactor, and a continuously oscillating reactor, preferably among a plain tubular reactor, a tubular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, and a continuously oscillating baffled reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor. Furthermore and inde pendently thereof, it is preferred that at least a portion of the preferred tubular reactor is of a regular cylindrical form having a constant inner diameter perpendicular to the direction of flow, wherein the inner diameter is preferably in the range of from 2 to 1200 mm, more preferably from 3 to 800 mm, more preferably from 3 to 500 mm, more preferably from 4 to 200 mm, more preferably from 4 to 100 mm, more preferably from 4.5 to 50 mm, more preferably from 4.5 to 30 mm, more preferably from 5 to 15 mm, more preferably from 5 to 10 mm, more preferably from 5.5 to 8 mm, and more preferably from 5.5 to 6.5 mm. Furthermore and independently thereof, it is preferred that the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 3 to 500 m more preferably from 3.5 to 200 m, more preferably from 3.5 to 100 m, more preferably from 4 to 50 m, more preferably from 4 to 30 m, more preferably from 4.5 to 20 m, more prefer ably from 4.5 to 15 m, more preferably from 5 to 10 m, and more preferably from 5 to 7 m. Fur thermore and independently thereof, it is preferred that the wall of the continuous flow reactor is made of a metallic material, wherein the metallic material comprises one or more metals select ed from the group consisting of Ta, Cr, Fe, Ni, Cu, Al, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Ta, Cr, Fe, Ni, Mo, and combina tions and/or alloys of two or more thereof, preferably from the group consisting of Cr, Fe, Ni,
Mo, and combinations and/or alloys of two or more thereof wherein preferably the metallic mate rial comprises a nickel alloy, a nickel-molybdenum alloy, and more preferably a nickel- molybdenum-chromium alloy. Furthermore and independently thereof, it is preferred that the surface of the inner wall of the continuous flow reactor is lined with an organic polymer material, wherein the organic polymer material preferably comprises one or more polymers selected from the group consisting of fluorinated polyalkylenes and mixtures of two or more thereof, preferably from the group consisting of (C2-C3)polyalkylenes and mixtures of two or more thereof, prefer ably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof, wherein more preferably the polymer material comprises poly(tetrafluoroethylene), wherein more preferably the inner wall of the continuous flow reactor is lined with
poly(tetrafluoroethylene). Furthermore and independently thereof, it is preferred that the contin uous flow reactor is straight and/or comprises one or more curves with respect to the direction of flow, wherein preferably the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow. Furthermore and independently thereof, it is preferred that the walls of the continuous flow reactor are subject to vibration during crystallization in (iv). As regards the conditions which may be employed according to the particular and preferred embodiments of the inventive process involving a continuous process, no particular restrictions apply, wherein it is preferred according to the present invention that the continuous flow reactor consists of a single stage. Furthermore and independently thereof, it is preferred that no matter is added to and/or removed from the reaction mixture during its passage through the continuous flow reactor in (iv), wherein preferably no matter is added, wherein more preferably no matter is added and no matter is removed from the reaction mixture during its passage through the con tinuous flow reactor in (iv). Furthermore and independently thereof, it is preferred that the mix ture prepared in (iii) is directly fed to the continuous flow reactor in (iv), wherein while being fed to the continuous flow reactor in (iv), the mixture prepared in (iii) is pre-heated, preferably to a temperature in the range of from 100 to 300°C, more preferably of from 100 to 280°C, more preferably of from 140 to 260°C, more preferably of from 160 to 250°C, more preferably of from 180 to 240°C, more preferably of from 190 to 230°C, and more preferably of from 200 to 220°C. Furthermore and independently thereof, it is preferred that the mixture crystallized in (iv) in the continuous flow reactor is mechanically agitated, wherein preferably mechanical agitation is achieved by movable parts contained in the continuous flow reactor, wherein more preferably the movable parts are provided such as to continually or periodically, preferably to continually free the walls of the continuous flow reactor from zeolitic materials and/or solid residue attached thereto, wherein more preferably the movable parts comprise a scraper, more preferably a screw, and more preferably a rotating screw.
Unless otherwise indicated in particular or preferred embodiments of the inventive process as described in the present application, there is generally no restriction as to the steps which in addition to steps (i) to (iv) may be comprised by the inventive process. Thus, it is preferred that the process further comprises
(v) quenching the reaction product effluent continuously exiting the reactor in (iv) with a liquid comprising one or more solvents and/or via expansion of the reaction product effluent;
and/or, preferably and,
(vi) isolating the zeolitic material obtained in (iv) or (v);
and/or, preferably and,
(vii) washing the zeolitic material obtained in (iv), (v) or (vi), preferably with distilled water; and/or, preferably and,
(viii) drying the zeolitic material obtained in (iv), (v), (vi), or (vii);
and/or, preferably and,
(ix) calcining the zeolitic material obtained in (iv), (v), (vi), (vii), or (viii).
Furthermore, it is preferred that in (v) the liquid comprises one or more solvents selected from the group consisting of polar protic solvents and mixtures thereof, preferably from the group consisting of n-butanol, isopropanol, propanol, ethanol, methanol, water, and mixtures thereof, more preferably from the group consisting of ethanol, methanol, water, and mixtures thereof, wherein more preferably the liquid comprises water, and wherein more preferably water is used as the liquid, preferably deionized water. Furthermore and independently thereof, it is preferred that in (v) the weight ratio of the liquid comprising one or more solvents to the reaction product effluent continuously exiting the reactor in the range of from 0.5 to 30, preferably from 1 to 25, more preferably from 2 to 20, more preferably from 3 to 18, more preferably from 4 to 15, more preferably from 5 to 12, more preferably from 6 to 10, more preferably from 6.5 to 9, more pref erably from 7 to 8.5, and more preferably from 7.5 to 8. Furthermore and independently thereof, it is preferred that drying in (viii) is effected at a temperature in the range from 50 to 220°C, preferably from 70 to 180°C, more preferably from 80 to 150°C, more preferably from 90 to 130°C, more preferably from 100 to 125°C, and more preferably from 1 10 to 120°C. Further more and independently thereof, it is preferred that calcining in (ix) is effected at a temperature in the range from 300 to 900 °C, preferably of from 400 to 700 °C, more preferably of from 450 to 650 °C, and more preferably of from 500 to 600 °C. Furthermore and independently thereof, it is preferred that calcining in (ix) is effected for a duration in the range of from 0.5 to 12 h, pref erably in the range of from 1 to 9 h, more preferably in the range of from 2 to 6 h. Furthermore and independently thereof, it is preferred that the supernatant obtained from the isolation of the zeolitic material in (vi), and/or a feed having the same composition as said supernatant, is not at any point recycled to the reaction mixture during its passage through the continuous flow reac tor. Furthermore and independently thereof, it is preferred that in (vi) isolating the zeolitic mate rial includes a step of spray-drying the zeolitic material obtained in (iv) or (v),
and/or
wherein in (viii) drying of the zeolitic material includes a step of spray-drying the zeolitic material obtained in (iv), (v), (vi), or (vii).
Furthermore, it is preferred according to the present invention that the inventive process further comprises
(x) subjecting the zeolitic material obtained in (iv), (v), (vi), (vii), (viii), or (ix) to one or more ion exchange procedures with H+ and/or NH4 +, preferably with NH4 +.
Furthermore and independently thereof, it is preferred that the process further comprises
(xi) subjecting the zeolitic material obtained in (iv), (v), (vi), (vii), (viii), (ix), or (x) to one or more ion exchange procedures with one or more cations and/or cationic elements selected from the group consisting of Sr, Zr, Cr, Mg, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more thereof, preferably from the group consisting of Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Cr, Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, wherein more preferably the one or more cation and/or cationic elements comprise Cu and/or Fe, pref erably Cu, wherein even more preferably the one or more cation and/or cationic elements con sist of Cu and/or Fe, preferably of Cu.
According to the present invention, Y may stand for any conceivable tetravalent element where in it is preferred that Y is selected from the group consisting of Si, Sn, Ti, Zr, Ge, and combina tions of two or more thereof, Y preferably being Si. As regards the one or more sources for YO2, any conceivable source may be employed wherein it is preferred that the one or more sources for YO2 are one or more solid sources for YO2, wherein preferably the one or more sources for YO2 comprises one or more compounds select ed from the group consisting of silicas, silicates, silicic acid and combinations of two or more thereof, preferably selected from the group consisting of silicas, alkali metal silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, colloidal silica, reactive amorphous solid silica, silica gel, pyrogenic silica, lithium silicates, sodium silicates, potassium silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na2Si03, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na2Si03, and combinations of two or more thereof, wherein more preferably the one or more sources for YO2 comprises Na2Si03 and/or silica gel, preferably Na2Si03 and silica gel, wherein more preferably the one or more sources for YO2 is Na2Si03 and/or silica gel, preferably Na2Si03 and silica gel. As regards the silica gel preferably used as the one or more sources for YO2 according to particular and preferred embodiments of the inventive process, it is preferred that the silica gel has the formula S1O2 x H2O, wherein x is in the range of from 0.1 to 1.165, preferably from 0.3 to 1.155, more preferably from 0.5 to 1.15, more preferably from 0.8 to 1.13, and more preferably from 1 to 1.1.
According to the present invention, X may stand for any conceivable trivalent element wherein it is preferred that X is selected from the group consisting of Al, B, In, Ga, and combinations of two or more thereof, X preferably being Al.
As regards the one or more sources for X2O3, any conceivable source may be employed where in it is preferred that the one or more sources for X2O3 are one or more solid sources for X2O3, wherein preferably the one or more sources for X2O3 comprises one or more compounds se lected from the group consisting of aluminum sulfates, sodium aluminates, and boehmite, wherein preferably the one or more sources for X2O3 comprises Al2(S04)3 and/or NaAI02, pref erably AI2(S04)3, wherein more preferably the one or more sources for X2O3 is Al2(S04)3 and/or NaAI02, preferably Al2(S04)3.
Regarding the YO2 : X2O3 molar ratio of the one or more sources of YO2, calculated as YO2, to the one or more sources for X2O3, calculated as X2O3, in the mixture prepared in (i), it is pre ferred that it is in the range of from 1 to 100, preferably of from 2 to 70, more preferably of from 4 to 50, more preferably of from 6 to 40, more preferably of from 8 to 35, more preferably of from 12 to 30, more preferably of from 15 to 25, more preferably of from 17 to 22, and more preferably of from 19 to 20.
