WO2021122533A1 - Process for continuous interzeolitic conversion - Google Patents

Process for continuous interzeolitic conversion Download PDF

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Publication number
WO2021122533A1
WO2021122533A1 PCT/EP2020/086126 EP2020086126W WO2021122533A1 WO 2021122533 A1 WO2021122533 A1 WO 2021122533A1 EP 2020086126 W EP2020086126 W EP 2020086126W WO 2021122533 A1 WO2021122533 A1 WO 2021122533A1
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zeolitic material
framework structure
alkyl
reactor
zeolite
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PCT/EP2020/086126
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French (fr)
Inventor
Hannah SCHREYER
Andrei-Nicolae PARVULESCU
Ulrich Mueller
Ralf Boehling
Toru Wakihara
Tatsuya Okubo
Zhendong Liu
Kenta Iyoki
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Basf Se
The University Of Tokyo
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Publication of WO2021122533A1 publication Critical patent/WO2021122533A1/en

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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
    • C01B39/026After-treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404Removing only nitrogen compounds
    • B01D53/9409Nitrogen oxides
    • B01D53/9413Processes characterised by a specific catalyst
    • B01D53/9418Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/70Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/7015CHA-type, e.g. Chabazite, LZ-218
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00Catalysts comprising molecular sieves
    • B01J29/04Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/70Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/72Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
    • B01J29/76Iron group metals or copper
    • B01J29/763CHA-type, e.g. Chabazite, LZ-218
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/40Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/60Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61Surface area
    • B01J35/617500-1000 m2/g
    • 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2251/00Reactants
    • B01D2251/20Reductants
    • B01D2251/206Ammonium compounds
    • B01D2251/2062Ammonia
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2255/00Catalysts
    • B01D2255/50Zeolites
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2255/00Catalysts
    • B01D2255/90Physical characteristics of catalysts
    • B01D2255/92Dimensions
    • B01D2255/9207Specific surface

Definitions

  • the present invention relates to a continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure comprising interzeolitic conversion, a zeo litic material obtainable and/or obtained according to said process, and a use of said zeolitic material as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support.
  • Zeolites are widely used in the technical field of emission control. However, the synthesis there of usually requires long processing times and high investments since zeolites are typically made in batch processes which take a long synthesis time, thus, a large capacity of resources, espe cially reactor allocation.
  • Y. Hu et al. disclose in Microporous and Mesoporous Materials 2018, 27, pp. 149-154 an ultra fast hydrothermal synthesis of TS-1 zeolite without extra-framework titanium species in a con tinuous flow system particularly using a tubular reactor.
  • a mixture com prising tetrapropylammonium hydroxide, tetra-butyl orthotitanate, tetraethyl orthosilicate and water was used.
  • CN 109336131 A relates to a method for rapidly synthesizing an AEI-type molecular sieve, the method comprising mixing of a templating agent, a water source, an alkali source, an aluminum source, a silicon source and seed crystals. The method further comprises a step of high shear aging of the synthesis mixture and crystallizing thereof at 130 to 150 °C for 3 to 24 h.
  • CN 109319804 A relates to a preparation method for a SSZ-13 zeolite under super/subcritical conditions, in particular at a temperature in the range of from 270 to 380 °C and a pressure in the range of from 12 to 35 MPa. Further, CN 109319804 A discloses a device for the continuous preparation of an SSZ-13 zeolite.
  • DE 3029787 A1 relates to a continuous process for preparing zeolites.
  • EP 0402801 A2 relates 20 to a method for the preparation of crystalline and zeolitic aluminosilicates.
  • US 4374093 discloses a continuous-stream zeolite crystallization apparatus particularly comprising a combination of a tubular reactor, a central stirring element, ingress and egress means, and recovery vessels.
  • US 6656447 B1 discloses a continuous process for the prepara tion of a molecular sieve.