According to the present invention, it is further preferred that the mixture prepared in (i) and crystallized in (iv) further comprises one or more structure directing agents, wherein preferably one or more organotemplates are employed as the one or more structure directing agents. As regards the molar ratio SDA : YO2 of the one or more structure directing agents (SDA) to the one or more sources of YO2, calculated as YO2, in the mixture prepared in (i) and heated in (iv), it is preferred that it ranges from 0.01 to 0.5, wherein the one or more structure directing agents do not include structure directing agents optionally contained in seed crystals optionally con tained in the mixture prepared in (i), and more preferably from 0.03 to 0.2, more preferably from 0.06 to 0.15, more preferably from 0.09 to 0.13, and more preferably from 0.1 1 to 0.12. Fur thermore and independently thereof, it is preferred that the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, preferably for 1 -adamantyl. In this respect, it is further preferred that R1 , R2, and R3 independently from one another stand for optionally substituted and/or op tionally branched (Ci-C6)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more pref erably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R1 , R2, and R3 independently from one another stand for optionally substituted me thyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more preferably R1 , R2, and R3 independently from one another stand for optionally substituted methyl, preferably unsubstituted methyl. Furthermore and independently thereof, it is preferred that R4 stands for optionally het erocyclic and/or optionally substituted adamantyl and/or benzyl, preferably for optionally hetero cyclic and/or optionally substituted 1 -adamantyl, more preferably for optionally substituted ada mantyl and/or benzyl, more preferably for optionally substituted 1 -adamantyl, more preferably for unsubstituted adamantyl and/or benzyl, and more preferably for unsubstituted 1 -adamantyl. According to said particular and preferred embodiments of the inventive process it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more /V,/V/V-tri(Ci-C4)alkyl-1 -adamantylammonium compounds, preferably one or more /V,/V,/V-tri(Ci-C3)alkyl-1 -adamantylammonium compounds, more preferably one or more N,N,N- tri(Ci-C2)alkyl-1 -adamantylammonium compounds, more preferably one or more N,N,N- tri(Ci- C2)alkyl-1 -adamantylammonium and/or one or more /V,/V,/V-tri(C-i-C2)alkyl-1 - adamantylammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-1 -adamantylammonium, /V/V-diethyl-/V-methyl-1 -adamantylammonium, N,N- dimethyl-/V -ethyl-1 -adamantylammonium, N, N,N -trimethyl-1 -adamantylammonium compounds, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammo nium cation R1R2R3R4N+-containing compounds comprise one or more N, N,N -trimethyl-1 - adamantylammonium compounds. Furthermore and independently thereof, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, pref erably one or more salts selected from the group consisting of halides, sulfate, nitrate, phos phate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of bromide, chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammonium hy droxides.
Alternatively, it is preferred that the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for cycloalkyl. In this respect, it is further preferred that R1 and R2 independently from one another stand for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci- C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R1 and R2 independently from one another stand for optionally substituted methyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more preferably R1 and R2 independently from one another stand for optionally substituted methyl, preferably un substituted methyl. Furthermore and independently thereof, it is preferred that R3 stands for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substi tuted methyl or ethyl, wherein more preferably R3 stands for optionally substituted ethyl, prefer ably unsubstituted ethyl. Furthermore and independently thereof, it is preferred that R4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cycloalkyl, preferably for 5- to 7-membered cycloalkyl, more preferably for 5- or 6-membered cycloalkyl, wherein more preferably R4 stands for optionally heterocyclic and/or optionally substituted 6-membered cyclo alkyl, preferably optionally substituted cyclohexyl, and more preferably unsubstituted cyclohexyl. According to said particular and preferred embodiments of the inventive process it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more /V,/V/V-tri(Ci-C4)alkyl-(C5-C7)cycloalkylammonium compounds, preferably one or more /V,/V,/V-tri(Ci-C3)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-cyclopentylammonium and/or one or more /V,/V,/V-tri(Ci-C2)alkyl- cyclohexylammonium compounds, more preferably one or more compounds selected from L/,L/,/V-triethyl-cyclohexylammonium, /V,/V-diethyl-/V-methyl-cyclohexylammonium, N,N- dimethyl-/V-ethyl-cyclohexylammonium, /V/V,/V-trimethyl-cyclohexylammonium compounds, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammo nium cation R1R2R3R4N+-containing compounds comprise one or more /V/V-dimethyl-/V-ethyl- cyclohexylammonium and/or /V,/V,/V-trimethyl-cyclohexylammonium compounds, more prefera bly one or more /V,/V,/V-trimethyl-cyclohexylammonium compounds. Furthermore and inde pendently thereof, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+- containing compounds are salts, preferably one or more salts selected from the group consist ing of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of bromide, chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammonium hydroxides.
Yet further alternatively, it is preferred that the one or more structure directing agents are se lected from the group consisting of tetra(C1 -C3)alkylammonium comounds, dibenzylme- thylammonium compounds, dibenzyl-1 ,4-diazabicyclo[2, 2, 2]octane, and mixture of two or more thereof, preferably from the group consisting of tetra(C1 -C2)alkylammonium comounds, diben- zylmethylammonium compounds, dibenzyl-1 ,4-diazabicyclo[2, 2, 2]octane, and mixture of two or more thereof, more preferably from the group consisting of tetraethylammonium comounds, triethylmethylammonium comounds, diethyldimethylammonium comounds, ethyltrimethylammo- nium comounds, tetramethylammonium comounds, and combinations of two or more thereof, wherein more preferably the one or more structure directing agents comprise one or more tetra- ethylammonium compounds. In this respect, it is further preferred that independently of one another the tetraalkylammonium compounds are salts, preferably one or more salts selected from the group consisting of halides, preferably chloride and/or bromide, more preferably chlo ride, hydroxide, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium compounds are tetraalkylammonium hydroxides and/or chlorides, and even more preferably tetraalkylammoni um hydroxides.
According to the inventive process, it is yet further alternatively preferred that the mixture pre pared in (i) and crystallized in (iv) does not comprise an organotemplate and preferably does not comprise a structure directing agent.
According to the inventive process it is preferred that the mixture prepared in (i) and crystallized in (iv) further comprises seed crystals, wherein the amount of seed crystals in the mixture pre pared in (i) preferably ranges from 0.5 to 25 wt.-% based on 100 wt.-% of the one or more sources of YO2 contained in the mixture, calculated as YO2, preferably from 3 to 25 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 18 wt.-%, more preferably from 10 to 16 wt.-%, and more preferably from 12 to 14 wt.-%. In this respect, it is further preferred that the seed crystals comprise one or more zeolitic materials having a framework structure type select ed from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX,
SFW, BEA, CHA, FAU, FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, FAU, FER, GME, LEV, MFI, MOR, and MWW, including mixed structures of two or more there of, more preferably from the group consisting of AEI, BEA, CHA, GME, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, including mixed structures of two or more thereof, wherein more preferably the seed crystals comprise one or more zeolitic mate rials having a CHA- and/or AEI-type framework structure, preferably a CHA-type framework structure. Furthermore, according to particular and preferred embodiments wherein one or more zeolitic materials having a CHA-type framework structure are comprised in the seed crystals , it is preferred that the one or more zeolitic materials having a CHA-type framework structure com prised in the seed crystals is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [AI-Si-0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ- 62, including mixtures of two or more thereof, preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ-62, including mixtures of two or more thereof, more pref erably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34, SSZ-13, and SSZ- 62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof, wherein more pref erably the one or more zeolitic materials having a CHA-type framework structure comprised in the seed crystals is chabazite and/or SSZ-13, preferably SSZ-13.
As regards the seed crystal preferably contained in the mixture prepared in (i), these may be obtained according to any suitable procedure. It is preferred according to the inventive process that the seed crystals contained in the mixture prepared in (i) and heated in (iv) comprise one or more zeolitic materials having the framework structure of the zeolitic material comprising YO2 and X2O3 in its framework structure obtained according to any of the particular and preferred embodiments of the inventive process as described in the present application, wherein prefera bly the one or more zeolitic materials of the seed crystals is obtainable and/or obtained accord ing to any of the particular and preferred embodiments of the inventive process as described in the present application.
According to the inventive process it is further preferred that the mixture prepared in (iii) and constituting the feed crystallized in (iv) consists of a single liquid phase and a solid phase com prising the seed crystals. Furthermore and independently thereof, it is preferred that the mixture constituting the feed crystallized in (iv) consists of two liquid phases and a solid phase compris ing the seed crystals, wherein the first liquid phase comprises H2O, and the second liquid phase comprises a lubricating agent. As regards the lubricating agent, it is preferred that it comprises one or more fluorinated compounds, preferably one or more fluorinated polymers, more prefer ably one or more fluorinated polyethers, and more preferably one or more perfluorinated poly ethers.
According to the inventive process it is preferred that the H2O : YO2 molar ratio of water to YO2 from the one or more sources of YO2, calculated as YO2, in the mixture obtained in (iii) ranges from 1 to 200, preferably from 3 to 100, more preferably from 5 to 50, more preferably from 6 to 30, more preferably from 7 to 20, more preferably from 8 to 15, more preferably from 9 to 13, and more preferably from 10 to 1 1. Furthermore and independently thereof, it is preferred that the mixture prepared in (i) comprises one or more alkali metals M, wherein the molar ratio M : YO2 of the one or more alkali metals M to the one or more sources of YO2, calculated as YO2, ranges from 0.05 to 3, preferably of from 0.1 to 2, more preferably of from 0.2 to 1.5, more pref erably of from 0.3 to 1 , more preferably of from 0.35 to 0.8, and more preferably of from 0.4 to 0.5. As regards the one or more alkali metals M it is preferred that they comprise one or more alkali metals selected from the group consisting of Li, Na, K, Rb, Cs, and combinations of two or more thereof, more preferably from the group consisting of Li, Na, Rb and combinations of two or more thereof, wherein more preferably the one or more alkali metals M are Li and/or Na, more preferably Na, wherein more preferably the one or more alkali metals M is sodium. Fur thermore and independently thereof, it is preferred that sodium is comprised in the mixture pre- pared in (i) in a compound selected from the group consisting of sodium hydroxide, sodium aluminates, and sodium silicates, wherein preferably sodium is comprised in the mixture pre pared in (i) as Na2SiC>3 and/or NaAIC>2, preferably as Na2SiC>3, and more preferably as Na2SiC>3 x 9 H2O.
It is preferred, according to the inventive process, that the crystallinity of the zeolitic material obtained in (ix) is in the range of from 45 to 99%, preferably from 50 to 95%, more preferably from 55 to 90%, more preferably from 60 to 85%, more preferably from 65 to 80%, and more preferably from 70 to 75%.
As regards the components which may be contained in the mixture prepared in (i) and ground in (ii), no particular restrictions apply. Nevertheless, it is preferred according to the present inven tion that the mixture prepared in (i) and crystallized in (iv) contains substantially no phosphorous and/or phosphorous containing compounds.
As regards the components which may be contained in the framework of the zeolitic material crystallized in (iv), no particular restrictions apply. Nevertheless, it is preferred according to the present invention that the framework of the zeolitic material crystallized in (iv) contains substan tially no phosphorous, wherein preferably the zeolitic material crystallized in (iv) contains sub stantially no phosphorous and/or phosphorous containing compounds.
In addition to the inventive process, the present invention further relates to a zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable and/or obtained according to according to any of the particular and preferred embodiments of the inventive process as de scribed in the present application. Furthermore it is preferred that the zeolitic material of the present invention has a CHA-type framework structure, wherein it is further preferred that the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [AI-Si-0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ- 218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ- 62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34, SSZ-13, and SSZ-62, including mixtures of two or more thereof, more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof, wherein more preferably the zeolitic material comprises chaba zite and/or SSZ-13, preferably SSZ-13, and wherein more preferably the zeolitic material is chabazite and/or SSZ-13, preferably SSZ-13. Furthermore and independently thereof, it is pre ferred that the mean particle size D50 by volume of the zeolitic material as determined accord ing to ISO 13320:2009 is in the range of from 0.1 to 10 pm, and is preferably in the range of from 0.3 to 6.0 pm, more preferably in the range of from 1.5 to 4.5 pm, and more preferably in the range of from 2.5 to 3.6 pm. When preparing specific catalytic compositions or compositions for different purposes, it is also conceivable to blend the zeolitic materials obtained according to the inventive process with at least one other catalytically active material or a material being active with respect to the intend ed purpose. It is also possible to blend at least two different inventive materials which may differ in their YO2 : X2O3 molar ratio, and in particular in their S1O2 : AI2O3 molar ratio, and/or in the presence or absence of one or more further metals such as one or more transition metals and/or in the specific amounts of a further metal such as a transition metal, wherein according to particularly preferred embodiments, the one or more transition metal comprises Cu and/or Fe, more preferably Cu. It is also possible to blend at least two different inventive materials with at least one other catalytically active material or a material being active with respect to the intend ed purpose.
Also, the catalyst may be disposed on a substrate. The substrate may be any of those materials typically used for preparing catalysts, and will usually comprise a ceramic or metal honeycomb structure. Any suitable substrate may be employed, such as a monolithic substrate of the type having fine, parallel gas flow passages extending there through from an inlet or an outlet face of the substrate, such that passages are open to fluid flow there through (referred to as honey comb flow through substrates). The passages, which are essentially straight paths from their fluid inlet to their fluid outlet, are defined by walls on which the catalytic material is disposed as a washcoat so that the gases flowing through the passages contact the catalytic material. The flow passages of the monolithic substrate are thin-walled channels, which can be of any suitable cross-sectional shape and size such as trapezoidal, rectangular, square, sinusoidal, hexagonal, oval, circular, etc. Such structures may contain from about 60 to about 400 or more gas inlet openings (i.e., cells) per square inch (2.54 cm x 2.54 cm) of cross section.
The substrate can also be a wall-flow filter substrate, where the channels are alternately blocked, allowing a gaseous stream entering the channels from one direction (inlet direction), to flow through the channel walls and exit from the channels from the other direction (outlet direc tion). The catalyst composition can be coated on the flow through or wall-flow filter. If a wall flow substrate is utilized, the resulting system will be able to remove particulate matter along with gaseous pollutants. The wall-flow filter substrate can be made from materials commonly known in the art, such as cordierite, aluminum titanate or silicon carbide. It will be understood that the loading of the catalytic composition on a wall flow substrate will depend on substrate properties such as porosity and wall thickness, and typically will be lower than loading on a flow through substrate.
The ceramic substrate may be made of any suitable refractory material, e.g., cordierite, cordier- ite-alumina, silicon nitride, zircon mullite, spodumene, alumina-silica magnesia, zircon silicate, sillimanite, a magnesium silicate, zircon, petalite, alpha-alumina, an aluminosilicate, and the like.
The substrates useful for the catalysts may also be metallic in nature and be composed of one or more metals or metal alloys. The metallic substrates may be employed in various shapes such as corrugated sheet or monolithic form. Suitable metallic supports include the heat re sistant metals and metal alloys such as titanium and stainless steel as well as other alloys in which iron is a substantial or major component. Such alloys may contain one or more of nickel, chromium and/or aluminum, and the total amount of these metals may advantageously com prise at least 15 wt. % of the alloy, e.g., 10-25 wt. % of chromium, 3-8 wt. % of aluminum and up to 20 wt. % of nickel. The alloys may also contain small or trace amounts of one or more other metals such as manganese, copper, vanadium, titanium, and the like. The surface or the metal substrates may be oxidized at high temperatures, e.g., 1000 °C and higher, to improve the resistance to corrosion of the alloys by forming an oxide layer on the surfaces of the sub strates. Such high temperature-induced oxidation may enhance the adherence of the refractory metal oxide support and catalytically promoting metal components to the substrate.
In alternative embodiments, zeolitic material obtained according to the inventive process may be deposited on an open cell foam substrate. Such substrates are well known in the art, and are typically formed of refractory ceramic or metallic materials.
Especially preferred is the use of a catalyst containing the zeolitic material obtained according to the inventive process for removal of nitrogen oxides NOx from exhaust gases of internal com bustion engines, in particular diesel engines, which operate at combustion conditions with air in excess of that required for stoichiometric combustion, i.e., lean.
In addition to the inventive process and to the inventive zeolitic material, the present invention further relates to the use of inventive zeolitic material according to any of the particular and pre ferred embodiments as described in the present application as a molecular sieve, as an adsor bent, for ion-exchange, as a catalyst or a precursor thereof, and/or as a catalyst support or a precursor thereof, preferably as a catalyst or a precursor thereof and/or as a catalyst support or a precursor thereof, more preferably as a catalyst or a precursor thereof, more preferably as a catalyst for the selective catalytic reduction (SCR) of nitrogen oxides NOx; for the storage and/or adsorption of CO2; for the oxidation of NH3, in particular for the oxidation of NH3 slip in diesel systems; for the decomposition of N2O; as an additive in fluid catalytic cracking (FCC) process es; and/or as a catalyst in organic conversion reactions, preferably in the conversion of alcohols to olefins, and more preferably in methanol to olefin (MTO) catalysis; more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NOx, and more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NOx in exhaust gas from a combustion engine, preferably from a diesel engine or from a lean burn gasoline engine.
The present invention is further illustrated by the following embodiments and combinations of embodiments as indicated by the respective dependencies and back-references. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The ... of any of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The ... of any of embodiments 1 , 2, 3, and 4". Further, it is explicitly noted that the following set of embodiments is not the set of claims determining the extent of protection, but represents a suitably structured part of the de scription directed to general and preferred aspects of the present invention.
1. A process for preparing a zeolitic material comprising YO2 and X2O3 in its framework
structure, wherein Y stands for a tetravalent element and X stands for a trivalent element, wherein said process comprises:
(i) preparing a mixture comprising one or more sources of YO2, one or more sources of X2O3, and H2O;
(ii) grinding and/or mixing the mixture prepared in (i), wherein the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.3 to 200 kJ/kg of the mixture;
(iii) adding water, preferably distilled water, to the ground mixture obtained in (ii) and preferably homogenizing the resulting mixture; and
(iv) crystallizing a zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture obtained in (iii), wherein the mixture is heated to a temperature in the range of from 80 to 300°C;
wherein the mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2,
wherein the energy intake is preferably determined as described in reference example 1.
2. The process of embodiment 1 , wherein the 27AI MAS NMR of the mixture obtained in (ii) comprises:
a first peak (P1) in the range of from 20 to 80 ppm, preferably of from 45 to 65 ppm, preferably of from 50 to 60 ppm, more preferably of from 52 to 58 ppm, more preferably of from 53 to 57 ppm, more preferably of from 53.5 to 56.5 ppm, more preferably of from 54 to 56 ppm, more preferably of from 54.5 to 55.5 ppm, and more preferably of from 55.0 to 55.5 ppm; and
one or more peaks (PX) in the range of from -20 to 15 ppm, preferably of from -10 to 12 ppm, more preferably of from -5 to 10 ppm, more preferably of from -3 to 8 ppm, more preferably of from -2 to 7 ppm, more preferably of from -1.5 to 6.5 ppm, more preferably of from -1 to 6 ppm, more preferably of from -0.5 to 5.5 ppm, and more preferably of from 0.5 to 5.0 ppm;
wherein the relative 27AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) and within the range of 15 to -20 ppm (h) of the zeolitic material offer a ratio of the integration values h : (h + h) comprised in the range of from 0.5 to 50%, preferably of from 1 to 35%, more preferably of from 3 to 25%, more preferably of from 5 to 18%, more preferably of from 8 to 15%, more preferably of from 9 to 14%, more preferably of from 10 to 13%, and more preferably of from 11 to 12%,
wherein preferably the relative 27AI solid-state NMR intensity integral ratio is measured at 9.4 Tesla and 10 kHz Magic Angle Spinning, and
wherein preferably the one or more peaks (PX) consists of one or two peaks (PX), more preferably of one peak (PX). The process of embodiment 1 or 2, wherein water is added in (iii) to the ground mixture, and wherein the resulting mixture comprises an amount of water in the range of from 68 to 94 weight-%, preferably in the range of from 70 to 92 weight-%, more preferably in the range of from 72 to 90 weight-%, more preferably in the range of from 74 to 88 weight-%, based on the total weight of the resulting mixture. The process of any one of embodiments 1 to 3, wherein the mixture prepared in (i) has a density in the range of from 0.1 to 5 g/ml, preferably in the range of from 0.5 to 3.5 g/ml, more preferably in the range of from 1.0 to 2.75 g/ml. The process of any one of embodiments 1 to 4, wherein homogenization in (iii) is achieved by grinding and/or mixing, preferably by mixing. The process of any of embodiments 1 to 5, wherein in (ii) the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 0.8 to 80 kJ/kg of the mixture, more preferably of from 1 to 50 kJ/kg of the mixture, more preferably of from 3 to 30 kJ/kg of the mixture, more preferably of from 4 to 25 kJ/kg, more preferably of from 5 to 20 kJ/kg of the mixture, more preferably of from 7 to 17 kJ/kg, more preferably of from 8 to 15 kJ/kg of the mixture, more preferably of from 9 to 13 kJ/kg, and more preferably of from 10 to 12 kJ/kg. The process of any of embodiments 1 to 5, wherein in (ii) the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.5 to 100 kJ/kg of the mixture, preferably of from 1 to 50 kJ/kg, more preferably of from 1.5 to 20 kJ/kg of the mixture, more preferably of from 2 to 10 kJ/kg, more preferably of from 2.5 to 7 kJ/kg of the mixture, more preferably of from 3 to 5 kJ/kg, and more preferably of from 3.5 to 4.5 kJ/kg. The process of any of embodiments 1 to 7, wherein the mixture prepared in (i) and ground in (ii) contains from 10 to 280 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2, contained in the mixture prepared in (i) and heated in (iv), preferably of from 20 to 260 wt.-%, more preferably of from 30 to 240 wt.-%, more preferably of from 40 to 230 wt.-%, more preferably of from 60 to 220 wt.-%, more prefer ably of from 80 to 210 wt.-%, more preferably of from 100 to 200 wt.-%, more preferably of from 120 to 190 wt.-%, more preferably of from 140 to 180 wt.-%, more preferably of from 150 to 170 wt.-%. The process of any of embodiments 1 to 8, wherein grinding and/or mixing in (ii) is carried out for a duration in the range of from 0.01 to 120 min, preferably of from 0.05 to 60 min, more preferably of from 0.1 to 30 min, more preferably of from 0.2 to 20 min, more prefer- ably of from 0.3 to 10 min, more preferably of from 0.4 to 7 min, more preferably of from 0.5 to 5 min, more preferably of from 0.7 to 4 min, more preferably of from 1 to 3 min, more preferably of from 1.2 to 2.8 min, more preferably of from 1.4 to 2.6 min, and more preferably of from 1.5 to 2.5 min.