  • a zeolitic material having a distinct framework structure type in a continuous process a zeolitic material having a different framework structure type can be obtained especial ly in a comparatively reduced synthesis time.
  • a zeolitic material can be prepared via the process of the present invention within a comparatively reduced synthesis time.
  • the synthesis time can be reduced from more than 20 h according to a common preparation process to less than 1 h according to the process of the present invention.
  • the present invention provides a method for preparing a CHA-type zeolite via a continuous interzeo- litic conversion.
  • CHA-type zeolites are commonly known for their broad field of application, in particular as a catalytic material.
  • the present invention relates to a continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein X stands for a trivalent element, said process comprising
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 independently from one another stand for alkyl;
  • the first zeolitic material has an FAU-, GIS-, MOR-, LTA-, FER-, TON-, MTT-, BEA-, MEL-, MWW-, MFS-, and/or M FI-type framework structure, more preferably an FAU-, GIS-, BEA-, and/or M FI-type framework struc ture, more preferably an FAU- and/or BEA-type framework structure, and more preferably an FAU-type framework structure.
  • the second zeolitic ma terial has a CHA-, AEI-, GME-, and/or M FI-type framework structure, preferably a CHA- and/or AEI-type framework structure.
  • the one or more solvents in the mixture prepared in (i) comprise water, pref erably distilled water, wherein more preferably water is contained as the one or more solvents in the mixture prepared in (i), preferably distilled water.
  • the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein said at least one source for OH- more preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH- is sodium hydroxide.
  • said at least one source for OH- more preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH- is sodium hydroxide.
  • the first zeolitic material has an FAU-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of ZSM-3, Faujasite, [Al-Ge- 0]-FAU, CSZ-1 , ECR-30, Zeolite X, Zeolite Y, LZ-210, SAPO-37, ZSM-20, Na-X, US-Y, Na-Y, [Ga-Ge-0]-FAU, Li-LSX, [Ga-AI-Si-0]-FAU, and [Ga-Si-0]-FAU, including mixtures of two or more thereof, more preferably from the group consisting of ZSM-3, Faujasite, CSZ-1 , ECR-30, Zeolite X, Zeolite Y, LZ-210, ZSM-20, Na
  • the first zeolitic material having an FAU-type framework structure is zeolite X and/or zeolite Y, more preferably zeolite Y.
  • the first zeolitic material has an GIS-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of zeolite P, TMA-gismondine, Na- P1 , Amicite, Gobbinsite, High-silica Na-P, Na-P2, SAPO-43, Gismondine, MAPSO-43, MAPSO- 43, Garronite, Synthetic amicite, Synthetic garronite, Synthetic gobbinsite, [Ga-Si-Oj-GIS, Syn thetic Ca-garronite, Low-silica Na-P (MAP), [AI-Ge-Oj-GIS, including mixtures of two or more thereof, more preferably from the group consisting of zeolite P, TMA-gismondine, Na-P1 , Amici te, Gob
  • the first zeolitic material having a GIS-type framework struc ture is zeolite P.
  • the first zeolitic material has an MOR-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Mordenite, [Ga-Si-0]-MOR, Maricopaite, Ca-Q, LZ-211, Na-D, RMA-1, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MOR-type framework structure comprises Mordenite.
  • the first zeolitic material having an MOR-type framework structure is Mordenite.
  • the first zeolitic material has an LTA-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Linde Type A (zeolite A), Alpha, [AI-Ge-0]-LTA, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd. Linde Type A (dehyd.
  • zeo lite A ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd.
  • Linde Type A, ZK-22, ITQ-29, UZM-9 including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21, Dehyd.
  • Linde Type A, ZK-22, ITQ-29, UZM-9 including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21 , ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof.