10. The process of any of embodiments 1 to 9, wherein the rate of energy transfer to the mix ture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg*h), preferably from 50 to 1 ,200 kJ/(kg*h), more preferably from 100 to 1 ,000 kJ/(kg*h), more preferably from 150 to 800 kJ/(kg*h), more preferably from 200 to 600 kJ/(kg*h), more preferably from 250 to 500 kJ/(kg*h), more preferably from 280 to 450 kJ/(kg*h), more preferably from 300 to 370 kJ/(kg*h), and more preferably from 320 to 340 kJ/(kg*h).
1 1. The process of any of embodiments 1 to 9, wherein the rate of energy transfer to the mix ture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg*h), preferably from 25 to 1 ,000 kJ/(kg*h), more preferably from 50 to 600 kJ/(kg*h), more preferably from 75 to 400 kJ/(kg*h), more preferably from 90 to 200 kJ/(kg*h), more preferably from 100 to 175 kJ/(kg*h), more preferably from 110 to 150 kJ/(kg*h), more preferably from 120 to 140 kJ/(kg*h), and more preferably from 125 to 135 kJ/(kg*h).
12. The process of any of embodiments 1 to 11 , wherein grinding and/or mixing in (ii) is car ried out in a mill selected from the group consisting of a stirred media mill, a ball mill, a roller mill, a kneader and a high shear mixer,
preferably from the group consisting of a stirred media mill, a planetary ball mill, a smooth wheel roller mill, a kneader with roller blades, a kneader with sigma blades, a high shear mixer equipped with a microgranulation tool, and a high shear mixer equipped with a pin mixing tool,
wherein more preferably grinding and/or mixing in (ii) is carried out in a stirred media mill and/or in a roller mill, preferably in a stirred media mill.
13. The process of embodiment 12, wherein grinding and/or mixing in (ii) is carried out in a stirred media mill using grinding beads made of a material selected from the group con sisting of stainless steel, ceramic, and rubber, preferably from the group consisting of chrome steel, flint, zirconia, and lead antimony alloy, wherein more preferably the grinding beads for stirred media milling are made of chrome steel and/or zirconia, preferably of zir conia.
14. The process of embodiment 12 or 13, wherein grinding and/or mixing in (ii) is carried out in a stirred media mill using grinding beads with a diameter in the range of from 0.1 to 50 mm, preferably of from 0.8 to 20 mm, more preferably of from 1 to 10 mm, more prefera bly of from 1.2 to 7 mm, more preferably of from 2 to 5 mm, more preferably of from 2.3 to 4 mm, more preferably of from 2.5 to 3.5 mm, more preferably of from 2.8 to 3.3 mm. 15. The process of any of embodiments 12 to 14, wherein grinding and/or mixing in (ii) is car ried out in a stirred media mill, wherein the filling degree of the grinding media in the stirred media mill is in the range of from 20 to 80%, preferably of from 25 to 75%, more preferably of from 30 to 70%, more preferably of from 35 to 65%, more preferably of from 40 to 60%, and more preferably of from 40 to 50%.
16. The process of any of embodiments 1 to 15, wherein grinding and/or mixing in (ii) is car ried out in a stirred media mill, wherein the tip speed of the ball mill is in the range of from 1 to 20 m/s, preferably of from 2 to 15 m/s, more preferably of from 3 to 12 m/s, more preferably of from 4 to 8 m/s.
17. The process of embodiment 12, wherein grinding and/or mixing in (ii) is carried out in a ball mill, wherein the ball mill is operated at a speed in the range of from 10 to 250 rpm, preferably of from 30 to 220 rpm, more preferably of from 50 to 200 rpm, more preferably of from 60 to 180 rpm, more preferably of from 70 to 150 rpm, more preferably of from 80 to 120 rpm, and more preferably of from 90 to 100 rpm.
18. The process of embodiment 16 or 17, wherein the ball mill comprises a volume having a cylindrical geometry, wherein the diameter of the volume having a cylindrical geometry is in the range of from 200 to 400 mm, preferably in the range of from 250 to 350 mm, more preferably in the range of from 280 to 320 mm, more preferably in the range of from 290 to 310 mm, more preferably in the range of from 295 to 305 mm.
19. The process of embodiments 16 to 18, wherein the ball mill is operated at a relative rota tion speed of from 30 to 150 % of the critical rotation speed, preferably of from 40 to 125 % of the critical rotation speed, more preferably of from 45 to 120 % of the critical rotation speed, more preferably of from 50 to 95 % of the critical rotation speed, more preferably of from 60 to 90 % of the critical rotation speed and more preferably of from 70 to 90 % of the critical rotation speed.
20. The process of any of embodiments 16 to 19, wherein the critical rotation speed is in the range of from 40 to 80 rpm, preferably in the range of from 50 to 70 rpm, more preferably in the range of from 55 to 65 rpm, more preferably in the range of from 58 to 62 rpm, more preferably in the range of from 59 to 61 rpm.
21. The process of any of embodiments 1 to 20, wherein the mixture prepared in (i) has an initial temperature in the range of from 10 to 50°C when subject to grinding and/or mixing in (ii), preferably in the range of from 15 to 40°C, and more preferably in the range of from 20 to 30°C. 22. The process of any of embodiments 1 to 21 , wherein in (i) and prior to (ii) the mixture pre pared in (i) is not heated to a temperature of 40°C or greater, preferably of 35°C or great er, more preferably of 30°C or greater, wherein more preferably in (i) and prior to (ii) the mixture prepared in (i) is not subject to a heating step.
23. The process of any of embodiments 1 to 22, wherein in (iv) the mixture is heated to a temperature in the range of from 100 to 280°C, preferably of from 120 to 270 °C, more preferably of from 140 to 260 °C, more preferably of from 160 to 255 °C, more preferably of from 180 to 250 °C, more preferably of from 200 to 245 °C, and more preferably of from 220 to 240 °C.
24. The process of any of embodiments 1 to 23, wherein in (iv) the mixture is heated under autogenous pressure, wherein preferably the pressure is in the range of from 0.1 to 9 MPa, more preferably in the range of from 0.5 to 7 MPa, more preferably from 0.8 to 5 MPa, more preferably from 1.2 to 4 MPa, more preferably from 1.6 to 3.5 MPa, more pref erably from 1.8 to 3 MPa, more preferably from 2 to 2.7 MPa, and more preferably from 2.2 to 2.5 MPa.
25. The process of any of embodiments 1 to 24, wherein crystallization in (iv) is conducted as a batch process.
26. The process of any of embodiments 1 to 25, wherein crystallization in (iv) is conducted for a duration in the range of from 0.2 to 96 h, preferably of from 0.5 to 48 h, preferably from 0.75 to 24 h, more preferably from 1 to 12 h, more preferably from 1.25 to 8 h, more pref erably from 1.5 to 5 h, more preferably from 1.75 to 4 h, and more preferably from 2 to 3 h.
27. The process of any of embodiments 1 to 26, wherein the mixture crystallized in (iv) is me chanically agitated, wherein preferably mechanical agitation is achieved by stirring.
28. The process of any of embodiments 1 to 27, wherein crystallization in (iv) is conducted as a continuous process.
29. The process of embodiment 28, wherein crystallization in (iv) comprises continuously feeding the mixture obtained in (iii) into a continuous flow reactor at a liquid hourly space velocity in the range of from 0.3 to 20 tv1 for a duration of at least 1 h, and crystallizing the zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture in the continuous flow reactor, wherein the mixture is heated to a temperature in the range of from 80 to 300°C. The process of embodiment 28 or 29, wherein the volume of the continuous flow reactor is in the range of from 150 cm3 to 75 m3, preferably from 50 cm3 to 3 m3, preferably from 55 cm3 to 1 m3, more preferably from 60 cm3 to 0.7 m3, more preferably from 65 cm3 to 0.3 m3, more preferably from 70 cm3 to 0.1 m3, more preferably from 75 to 70,000 cm3, more preferably from 80 to 50,000 cm3, more preferably from 85 to 30,000 cm3, more preferably from 90 to 10,000 cm3, more preferably from 95 to 7,000 cm3, more preferably from 100 to 5,000 cm3, more preferably from 105 to 3,000 cm3, more preferably from 110 to 1 ,000 cm3, more preferably from 1 15 to 700 cm3, more preferably from 120 to 500 cm3, more preferably from 125 to 350 cm3, more preferably from 130 to 250 cm3, more preferably from 135 to 200 cm3, more preferably from 140 to 180 cm3, and more preferably from 145 to 160 cm3. The process of any of embodiments 28 to 30, wherein the continuous feeding is per formed such that the liquid hourly space velocity is in the range of from 0.05 to 10 IT1, more preferably from 0.1 to 5 IT1, more preferably from 0.2 to 3 IT1, more preferably from 0.4 to 2 IT1 , more preferably from 0.6 to 1.5 IT1 , more preferably from 0.8 to 1.2 IT1 , and more preferably from 0.9 to 1 IT1. The process of any of embodiments 28 to 31 , wherein in (iv) the mixture obtained in (iii) is continuously fed into the continuous flow reactor for a duration ranging from 3 h to 360 d, more preferably from 6 h to 120 d, more preferably from 12 h to 90 d, more preferably from 18 h to 60 d, more preferably from 1 to 30 d, more preferably from 1.5 to 25 d, more preferably from 2 to 20 d, more preferably from 2.5 to 15 d, more preferably from 3 to 12 d, more preferably from 3.5 to 8 d, and more preferably from 4 to 6 d. The process of any of embodiments 28 to 32, wherein the continuous flow reactor is se lected among a tubular reactor, a ring reactor, and a continuously oscillating reactor, pref erably among a plain tubular reactor, a tubular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, and a continuously oscillating baffled reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor. The process of any of embodiments 28 to 33, wherein at least a portion of the tubular re actor is of a regular cylindrical form having a constant inner diameter perpendicular to the direction of flow, wherein the inner diameter is preferably in the range of from 2 to 1200 mm, more preferably from 3 to 800 mm, more preferably from 3 to 500 mm, more prefera bly from 4 to 200 mm, more preferably from 4 to 100 mm, more preferably from 4.5 to 50 mm, more preferably from 4.5 to 30 mm, more preferably from 5 to 15 mm, more prefera bly from 5 to 10 mm, more preferably from 5.5 to 8 mm, and more preferably from 5.5 to 6.5 mm. 35. The process of any of embodiments 28 to 34, wherein the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 3 to 500 m more preferably from 3.5 to 200 m, more preferably from 3.5 to 100 m, more preferably from 4 to 50 m, more preferably from 4 to 30 m, more preferably from 4.5 to 20 m, more preferably from 4.5 to 15 m, more pref erably from 5 to 10 m, and more preferably from 5 to 7 m.