  • the first zeolitic material has an BEA-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of zeolite beta, Tschernichite, [B-Si-0]- * BEA, CIT-6, [Ga-Si-0]- * BEA, Beta polymorph B, SSZ-26, SSZ-33, Beta polymorph A, [Ti-Si-0]- * BEA, and pure silica beta, including mixtures of two or more thereof, more preferably from the group consisting of zeolite beta, CIT-6, Beta polymorph B, SSZ-26, SSZ-33, Beta pol ymorph A, and pure silica beta, including mixtures of two or more thereof, wherein more prefer ably the first zeolitic material having a BEA-type framework
  • the first zeolitic material having a BEA-type framework struc ture is zeolite beta, more preferably zeolite beta obtained from organotemplate mediated syn thesis or obtained from organotemplate-free synthesis, and more preferably zeolite beta ob tained from organotemplate-free synthesis.
  • the first zeolitic material has an M FI-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Silicalite, ZSM-5, [Fe-Si-0]-MFI, [Ga-Si-0]-MFI, [As-Si-0]-MFI, AMS-1 B, AZ-1 , Bor-C, Encilite, Boralite C, FZ-1 , LZ-105, Mu- tinaite, NU-4, NU-5, TS-1 , TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, MnS- 1 , and FeS-1 , including mixtures of two or more thereof, more preferably from the group consist ing of Silicalite, ZSM-5, [Fe-Si-0]-MFI, [Ga-Si-0]
  • the first zeolitic material having an M FI-type framework structure is zeolite Silicalite and/or ZSM-5, preferably ZSM-5.
  • the first zeolitic material has an FER-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Ferrierite, [Ga-Si-0]-FER, [Si-0]-FER, FU-9, ISI-6, NU-23, Sr-D, ZSM-35, and [B-Si-0]-FER, including mixtures of two or more thereof, more preferably from the group consisting of Ferrierite, FU-9, ISI-6, NU-23, and ZSM-35, including mixtures of two or more thereof.
  • the first zeolitic material having an FER-type framework structure is Ferrierite.
  • the first zeolitic material has an TON-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Theta-1 , ZSM-22, ISI-1 , KZ-2, and NU-10, including mixtures of two or more thereof.
  • the first zeolitic material having a TON-type framework structure is ZSM-22.
  • the first zeolitic material has an MTT-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of ZSM-23, EU-13, ISI-4, and KZ-1 , including mixtures of two or more thereof.
  • the first zeolitic material having a MTT-type framework structure is ZSM-23.
  • the first zeolitic material has an MEL-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of Boralite D, SSZ-46, and ZSM-11 , including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MEL-type framework structure comprises ZSM-11.
  • the first zeolitic material having an MEL-type framework structure is ZSM-11.
  • the first zeolitic material has an MWW-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material is selected from the group consisting of MCM-22, ERB-1 , ITQ-1 , PSH-3, and SSZ-25 and MCM-22, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MWW-type framework structure comprises MCM- 22.
  • the first zeolitic material having an MWW-type framework structure is MCM-22.
  • the first zeolitic material has an MFS-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material.
  • the first zeolitic material comprises ZSM-57.
  • the first zeolitic material having an MFS-type framework structure is ZSM-57.
  • the second zeolitic material obtained in (iii) has an CHA-type framework structure, also in combination with another framework structure type as an inter growth zeolitic material.
  • the second zeolitic material obtained in (iii) has 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 second zeolitic material obtained in (iii) is chabazite and/or SSZ-13, more preferably SSZ-13.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl, more preferably for 1 -adamantyl.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl
  • R 1 , R 2 , and R 3 independently from one another stand for optionally substitut ed and/or optionally branched (CrC 6 )alkyl, more preferably (CrC5)alkyl, more preferably (Ci- C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl
  • R 1 , R 2 , and R 3 independently from one another stand for option ally substituted methyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more prefera
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl
  • R 4 stands for optionally heterocyclic and/or optionally substituted adamantyl and/or benzyl, more preferably for optionally heterocyclic and/or optionally substituted 1- adamantyl, more preferably for optionally substituted adamantyl and/or benzyl, more preferably for optionally substituted 1 -adamantyl, more preferably for unsubstituted adamantyl and/or ben zyl, and more preferably for unsubstituted 1-adamantyl.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing com pounds comprise one or more /V,/V,/V-tri(Ci-C 4 )alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C 3 )alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V-tri(CrC 2 )alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V,tri(Cr
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing com pounds are salts, more preferably one or more salts selected from the group consisting of hal ides, 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
  • the one or more structure directing agents comprises 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.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently 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 (CrC 6 )alkyl, more preferably (Ci-C5)alkyl, more preferably (CrC ⁇ alkyl, more prefera bly (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 independent ly from one another stand for optionally substituted methyl,
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl
  • R 3 stands for optionally substituted and/or optionally branched (Ci-C 6 )alkyl, more preferably (Ci-C5)alkyl, more preferably (CrC ⁇ alkyl, more preferably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 3 stands for optionally substi tuted ethyl, preferably unsubstituted ethyl.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl
  • R 4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cyclo alkyl, more preferably for 5- to 7-membered cycloalkyl, more preferably for 5- or 6-membered cycloalkyl
  • R 4 stands for optionally heterocyclic and/or optionally sub stituted 6-membered cycloalkyl, preferably optionally substituted cyclohexyl, and more prefera bly unsubstituted cyclohexyl.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl
  • 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, more 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,
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for cycloalkyl
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are salts, more preferably one or more salts selected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group con sisting 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 com pounds are tetraalkyl
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl, or where the one or more structure directing agents comprises 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 an other stand for alkyl, and wherein R 4 stands for cycloalkyl, it is preferred that the FI2O : S1O2 mo lar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 7 to 40, more preferably of from 9 to 30, more preferably of from 11 to 25, more preferably of from 13 to 22, more preferably of from 15 to 20, more
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , and R 3 inde pendently from one another stand for alkyl, and wherein R 4 stands for adamantyl and/or benzyl, or where the one or more structure directing agents comprises 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 an other stand for alkyl, and wherein R 4 stands for cycloalkyl, it is preferred that continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 IT 1 , more pref erably from 0.1 to 3 IT 1 , more preferably from 0.2 to 2 IT 1 , more preferably from 0.3 to 1 .5 IT 1 , more preferably from
  • the second zeolitic material obtained in (iii) has an AEI-type framework struc ture, wherein more preferably the zeolitic material having an AEI-type framework structure is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the second zeolitic material obtained in (iii) comprises SSZ-39, and wherein more preferably the second zeolitic material obtained in (iii) is SSZ-39.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • R 1 and R 2 independently from one another stand for optionally substi tuted and/or optionally branched (Ci-C 6 )alkyl, more preferably (CrC5)alkyl, more preferably (Cr C ⁇ 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.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • R 3 and R 4 form a common derivatized or underivatized, more prefera bly underivatized alkyl chain, preferably a common (C4 - Cs)alkyl chain, more preferably a common (C - C 7 )alkyl chain, more preferably a common (C - Ce)alkyl chain.
  • said common alkyl chain is a derivatized or underivatized, more preferably un- derivatized C or C alkyl chain, and more preferably a derivatized or underivatized, preferably underivatized C alkyl chain.
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more ammonium compounds selected from the group consisting of derivatized or underivatized, more preferably underivatized /V, /V-d i (C i -C 4 ) al ky I-3 , 5-d i (C i - C 4 )alkylpyrrolidinium compounds, /V,/V-di(Ci-C )alkyl-3,5-di(Ci-C )alkylpiperidinium compounds, /V,/V
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the cis and trans isomers, wherein preferably the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6- dialkylpiperidinium compounds, and/or /or /
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the cis and trans isomers, wherein preferably the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5- dialkylpiperidinium compounds, and/or /or /
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 in dependently from one another stand for alkyl, and wherein R 3 and R 4 form a common alkyl chain
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds are salts, more preferably one or more salts selected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more prefera bly 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 tetraal
  • the FI2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 4 to 30, more preferably of from 5 to 23, more preferably of from 6 to 18, more preferably of from 7 to 15, more preferably of from 8 to 13, more preferably of from 9 to 12, and more preferably of from 10 to 11.