36. The process of any of embodiments 28 to 35, wherein the wall of the continuous flow re actor is made of a metallic material, wherein the metallic material comprises one or more metals selected from the group consisting of Ta, Cr, Fe, Ni, Cu, Al, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Ta, Cr, Fe, Ni, Mo, and combinations and/or alloys of two or more thereof, preferably from the group consisting of Cr, Fe, Ni, Mo, and combinations and/or alloys of two or more thereof where in preferably the metallic material comprises a nickel alloy, a nickel-molybdenum alloy, and more preferably a nickel-molybdenum-chromium alloy.
37. The process of any of embodiments 28 to 36, wherein the surface of the inner wall of the continuous flow reactor is lined with an organic polymer material, wherein the organic pol ymer material preferably comprises one or more polymers selected from the group con sisting of fluorinated polyalkylenes and mixtures of two or more thereof, preferably from the group consisting of (C2-C3)polyalkylenes and mixtures of two or more thereof, prefer ably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof, wherein more preferably the polymer material comprises
poly(tetrafluoroethylene), wherein more preferably the inner wall of the continuous flow reactor is lined with poly(tetrafluoroethylene).
38. The process of any of embodiments 28 to 37, wherein the continuous flow reactor is
straight and/or comprises one or more curves with respect to the direction of flow, wherein preferably the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow.
39. The process of any of embodiments 28 to 38, wherein the walls of the continuous flow reactor are subject to vibration during crystallization in (iv).
40. The process of any of embodiments 28 to 39, wherein the continuous flow reactor con sists of a single stage.
41. The process of any of embodiments 28 to 40, wherein no matter is added to and/or re moved from the reaction mixture during its passage through the continuous flow reactor in (iv), wherein preferably no matter is added, wherein more preferably no matter is added and no matter is removed from the reaction mixture during its passage through the contin uous flow reactor in (iv).
42. The process of any of embodiments 28 to 41 , wherein the mixture prepared in (iii) is di rectly fed to the continuous flow reactor in (iv), wherein while being fed to the continuous flow reactor in (iv), the mixture prepared in (iii) is pre-heated, preferably to a temperature in the range of from 100 to 300°C, more preferably of from 100 to 280°C, more preferably of from 140 to 260°C, more preferably of from 160 to 250°C, more preferably of from 180 to 240°C, more preferably of from 190 to 230°C, and more preferably of from 200 to 220°C.
43. The process of any of embodiments 28 to 42, wherein the mixture crystallized in (iv) in the continuous flow reactor is mechanically agitated, wherein preferably mechanical agitation is achieved by movable parts contained in the continuous flow reactor, wherein more preferably the movable parts are provided such as to continually or periodically, preferably to continually free the walls of the continuous flow reactor from zeolitic materials and/or solid residue attached thereto, wherein more preferably the movable parts comprise a scraper, more preferably a screw, and more preferably a rotating screw.
44. The process of any of embodiments 28 to 43, wherein the process further comprises
(v) quenching the reaction product effluent continuously exiting the reactor in (iv) with a liquid comprising one or more solvents and/or via expansion of the reaction product efflu ent;
and/or, preferably and,
(vi) isolating the zeolitic material obtained in (iv) or (v);
and/or, preferably and,
(vii) washing the zeolitic material obtained in (iv), (v) or (vi), preferably with distilled wa ter;
and/or, preferably and,
(viii) drying the zeolitic material obtained in (iv), (v), (vi), or (vii);
and/or, preferably and,
(ix) calcining the zeolitic material obtained in (iv), (v), (vi), (vii), or (viii).
45. The process of embodiment 44, wherein in (v) the liquid comprises one or more solvents selected from the group consisting of polar protic solvents and mixtures thereof, preferably from the group consisting of n-butanol, isopropanol, propanol, ethanol, metha nol, water, and mixtures thereof,
more preferably from the group consisting of ethanol, methanol, water, and mixtures thereof,
wherein more preferably the liquid comprises water, and wherein more preferably water is used as the liquid, preferably deionized water. The process of embodiment 44 or 45, wherein in (v) the weight ratio of the liquid compris ing one or more solvents to the reaction product effluent continuously exiting the reactor in the range of from 0.5 to 30, preferably from 1 to 25, more preferably from 2 to 20, more preferably from 3 to 18, more preferably from 4 to 15, more preferably from 5 to 12, more preferably from 6 to 10, more preferably from 6.5 to 9, more preferably from 7 to 8.5, and more preferably from 7.5 to 8. The process of any of embodiments 44 to 46, wherein drying in (viii) is effected at a tem perature in the range from 50 to 220°C, preferably from 70 to 180°C, more preferably from 80 to 150°C, more preferably from 90 to 130°C, more preferably from 100 to 125°C, and more preferably from 110 to 120°C. The process of any of embodiments 44 to 47, wherein the calcining in (ix) is effected at a temperature in the range from 300 to 900 °C, preferably of from 400 to 700 °C, more pref erably of from 450 to 650 °C, and more preferably of from 500 to 600 °C. The process of any of embodiments 44 to 48, wherein the calcining in (ix) is effected for a duration in the range of from 0.5 to 12 h, preferably in the range of from 1 to 9 h, more preferably in the range of from 2 to 6 h. The process of any of embodiments 44 to 49, wherein the supernatant obtained from the isolation of the zeolitic material in (vi), and/or a feed having the same composition as said supernatant, is not at any point recycled to the reaction mixture during its passage through the continuous flow reactor. The process of any of embodiments 44 to 50, wherein in (vi) isolating the zeolitic material includes a step of spray-drying the zeolitic material obtained in (iv) or (v),
and/or
wherein in (viii) drying of the zeolitic material includes a step of spray-drying the zeolitic material obtained in (iv), (v), (vi), or (vii). The process of any of embodiments 1 to 51 , wherein the process further comprises
(x) subjecting the zeolitic material obtained in (iv), (v), (vi), (vii), (viii), or (ix) to one or more ion exchange procedures with H+ and/or Nh , preferably with Nh . The process of any of embodiments 1 to 52, wherein the process further comprises
(xi) subjecting the zeolitic material obtained in (iv), (v), (vi), (vii), (viii), (ix), or (x) to one or more ion exchange procedures with one or more cations and/or cationic elements se lected from the group consisting of Sr, Zr, Cr, Mg, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more thereof, preferably from the group consisting of Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Cr, Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mix tures of two or more thereof, wherein more preferably the one or more cation and/or cati onic elements comprise Cu and/or Fe, preferably Cu, wherein even more preferably the one or more cation and/or cationic elements consist of Cu and/or Fe, preferably of Cu.
54. The process of any of embodiments 1 to 53, wherein the mixture prepared in (i) and crys tallized in (iv) further comprises one or more structure directing agents, wherein preferably one or more organotemplates are employed as the one or more structure directing agents.
55. The process of embodiment 54, wherein the molar ratio SDA : YO2 of the one or more structure directing agents (SDA) to the one or more sources of YO2, calculated as YO2, in the mixture prepared in (i) and heated in (iv) ranges from 0.01 to 0.5, wherein the one or more structure directing agents do not include structure directing agents optionally con tained in seed crystals optionally contained in the mixture prepared in (i), preferably from 0.03 to 0.2, more preferably from 0.06 to 0.15, more preferably from 0.09 to 0.13, and more preferably from 0.11 to 0.12.
56. The process of embodiment 54 or 55, wherein the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, preferably for 1-adamantyl.
57. The process of embodiment 56, wherein R1 , R2, and R3 independently from one another stand for optionally substituted and/or optionally branched (Ci-C6)alkyl, preferably (Ci- C5)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R1 , R2, and R3 inde pendently from one another stand for optionally substituted methyl or ethyl, preferably un substituted methyl or ethyl, wherein more preferably R1 , R2, and R3 independently from one another stand for optionally substituted methyl, preferably unsubstituted methyl.
58. The process of embodiment 56 or 57, wherein R4 stands for optionally heterocyclic and/or optionally substituted adamantyl and/or benzyl, preferably for optionally heterocyclic and/or optionally substituted 1-adamantyl, more preferably for optionally substituted ada mantyl and/or benzyl, more preferably for optionally substituted 1-adamantyl, more prefer ably for unsubstituted adamantyl and/or benzyl, and more preferably for unsubstituted 1- adamantyl. 59. The process of any of embodiments 56 to 58, wherein the one or more tetraalkylammoni- um cation R1R2R3R4N+-containing compounds comprise one or more /V,/V,/V-tri(Ci- C4)alkyl-1-adamantylammonium compounds, preferably one or more /V,/V,/V-tri(Ci- C3)alkyl-1-adamantylammonium compounds, more preferably one or more /V/V,/V-tri(Ci- C2)alkyl-1-adamantylammonium compounds, more preferably one or more /V/V,/V-tri(Ci- C2)alkyl-1-adamantylammonium and/or one or more /V,/V,/V-tri(Ci-C2)alkyl-1- adamantylammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-1-adamantylammonium, /V,/V-diethyl-/V-methyl-1- adamantylammonium, /V/V-dimethyl-/V -ethyl-1 -adamantylammonium, N, N,N -trimethyl-1 - adamantylammonium compounds, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds comprise one or more N,N,N -trimethyl-1 -adamantylammonium compounds.
60. The process of any of embodiments 56 to 59, wherein the one or more tetraalkylammoni um cation R1R2R3R4N+-containing compounds are salts, preferably one or more salts se lected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mix tures of two or more thereof, more preferably from the group consisting of bromide, chlo ride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammoni um hydroxides.
61. The process of embodiment 54 or 55, wherein the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for cycloalkyl.
62. The process of embodiment 61 , wherein R1 and R2 independently from one another stand for optionally substituted and/or optionally branched (Ci-C6)alkyl, preferably (Ci-C5)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-C3)alkyl, and more preferably for option ally substituted methyl or ethyl, wherein more preferably R1 and R2 independently from one another stand for optionally substituted methyl or ethyl, preferably unsubstituted me thyl or ethyl, wherein more preferably R1 and R2 independently from one another stand for optionally substituted methyl, preferably unsubstituted methyl.