  • the second zeolitic material obtained in (iii) has an AEI-type frame work structure
  • continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 1 IT 1 , more preferably from 0.1 to 0.8 IT 1 , more preferably from 0.2 to 0.7 IT 1 , more preferably from 0.3 to 0.65 IT 1 , more preferably from 0.35 to 0.6 IT 1 , more preferably from 0.4 to 0.55 IT 1 , and more preferably from 0.45 to 0.5 IT 1 .
  • the mixture prepared in (i) and heated in (iii) displays an R 1 R 2 R 3 R 4 N + : S1O2 molar ratio of the one or more tetraalkylammonium cations to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1.5, more preferably from 0.1 to 0.8, more preferably from 0.3 to 0.5, more preferably from 0.5 to 0.3, more preferably from 0.7 to 0.2, more preferably from 0.8 to 0.15, more preferably from 0.85 to 0.12, more preferably from 0.9 to 0.11 , and more preferably from 0.95 to 0.1.
  • the framework structure of the first zeolitic material displays a YO2 : X2O3 molar ratio ranging from 5 to 120, more preferably from 8 to 80, more preferably from 10 to 50, more preferably from 15 to 40, more preferably from 20 to 30, more preferably from 22 to 28, and more preferably from 24 to 26.
  • the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein the mixture displays an OH- : S1O2 molar ratio of hydroxide to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1 , more prefera bly from 0.1 to 0.7, more preferably from 0.3 to 0.6, more preferably from 0.4 to 0.55, more preferably from 0.45 to 0.5, more preferably from 0.46 to 0.49, and more preferably from 0.47 to 0.48.
  • X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, X more preferably being Al and/or B, and more preferably being Al.
  • the volume of the continuous flow reactor is in the range of from 50 cm 3 to 75 m 3 , more preferably from 55 cm 3 to 3 m 3 , more preferably from 60 cm 3 to 1 m 3 , more preferably from 65 cm 3 to 0.7 m 3 , more preferably from 70 cm 3 to 0.3 m 3 , more preferably from 75 cm 3 to 0.1 m 3 , more preferably from 80 to 70,000 cm 3 , more preferably from 85 to 50,000 cm 3 , more preferably from 90 to 30,000 cm 3 , more preferably from 95 to 10,000 cm 3 , more preferably from 100 to 7,000 cm 3 , more preferably from 105 to 5,000 cm 3 , more preferably from 110 to 3,000 cm 3 , more preferably from 115 to 1 ,000 cm 3 , more preferably from 120 to 700 cm 3 , more prefer ably from 125 to 500 cm 3 , more preferably from 130 to 350 cm 3 , more preferably from 135 to 250 cm 3 , more preferably from 140 to 200 cm 3
  • the continuous flow reactor is selected among a tubular reactor, a ring reac tor, and a continuously oscillating reactor, more preferably among a plain tubular reactor, a tub ular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, a continuously os cillating baffled reactor, and combinations thereof, 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 continuous flow reactor is a tubular reactor, and wherein at least a portion of the tubular reactor is of a regular cylindrical form having a constant inner diameter perpen dicular 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 4 to 500 mm, more prefera bly from 4.5 to 200 mm, more preferably from 4.5 to 100 mm, more preferably from 5 to 50 mm, more preferably from 5 to 30 mm, more preferably from 5.5 to 15 mm, more preferably from 5.5 to 10 mm, more preferably from 6 to 8 mm, and more preferably from 6 to 6.5 mm.