63. The process of embodiment 61 or 62, wherein R3 stands for optionally substituted and/or optionally branched (Ci-Ce)alkyl, preferably (Ci-Cs)alkyl, more preferably (Ci-C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R3 stands for optionally substituted ethyl, preferably un substituted ethyl. 64. The process of any of embodiments 61 to 63, wherein R4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cycloalkyl, preferably for 5- to 7-membered cycloalkyl, more preferably for 5- or 6-membered cycloalkyl, wherein more preferably R4 stands for optionally heterocyclic and/or optionally substituted 6-membered cycloalkyl, preferably optionally substituted cyclohexyl, and more preferably unsubstituted cyclohexyl.
65. The process of any of embodiments 61 to 64, wherein the one or more tetraalkylammoni- um cation R1R2R3R4N+-containing compounds comprise one or more /V,/V,/V-tri(Ci- C4)alkyl-(C5-C7)cycloalkylammonium compounds, preferably one or more /V,/V,/V-tri(Ci- C3)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more N,N,N- tri(Ci-C2)alkyl-(C5-C6)cycloalkylammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-cyclopentylammonium and/or one or more /V,/V/V-tri(Ci-C2)alkyl- cyclohexylammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-cyclohexylammonium, /V,/V-diethyl-/V-methyl-cyclohexylammonium, /V,/V-dimethyl-/V-ethyl-cyclohexylammonium, L/,/V/V-trimethyl-cyclohexylammonium com pounds, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more /V,/V-dimethyl-/V-ethyl-cyclohexylammonium and/or /V,/V,/V-trimethyl-cyclohexylammonium compounds, more preferably one or more L/,/V/V-trimethyl-cyclohexylammonium com pounds.
66. The process of any of embodiments 61 to 65, wherein the one or more tetraalkylammoni um cation R1R2R3R4N+-containing compounds are salts, preferably one or more salts se lected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mix tures of two or more thereof, more preferably from the group consisting of bromide, chlo ride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are tetraalkylammonium hydroxides and/or bromides, and more preferably tetraalkylammoni um hydroxides.
67. The process of embodiment 54 or 55, wherein the one or more structure directing agents are selected from the group consisting of tetra(C1-C3)alkylammonium comounds, diben- zylmethylammonium compounds, dibenzyl-1 ,4-diazabicyclo[2, 2, 2]octane, and mixture of two or more thereof, preferably from the group consisting of tetra(C1-C2)alkylammonium comounds, dibenzylmethylammonium compounds, dibenzyl-1 ,4- diazabicyclo[2,2,2]octane, and mixture of two or more thereof, more preferably from the group consisting of tetraethylammonium comounds, triethylmethylammonium comounds, diethyldimethylammonium comounds, ethyltrimethylammonium comounds, tetrame- thylammonium comounds, and combinations of two or more thereof, wherein more prefer ably the one or more structure directing agents comprise one or more tetraethylammoni um compounds. The process of embodiment 67, wherein independently of one another the
tetraalkylammonium compounds are salts, preferably one or more salts selected from the group consisting of halides, preferably chloride and/or bromide, more preferably chloride, hydroxide, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group consisting of chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium compounds are tetraalkylammonium hydroxides and/or chlorides, and even more preferably tetraalkylammonium hydroxides. The process of any of embodiments 1 to 68, wherein the mixture prepared in (i) and crys tallized in (iv) does not comprise an organotemplate and preferably does not comprise a structure directing agent. The process of any of embodiments 1 to 69, wherein Y is selected from the group consist ing of Si, Sn, Ti, Zr, Ge, and combinations of two or more thereof, Y preferably being Si. The process of any of embodiments 1 to 70, wherein the one or more sources for YO2 are one or more solid sources for YO2, wherein preferably the one or more sources for YO2 comprises one or more compounds selected from the group consisting of silicas, silicates, silicic acid and combinations of two or more thereof, preferably selected from the group consisting of silicas, alkali metal silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, colloidal silica, reactive amorphous solid silica, silica gel, pyrogenic silica, lithium silicates, sodium sili cates, potassium silicates, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na2Si03, silicic acid, and combinations of two or more thereof, more preferably selected from the group consisting of fumed silica, silica gel, pyrogenic silica, Na2Si03, and combi nations of two or more thereof, wherein more preferably the one or more sources for YO2 comprises Na2Si03 and/or silica gel, preferably Na2Si03 and silica gel, wherein more pref erably the one or more sources for YO2 is Na2Si03 and/or silica gel, preferably Na2Si03 and silica gel. The process of embodiment 71 , wherein the silica gel has the formula S1O2 x H2O, wherein x is in the range of from 0.1 to 1.165, preferably from 0.3 to 1.155, more prefera bly from 0.5 to 1.15, more preferably from 0.8 to 1.13, and more preferably from 1 to 1.1. The process of any of embodiments 1 to 72, wherein X is selected from the group consist ing of Al, B, In, Ga, and combinations of two or more thereof, X preferably being Al. 74. The process of any of embodiments 1 to 73, wherein the one or more sources for X2O3 are one or more solid sources for X2O3, wherein preferably the one or more sources for X2O3 comprises one or more compounds selected from the group consisting of aluminum sulfates, sodium aluminates, and boehmite, wherein preferably the one or more sources for X2O3 comprises Al2(S04)3 and/or NaAI02, preferably A^SC H wherein more prefera bly the one or more sources for X2O3 is Al2(S04)3 and/or NaAI02, preferably Al2(S04)3.
75. The process of any of embodiments 1 to 74, wherein the molar ratio YO2 : X2O3 of the one or more sources of YO2, calculated as YO2, to the one or more sources for X2O3, calculat ed as X2O3, in the mixture prepared in (i) is in the range of from 1 to 100, preferably of from 2 to 70, more preferably of from 4 to 50, more preferably of from 6 to 40, more pref erably of from 8 to 35, more preferably of from 12 to 30, more preferably of from 15 to 25, more preferably of from 17 to 22, and more preferably of from 19 to 20.
76. The process of any of embodiments 1 to 75, wherein the mixture prepared in (i) and crys tallized in (iv) further comprises seed crystals, wherein the amount of seed crystals in the mixture prepared in (i) preferably ranges from 0.5 to 25 wt.-% based on 100 wt.-% of the one or more sources of YO2 contained in the mixture, calculated as YO2, preferably from 3 to 25 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 18 wt.-%, more preferably from 10 to 16 wt.-%, and more preferably from 12 to 14 wt.-%.
77. The process of embodiment 76, wherein the seed crystals comprise one or more zeolitic materials having a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX, SFW, BEA, CHA, FAU, FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, FAU, FER, GME, LEV, MFI, MOR, and MWW, including mixed structures of two or more there of, more preferably from the group consisting of AEI, BEA, CHA, GME, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, including mixed structures of two or more thereof, wherein more preferably the seed crystals com prise one or more zeolitic materials having a CHA- and/or AEI-type framework structure, preferably a CHA-type framework structure.
78. The process of embodiment 77, wherein the one or more zeolitic materials having a CHA- type framework structure comprised in the seed crystals is selected from the group con sisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [Al-Si- 0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ-62, including mixtures of two or more there of,
preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ- 218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34, SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof,
wherein more preferably the one or more zeolitic materials having a CHA-type framework structure comprised in the seed crystals is chabazite and/or SSZ-13, preferably SSZ-13.
79. The process of any of embodiments 76 to 78, wherein the seed crystals comprised in the mixture prepared in (i) and heated in (iv) comprise one or more zeolitic materials having the framework structure of the zeolitic material comprising YO2 and X2O3 in its framework structure obtained according to the process of any of embodiments 1 to 78, wherein pref erably the one or more zeolitic materials of the seed crystals is obtainable and/or obtained according to the process of any of embodiments 1 to 78.
80. The process of any of embodiments 76 to 79, wherein the mixture prepared in (iii) and constituting the feed crystallized in (iv) consists of a single liquid phase and a solid phase comprising the seed crystals.
81. The process of any of embodiments 76 to 80, wherein the mixture constituting the feed crystallized in (iv) consists of two liquid phases and a solid phase comprising the seed crystals, wherein the first liquid phase comprises H2O, and the second liquid phase com prises a lubricating agent.
82. The process of embodiment 81 , wherein the lubricating agent comprises one or more fluorinated compounds, preferably one or more fluorinated polymers, more preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyeth ers.
83. The process of any of embodiments 1 to 82, wherein the H2O : YO2 molar ratio of water to YO2 from the one or more sources of YO2, calculated as YO2, in the mixture obtained in (iii) ranges from 1 to 200, preferably from 3 to 100, more preferably from 5 to 50, more preferably from 6 to 30, more preferably from 7 to 20, more preferably from 8 to 15, more preferably from 9 to 13, and more preferably from 10 to 1 1. The process of any of embodiments 1 to 83, wherein the mixture prepared in (i) comprises one or more alkali metals M, wherein the molar ratio M : YO2 of the one or more alkali metals M to the one or more sources of YO2, calculated as YO2, ranges from 0.05 to 3, preferably of from 0.1 to 2, more preferably of from 0.2 to 1.5, more preferably of from 0.3 to 1 , more preferably of from 0.35 to 0.8, and more preferably of from 0.4 to 0.5. The process of embodiment 84, wherein the one or more alkali metals M comprise one or more alkali metals selected from the group consisting of Li, Na, K, Rb, Cs, and combina tions of two or more thereof, more preferably from the group consisting of Li, Na, Rb and combinations of two or more thereof, wherein more preferably the one or more alkali met als M are Li and/or Na, more preferably Na, wherein more preferably the one or more al kali metals M is sodium. The process of embodiment 85, wherein sodium is comprised in the mixture prepared in (i) in a compound selected from the group consisting of sodium hydroxide, sodium alumi- nates, and sodium silicates, wherein preferably sodium is comprised in the mixture pre pared in (i) as Na2Si03 and/or NaAIC>2, preferably as Na2Si03, and more preferably as Na2Si03 x 9 H20. The process of any of embodiments 1 to 86, wherein the crystallinity of the zeolitic materi al obtained in (ix) is in the range of from 45 to 99%, preferably from 50 to 95%, more pref erably from 55 to 90%, more preferably from 60 to 85%, more preferably from 65 to 80%, and more preferably from 70 to 75%. The process of any of embodiments 1 to 87, wherein the zeolitic material crystallized in (iv) has a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI,
LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof, preferably from the group consisting of CAN, AEI, EMT, SAV, SZR, KFI, ERI, OFF, RTH, GME, AFX, SFW, BEA, CHA, FAU,
FER, HEU, LEV, MEI, MEL, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, FAU, FER, GME, LEV, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, GME, MFI, MOR, and MWW, including mixed structures of two or more thereof, more preferably from the group consisting of AEI, BEA, CHA, MFI, and MWW, including mixed structures of two or more thereof, and more preferably from the group consisting of AEI, CHA, and MWW, including mixed structures of two or more thereof, wherein more preferably the zeolitic material crystallized in (iv) has a CHA- and/or AEI-type framework structure, preferably a CHA-type framework structure. 89. The process of any of embodiments 1 to 88, wherein the zeolitic material crystallized in (iv) has a CHA-type framework structure, wherein preferably the zeolitic material having a CHA-type framework structure is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [AI-Si-0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34, SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof,
wherein more preferably the zeolitic material crystallized in (iv) comprises chabazite and/or SSZ-13, preferably chabazite, and wherein more preferably the zeolitic material crystallized in (iv) is chabazite and/or SSZ-13, preferably SSZ-13.