  • the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, more preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 2 to 500 m more preferably from 3 to 200 m, more preferably from 4 to 100 m, more preferably from 4.5 to 50 m, more preferably from 4.5 to 30 m, more preferably from 4 to 20 m, more pref erably from 4 to 15 m, more preferably from 4.5 to 10 m, and more preferably from 4.5 to 5.5 m.
  • the wall of the continuous flow reactor is made of a metallic material, wherein the metallic material comprises one or more metals selected from the group consisting of Ta,
  • the metallic material comprises a nickel alloy, a nick- el-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 more 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 mix tures of two or more thereof, preferably 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).
  • the organic polymer material more 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 mix tures of two or more thereof, preferably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof,
  • the walls of the continuous flow reactor may comprise, preferably consist of, 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, preferably 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).
  • 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, preferably from the group consisting of fluorinated polyethylenes and mixtures of two or more thereof, wherein more
  • the continuous flow reactor is straight and/or comprises one or more curves with respect to the direction of flow, wherein more preferably the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow.
  • the walls of the continuous flow reactor are subject to vibration during crystal lization in (iii). It is preferred that 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 (iii), wherein more preferably no matter is add ed, wherein more preferably no matter is added and no matter is removed from the reaction mixture during its passage through the continuous flow reactor in (iii).
  • the mixture prepared in (i) contains substantially no phosphorous and/or phosphorous containing compounds.
  • the framework of the second zeolitic material obtained in (iii) contains sub stantially no phosphorous, wherein more preferably the second zeolitic material obtained in (iii) contains substantially no phosphorous and/or phosphorous containing compounds.
  • continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 IT 1 , more preferably from 0.1 to 3 IT 1 , more preferably from 0.2 to 2 IT 1 , more preferably from 0.3 to 1.5 IT 1 , more preferably from 0.4 to 1.2 IT 1 , more preferably from 0.5 to 1 IT 1 , and more preferably from 0.7 to 0.8 IT 1 .
  • the mixture prepared in (i) 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 prefer ably 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 mixture is heated to a temperature in the range of from 90 to 280 °C, more preferably of from 120 to 250 °C, more preferably of from 140 to 230 °C, more preferably of from 160 to 220 °C, more preferably of from 180 to 210 °C, and more preferably of from 190 to 200 °C.
  • the mixture is heated under autogenous pressure, wherein more pref erably the pressure is in the range of from 0.5 to 15 MPa, more preferably in the range of from 1 to 10 MPa, more preferably from 1.5 to 8 MPa, more preferably from 2 to 6 MPa, more prefera bly from 2.5 to 5.5 MPa, more preferably from 3 to 5 MPa, more preferably from 3.5 to 4.5 MPa, and more preferably from 3.8 to 4.2 MPa.
  • the mixture prepared in (i) is aged at a temperature in the range of from 40 to 120 °C, preferably from 50 to 110 °C, more preferably from 60 to 105 °C, more pref erably from 70 to 100 °C, more preferably from 75 to 95 °C, and more preferably from 80 to 90 °C. It is preferred that prior to (ii) the mixture prepared in (i) is aged for a duration ranging from 1 to 72 h, more preferably from 6 to 60 h, more preferably from 12 to 54 h, more preferably from 14 to 42 h, more preferably from 16 to 36 h, more preferably from 18 to 32 h, and more preferably from 20 to 28 h.
  • (i) includes a step of milling the mixture prior to and/or during continuous feeding in (ii).
  • the mixture prepared in (i) is directly fed to the continuous flow reactor in (ii), wherein while being fed to the continuous flow reactor in (ii), the mixture prepared in (i) is pre heated, more preferably to a temperature in the range of from 90 to 280 °C, preferably of from 120 to 250 °C, more preferably of from 140 to 230 °C, more preferably of from 160 to 220 °C, more preferably of from 180 to 210 °C, and more preferably of from 190 to 200 °C.
  • the process may comprise further process steps. It is preferred that the process further com prises
  • the liquid in (iv) the liquid com prises one or more solvents selected from the group consisting of polar protic solvents and mix tures thereof, more 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 mix tures thereof, more 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.
  • drying in (vii) is effected at a temperature in the range from 50 to 220 °C, more preferably from 70 to 190 °C, more pref erably from 80 to 170 °C, more preferably from 90 to 150 °C, more preferably from 100 to 140 °C, and more preferably from 110 to 130 °C.
  • the process further comprises (v) it is preferred that the supernatant obtained from the isolation of the zeolitic material in (v), 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.
  • in (v) isolating the zeolitic material includes a step of spray-drying the second zeolitic material ob tained in (iii) or (iv).
  • drying of the zeolitic material includes a step of spray-drying the second zeolitic material obtained in (iii), (iv), (v), or (vi).
  • the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, wherein the lubricating agent more preferably com prises one or more fluorinated compounds.
  • the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, it is preferred that the lubricating agent comprises one or more fluorinated polymers, more preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyethers.
  • the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, it is preferred that the lubricating agent com prises one or more fluorocarbons, more preferably one or more perfluorocarbons, more prefer ably the lubricating agent comprises perfluorodecalin.
  • the mixture crystallized in (iii) in the continuous flow reactor is mechanically agitated, wherein more 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 reac tor 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 process may comprise further process steps. It is preferred that the process further comprises
  • the step of sub jecting the zeolitic material to an ion-exchange procedure includes the steps of (ix.a) subjecting the zeolitic material obtained in (v), (vi), (vii), or (viii) to an ion-exchange proce dure, wherein at least one ionic non-framework element or compound contained in the zeolitic material is ion-exchanged against NFU + ;
  • the one or more metal ions are selected from the group consisting of ions of alkaline earth metal elements and/or transition metal elements, more preferably from the group consisting of ions of metals selected from group Mg, Sr, Zr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Cr, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, and even more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof.
  • the process further comprises (viii) and/or (ix.b)
  • the calcin ing in (viii) and/or (ix.b) is effected at a temperature in the range from 250 to 800 °C, more pref erably from 300 to 750 °C, more preferably from 350 to 700 °C, more preferably from 400 to 650 °C, more preferably from 450 to 600 °C, and more preferably from 500 to 550 °C.
  • calcining in (viii) and/or (ix.b) is conducted for a period in the range of from 0.5 to 15 h, more preferably from 1 to 12 h, more preferably from 2 to 10 h, more preferably from 2.5 to 9 h, more preferably from 3 to 7 h, more preferably from 3.5 to 6.5 h, more preferably from 4 to 6 h, and more preferably from 4.5 to 5.5 h.
  • the mixture prepared in (i) further comprises seed crystals, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-, AEI-, GME-, and/or M FI-type framework structure, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-type and/or an AEI-type framework structure, wherein more preferably the zeolitic material of the seed crystals is obtainable and/or obtained according to any one of the embodiments disclosed herein.
  • the seed crystals comprises a zeolitic material having a CFIA-type framework structure.
  • the seed crystals comprises a zeolitic material having a CFIA-type framework struc ture
  • the zeolitic material comprised in the seed crystals is selected from the group consisting of Willhendersonite, ZYT-6, SAPO-47, Na-Chabazite, Chabazite, LZ-218,
  • the seed crystals comprises a zeolitic material having a AEI-type framework struc ture.
  • the seed crystals comprises a zeolitic material having a AEI-type framework structure
  • the zeolitic material comprised in the seed crystals is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof. It is particularly preferred that the zeolitic material having an AEI-type framework structure comprised in the seed crystals is SSZ-39.
  • the amount of seed crystals in the mixture prepared in (i) and heated in (iii) ranges from 0.1 to 25 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material, more preferably from 0.5 to 15 wt.-%, more preferably from 1 to 10 wt.-%, more preferably from 2 to 7 wt.-%, more preferably from 3 to 6 wt.-%, and more preferably from 4 to 5 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material.