90. The process of any of embodiments 1 to 89, wherein the mixture prepared in (i) and crys tallized in (iv) contains substantially no phosphorous and/or phosphorous containing com pounds.
91. The process of any of embodiments 1 to 90, wherein the framework of the zeolitic material crystallized in (iv) contains substantially no phosphorous, wherein preferably the zeolitic material crystallized in (iv) contains substantially no phosphorous and/or phosphorous containing compounds.
92. A zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable
and/or obtained according to the process of any of embodiments 1 to 91.
93. The zeolitic material of embodiment 92, wherein the zeolitic material has a CHA-type
framework structure, wherein preferably the zeolitic material is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, MeAPSO-47, Phi, DAF-5, UiO-21 , |Li-Na| [Al- Si-0]-CHA, (Ni(deta)2)-UT-6, SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218, Linde D, Linde R, SAPO-34, ZK-14, K-Chabazite, Phi, DAF-5, UiO-21 , SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, Linde D, Linde R, SAPO-34,
SSZ-13, and SSZ-62, including mixtures of two or more thereof,
more preferably from the group consisting of Chabazite, SSZ-13, and SSZ-62, including mixtures of two or three thereof,
wherein more preferably the zeolitic material comprises chabazite and/or SSZ-13, prefer ably SSZ-13, and wherein more preferably the zeolitic material is chabazite and/or SSZ- 13, preferably SSZ-13.
94. The zeolitic material of claim 92 or 903, wherein the mean particle size D50 by volume of the zeolitic material as determined according to ISO 13320:2009 is in the range of from 0.1 to 10 pm, and is preferably in the range of from 0.3 to 6.0 pm, more preferably in the range of from 1.5 to 4.5 pm, and more preferably in the range of from 2.5 to 3.6 pm.
95. Use of a zeolitic material according to any of embodiments 92 to 94 as a molecular sieve, as an adsorbent, for ion-exchange, as a catalyst or a precursor thereof, and/or as a cata lyst support or a precursor thereof, preferably as a catalyst or a precursor thereof and/or as a catalyst support or a precursor thereof, more preferably as a catalyst or a precursor thereof, more preferably as a catalyst for the selective catalytic reduction (SCR) of nitro gen oxides NOx; for the storage and/or adsorption of CO2; for the oxidation of NH3, in par ticular for the oxidation of NH3 slip in diesel systems; for the decomposition of N2O; as an additive in fluid catalytic cracking (FCC) processes; and/or as a catalyst in organic con version reactions, preferably in the conversion of alcohols to olefins, and more preferably in methanol to olefin (MTO) catalysis; more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NOx, and more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NOx in exhaust gas from a combustion engine, preferably from a diesel engine or from a lean burn gasoline engine.
DESCRIPTION OF THE FIGURES
Figure 1 displays the 27AI MAS NMR of the mechanochemically activated reaction mixture of example 1 , wherein the chemical shift in ppm is plotted along the abscissa and the relative intensity in arbitrary units is shown along the ordinate. Furthermore, the in tegration values for the relative intensity integral within the range of 80 to 20 ppm and within the range of 15 to -20 ppm are respectively indicated along the ordinate.
Figure 2 displays the 27AI MAS NMR of the mechanochemically activated reaction mixture of reference example 4, wherein the chemical shift in ppm is plotted along the abscissa and the relative intensity in arbitrary units is shown along the ordinate. Furthermore, the integration values for the relative intensity integral within the range of 80 to 20 ppm and within the range of 15 to -20 ppm are respectively indicated along the ordi nate.
EXAMPLES Reference Example 1 : Determination of the energy intake of the mixture during the grinding procedure
The energy intake can be determined via determination of the torque with the stirred media mill. The torque has to be determined, first without the material of which the energy intake is to be determined and, second, with said material. The torque determined for the experiment without the material of which the energy intake is to be determined is subtracted from the torque deter mined for the experiment with said material. Based on the result from said calculation, the spe cific energy input in kJ/kg can be calculated. It is also possible to determine the torque with oth er devices. Thus, either the torque with and without material load is determined and the energy intake is calculated as described above or the power input with material (load value) and without material (no-load value) is determined. With regards to the latter, the no-load value is subtracted from the load value und the energy intake as introduced into the product can be calculated.
Presently, the energy intake was determined via determination of the torque using a torque- determination apparatus IC3001-Ex (German:“Drehmoment-Messeinrichtung IC3001-Ex”; Dr. Staiger, Mohilo & Co. GmbH, Schorndorf) and a torque-rotation speed determination apparatus IC3001-Ex-n (German:“Drehmoment-Drehzahl-Messeinrichtung IC3001-Ex-n”; Dr. Staiger, Mo hilo & Co. GmbH, Schorndorf), whereby manual no. 1294 dated May 13, 1993 (German:
“Prufanleitung Nr. 1294”) was used. The torque-determination apparatus was used according to the suggested installation under item 5.1 in manual no. 1234 (German:“Bedienungsanleitung Nr. 1234”), the mechanical installation (German:“3.1 Mechanischer Aufbau”) was done accord ing to the suggested installation under item 3.1 of said manual, and the electrical installation (German:“3.2 Elektrischer Aufbau”) according to the suggested installation under item 3.2 of said manual.
Reference Example 2: 27 Al MAS solid-state NMR analysis
Prior to solid-state NMR experiments, samples were 27AI solid-state nuclear magnetic reso nance (NMR) was performed using the following devices, procedures and parameters: Storage of samples at 62% relative humidity for at least 60 hours prior to packing, packing of samples into 4mm Zr02 rotors with Kel-F caps, Bruker Avance III spectrometer with 9.4 Tesla magnet, 10 kHz (w/2tt) magic angle spinning, one-pulse radiofrequency excitation corresponding to a 0.83ps 15°-pulse on AlC -solution (1 % in H2O), 10 ms acquisition of the free induction decay, no heteronuclear 1H radiofrequency decoupling, averaging of at least 5120 scans with a recycle delay of 0.5s, Fourier transform with 10 Hz exponential line broadening for noise suppression, manual phasing and baseline correction in Bruker Topspin 3.0. Spectra were referenced relative to AI(N03)3 in D2O, 1.1 mol/kg at a frequency ratio of 0.26056859 on the absolute chemical shift scale, according to Pure Appl. Chem., Vol. 80, No. 1 , pp. 59-84, 2008, using adamantane with a 13C methylene resonance at 37.77ppm as a secondary standard. For each spectrum, two in tegral ranges were defined, integral h ranging from 80 ppm to 20 ppm, and Integral I2 ranging from 15 to -20 ppm. A relative integral lr defined as 1 = 12 / (h + I2) was calculated. Reference Example 3: X-ray diffraction analysis
Powder X-ray diffraction (PXRD) data was collected using a diffractometer (D8 Advance Series II, Bruker AXS GmbH) equipped with a LYNXEYE detector operated with a Copper anode X-ray tube running at 40kV and 40mA. The geometry was Bragg-Brentano, and air scattering was reduced using an air scatter shield. The crystallinity was determined using DIFFRAC.EVA soft ware (User Manual for DIFFRAC.EVA, Bruker AXS GmbH, Karlsruhe).
Example 1 : Synthesis of a zeolitic material having a CHA-type framework structure via mecha- nochemical activation
27.73 g silica gel (S1O2 1.16 H2O, obtained from Qingdao Haiyang Chemical Reagent Co,
Ltd.), 28.58 g Na2Si03 x9 H2O, 12.31 g Al2(S04)3 hydrate (analytical grade, 98 %; ABCR GmbH Karlsruhe), 3.37 g CHA seeds (as obtained according to Reference Example 1 of WO
2017/216236 A1 ) were gently mixed in a vessel with a spatula. The powder was then introduced into a stirred media mill with a grinding volume of 0.94 I. As grinding media zircon oxide beads with a diameter of 1 .2 - 1 .7 mm were taken. The filling degree of the grinding media was 50 %. 22 g of a 47.8 wt.-% solution of N,N,N-trimethyl-1 -adamantanammonium hydroxide (TMAdOH) in distilled water were introduced into a scalable stirred media mill (PML Drais from Buhler) with a grinding volume of 0,94 I. As grinding media zircon oxide beads with a diameter of 2.8 - 3.3 mm were taken. The filling degree of the grinding media was 50 %. Afterwards the mill was closed and operated in batch mode. The tip speed was set to 5 m/s. The mixture was ground for 2 minutes (1 1 kJ/kg).
The 27AI MAS NMR of the mechanochemically activated reaction mixture is displayed in figure 1 and shows a relative 27AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) of 82.7 and within the range of 15 to -20 ppm (I2) of 17.3 such as to afford a ratio of the integra tion values I2 : (h + I2) of 17.3.
5 g of the resulting mixture were then mixed with 7.5 g of distilled water, and 5.9 g of the result ing slurry was then placed in an autoclave. The autoclave was heated over 2 h to 230°C and subsequently held at that temperature for 3 h. The reaction product was filtered, washed with distilled water and dried at 120°C for 16 h. The dried solid was then heated over 3 h to 550°C and calcined at that temperature for 3 h, thus affording a solid product having a CHA-type framework structure with a crystallinity of 70%.
Reference Example 4: Preparation of a reaction mixture including mechanochemical activation
55.46 g Silicagel (S1O2 - 1.16 H2O; Qingdao Haiyang Chemical Reagent Co, Ltd.), 57.16 g Na2Si03 x 9H2O (analytical grade, S1O2 of 20 weight-%, Aladdin Chemistry Co., Ltd.), 24.62 g AI2(S04)3 hydrate (analytical grade, 98 %; ABCR GmbH Karlsruhe), 6.74 g CHA seeds were gently mixed in a vessel with a spatula. The powder was then introduced into a stirred media mill (PML Drais from Buhler) with a grinding volume of 0,94 I. As grinding media zircon oxide beads with a diameter of 2.8 - 3.3 mm were taken. The filling degree of the grinding media was 50 %. 44 g of 47.8 % N,N,N-trimethyl-1 -adamantanammonium hydroxide (TMAdAOH) were introduced into the mill. Afterwards the mill was closed and operated in batch mode. The tip speed was set to 5 m/s. The mixture was ground for 2 minutes for affording a mechanochemi cally activated reaction mixture (approximately 5.5 kJ/kg).
The 27AI MAS NMR of the mechanochemically activated reaction mixture is displayed in figure 2 and shows a relative 27AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) of 91.2 and within the range of 15 to -20 ppm (I2) of 8.8 such as to afford a ratio of the integra tion values I2 : (h + I2) of 8.8.
Example 2: Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture
5.01 g of the sample obtained according to Reference Example 4 was diluted with 1 1.10 g of distilled water, thus affording a dilution rate of S1O2 : H2O of 1 : 7. The mixture was then stirred, and 7.5 g of the mixture were removed from with a pipette and placed in an autoclave. The au toclave was then sealed and subsequently heated at 230 °C for 3 h. The solid reaction product was then washed with 3 I of distilled water, filtered dry over a suction filter, after which it was dried for 2 h at 120 °C and then calcined for 5 h at 550 °C. As determined by x-ray diffraction, the product displayed a crystallinity of 62% and consisted of 45% ZSM-39, 27% chabazite, 23% mordenite, and 5% dodecasil.
Example 3: Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture
5.01 g of the sample obtained according to Reference Example 4 was diluted with 16.65 g of distilled water, thus affording a dilution rate of S1O2 : H2O of 1 : 10. The mixture was then stirred, and 7.5 g of the mixture were removed from with a pipette and placed in an autoclave. The au toclave was then sealed and subsequently heated at 230 °C for 3 h. The solid reaction product was then washed with 3 I of distilled water, filtered dry over a suction filter, after which it was dried for 2 h at 120 °C and then calcined for 5 h at 550 °C. As determined by x-ray diffraction, the product displayed a crystallinity of 63% and consisted of 22% ZSM-39, 76% chabazite, and 2% dodecasil.
Example 4: Synthesis of a zeolitic material having a CHA-type framework structure using a mechanochemically activated reaction mixture 5.01 g of the sample obtained according to Reference Example 4 was diluted with 18.65 g of distilled water, thus affording a dilution rate of S1O2 : H2O of 1 : 1 1. The mixture was then stirred, and 7.5 g of the mixture were removed from with a pipette and placed in an autoclave. The au toclave was then sealed and subsequently heated at 230 °C for 3 h. The solid reaction product was then washed with 3 I of distilled water, filtered dry over a suction filter, after which it was dried for 2 h at 120 °C and then calcined for 5 h at 550 °C. As determined by x-ray diffraction, the product displayed a crystallinity of 65% and consisted of 15% ZSM-39, 85% chabazite, <0.5% dodecasil.
Comparative Example: Synthesis of a zeolitic material having a CHA-type framework structure according to a conventional synthesis method
27.73 g silica gel (S1O2 - 1.16 H2O, obtained from Qingdao Haiyang Chemical Reagent Co,
Ltd.), 28.60 g Na2Si03 x 9 H2O, 12.31 g Al2(S04)3 hydrate (analytical grade, 98 %; ABCR GmbH Karlsruhe), 22 g of a 47.8 wt.-% solution of N,N,N-trimethyl-1-adamantanammonium hydroxide (TMAdOH) in distilled water, 3.37 g CHA seeds (as obtained according to Reference Example 1 of WO 2017/216236 A1 ), and 140.37 g of distilled water were mixed together. The resulting re action mixture was divided over two autoclaves which were respectively heated over 2 h to 230°C and subsequently held at that temperature for 3 h. The resulting mixtures were then re spectively filtered, washed with 2 L distilled water and dried at 120°C for 16 h. The dried solid was then heated over 3 h to 550°C and calcined at that temperature for 3 h for affording 36 g of a solid product having a CHA-type framework structure with a crystallinity of 27%.
Thus, as may be taken from the results obtained in the inventive examples and the Comparative Example, the mechanochemical activation of the reactants in the inventive Example prior to crystallization leads to a considerably increased crystallization rate of the reaction mixture, the product of the Comparative Example displaying only a fraction of the crystallinity of the inventive Example after crystallization under the same conditions. In fact, the surprising technical effect is even more pronounced than would appear to be the case since mixture in the Comparative Ex ample was placed in two autoclaves, such that the surface to volume ratio in the Comparative Example was higher than in the inventive examples, as a result of which a faster rate of heating was achieved in the Comparative Example. Thus, without proceeding to mechanochemical acti vation in the inventive examples, the rate of crystallization in the Comparative Example and thus the obtained crystallinity would have been higher for the product of the Comparative Example due to the higher surface to volume ratio achieved by the distribution of the reactions mixture into two autoclaves instead of one in the inventive examples. Consequently, the fact that the crystallinity of the product of the inventive examples is in fact substantially higher than the Com parative Example after heating under the same conditions only emphasizes the pronounced effect of the mechanochemical activation on the reaction mixture with regard to the rate of crys tallization. List of cited prior art
- WO 2005/039761 A2
- US 7,528,089 B2
- WO 2016/153950 A1
- US 5,989,518
- US 2016/0115039 A1
- Liu et al. in Angew. Chem. Int. Ed. 2015, 54, 5683-5687
- Ju, J. et al. in Chemical Engineering Journal 2006, 1 16, 115-121
- Vandermeersch, T. et al. in Microporous and Mesoporous Materials 2016, 226, 133-139
- Liu, Z. et al. in Chemistry of Materials 2014, 26, 2327-2331
- Slangen et al.“Continuous Synthesis of Zeolites using a Tubular Reactor”, 12th Interna tional Zeolite Conference, Materials Research Society 1999
- Bonaccorsi, L. et al. in Microporous and Mesoporous Materials 2008, 112, 481-493
- US 2001/0054549 A1
- DE 39 19 400 A1
- WO 2017/216236 A1
- WO 2015/185625 A2
- WO 03/020641 A1
- WO 2018/059316 A1
- WO 2012/072527 A2
- N. E. Gordina et al.:“Use of Mechanochemical Activation and Ultrasonic Treatment for the
Synthesis of LTA Zeolite”, Russ. J. Gen. Chem. 2018, M A I K Nauka-lnterperiodica, vol. 88, p. 1981-1989
- K. Wantae et al.:“Effect of Dry Grinding of Pyrophyllite on the Hydrothermal Synthesis of
Zeolite Na-X and Na-A”, Materials Transactions 2014, vol. 55, p. 1488-1493
- N. E. Gordina et al.:“Synthesis of NaA Zeolite by Mechanochemical Methods”, Russ. J.
Appl. Chem. 2003, vol. 76, p. 661-662
- DD 205 674 A1
- V. Valtchev et al.:“Tribochemical activation of seeds for rapid crystallization of zeolite Y”,
Zeolites 1995, vol. 15, p. 193-197
- R. Limin et al.:“Solvent-Free Synthesis of Zeolites from Solid Raw Materials”, J. Am.
Chem Soc. 2012, vol. 134, p. 15173-15176
- G. Majano et al.:“Rediscovering zeolite mechanochemistry - A pathway beyond current synthesis and modification boundaries”, Microporous and Mesoporous Mat. 2014, vol. 194, p. 106-1 14
- Y. Wu et al.:“Effect of microwave-assisted aging on the static hydrothermal synthesis of zeolite MCM-22”, Microporous and mesoporous Mat. 2008, vol. 1 16, p. 386-393

Claims

Claims
1. A process for preparing a zeolitic material comprising YO2 and X2O3 in its framework
structure, wherein Y stands for a tetravalent element and X stands for a trivalent element, wherein said process comprises:
(i) preparing a mixture comprising one or more sources of YO2, one or more sources of X2O3, and H2O;
(ii) grinding and/or mixing the mixture prepared in (i), wherein the energy intake of the mixture during the grinding and/or mixing procedure is in the range of from 0.3 to 200 kJ/kg of the mixture;
(iii) adding water, preferably distilled water, to the ground mixture obtained in (ii); and
(iv) crystallizing a zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture obtained in (iii), wherein the mixture is heated to a temperature in the range of from 80 to 300°C;
wherein the mixture prepared in (i) and ground in (ii) contains from 5 to 300 wt.-% of H2O based on 100 wt.-% of the one or more sources of YO2, calculated as YO2.
2. The process of claim 1 , wherein the 27AI MAS NMR of the mixture obtained in (ii) compris es:
a first peak (P1 ) in the range of from 20 to 80 ppm; and
one or more peaks (PX) in the range of from -20 to 15 ppm;
wherein the relative 27AI solid-state NMR intensity integral within the range of 80 to 20 ppm (h) and within the range of 15 to -20 ppm (I2) of the zeolitic material offer a ratio of the integration values I2 : (h + I2) comprised in the range of from 0.5 to 50%.
3. The process of claim 1 or 2, wherein the rate of energy transfer to the mixture in (ii) is in the range of from 10 to 1 ,500 kJ/(kg*h).
4. The process of any of claims 1 to 3, wherein grinding and/or mixing in (ii) is carried out in a mill selected from the group consisting of a stirred media mill, a ball mill, a roller mill, a kneader and a high shear mixer.
5. The process of any of claims 1 to 4, wherein crystallization in (iv) is conducted as a con tinuous process.
6. The process of claim 5, wherein crystallization in (iv) comprises continuously feeding the mixture obtained in (iii) into a continuous flow reactor at a liquid hourly space velocity in the range of from 0.3 to 20 tv1 for a duration of at least 1 h, and crystallizing the zeolitic material comprising YO2 and X2O3 in its framework structure from the mixture in the con- tinuous flow reactor, wherein the mixture is heated to a temperature in the range of from 80 to 300°C.
7. The process of any of claims 1 to 6, wherein the mixture prepared in (i) and crystallized in (iv) further comprises one or more structure directing agents.
8. The process of claim 7, wherein the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for ada- mantyl and/or benzyl.
9. The process of claim 7, wherein the one or more structure directing agents comprise one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one another stand for alkyl, and wherein R4 stands for cycloal kyl.
10. The process of any of claims 1 to 9, wherein Y is selected from the group consisting of Si, Sn, Ti, Zr, Ge, and combinations of two or more thereof.
1 1. The process of any of claims 1 to 10, wherein the mixture prepared in (i) and crystallized in (iv) further comprises seed crystals.
12. The process of claim 11 , wherein the seed crystals comprise one or more zeolitic materi als having a framework structure type selected from the group consisting of AEI, AFX, ANA, BEA, BEC, CAN, CHA, CDO, EMT, ERI, EUO, FAU, FER, GME, HEU, ITH, ITW, KFI, LEV, MEI, MEL, MFI, MOR, MTN, MWW, OFF, RRO, RTH, SAV, SFW, SZR, and TON, including mixed structures of two or more thereof.
13. A zeolitic material comprising YO2 and X2O3 in its framework structure as obtainable
and/or obtained according to the process of any of claims 1 to 12.
14. The zeolitic material of claim 13, wherein the zeolitic material has a CHA-type framework structure.
15. Use of a zeolitic material according to claim 13 or 14 as a molecular sieve, as an adsor bent, for ion-exchange, as a catalyst or a precursor thereof, and/or as a catalyst support or a precursor thereof.
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