  • the present invention relates to a zeolitic material as obtainable and/or obtained ac cording to the process of any one of the embodiments disclosed herein.
  • the zeolitic material has a CHA-type framework structure, wherein more pref erably 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 is chabazite and/or SSZ-13, more preferably SSZ- 13.
  • the zeolitic material has an AEI-type framework structure, wherein more preferably the zeolitic material is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the zeolitic material comprises SSZ-39. It is particularly preferred that the zeolitic material is SSZ-39.
  • the present invention relates to a use of a zeolitic material according to any one of the embodiments disclosed herein as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support, more preferably as a catalyst for the selective catalyt ic reduction (SCR) of nitrogen oxides NO x ; for the storage and/or adsorption of CO2; for the oxi dation of N H3, in particular for the oxidation of N H3 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 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 NO x , and more preferably for the selective catalytic reduction (SCR)
  • the unit bar(abs) refers to an absolute pressure wherein 1 bar equals 10 5 Pa.
  • a continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein X stands for a trivalent element, said process comprising
  • the one or more structure directing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, wherein R 1 , R 2 , R 3 and R 4 independently from one another stand for alkyl;
  • the first zeolitic material has an FAU-, GIS-, MOR- , LTA-, FER-, TON-, MTT-, BEA-, MEL-, MWW-, MFS-, and/or M FI-type framework struc ture, preferably an FAU-, GIS-, BEA-, and/or M FI-type framework structure, more prefera bly an FAU- and/or BEA-type framework structure, and more preferably an FAU-type framework structure.
  • the second zeolitic material has a CFIA-, AEI-, GME-, and/or M FI-type framework structure, preferably a CFIA- and/or AEI-type frame work structure.
  • the one or more solvents in the mixture prepared in (i) comprise water, preferably distilled water, wherein more preferably water is contained as the one or more solvents in the mixture prepared in (i), preferably distilled water.
  • the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein said at least one source for OH ⁇ preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH ⁇ is sodium hy droxide.
  • said at least one source for OH ⁇ preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH ⁇ is sodium hy droxide.
  • the first zeolitic material having an FAU-type framework structure is selected from the group consisting of ZSM-3, Faujasite, [AI-Ge-0]-FAU, CSZ-1, ECR-30, Zeolite X, Zeolite Y, LZ-210, SAPO-37, ZSM- 20, Na-X, US-Y, Na-Y, [Ga-Ge-0]-FAU, Li-LSX, [Ga-AI-Si-0]-FAU, and [Ga-Si-0]-FAU, including mixtures of two or more thereof, preferably from the group consisting of ZSM-3, Faujasite, CSZ-1, ECR-30, Zeolite X, Zeolite Y, LZ-210, ZSM-20, Na-X, US-Y, Na-Y, and Li-LSX, including mixtures of two or more thereof, more preferably from the group consisting of Faujasite, Zeolite X,
  • the first zeolitic material having a GIS-type framework structure is selected from the group consisting of zeolite P, TMA- gismondine, Na-P1, Amicite, Gobbinsite, High-silica Na-P, Na-P2, SAPO-43, Gismondine, MAPSO-43, MAPSO-43, Garronite, Synthetic amicite, Synthetic garronite, Synthetic gob binsite, [Ga-Si-0]-GIS, Synthetic Ca-garronite, Low-silica Na-P (MAP), [AI-Ge-0]-GIS, in cluding mixtures of two or more thereof, preferably from the group consisting of zeolite P, TMA-gismondine, Na-P1 , Amicite, Gobbinsite, High-silica Na-P, Na-P2, Gismondine, Gar ronite, Synthetic amicite, Synthetic garronite, Synthetic gob binsite, [Ga-Si-0
  • the first zeolitic material having an MOR-type framework structure is selected from the group consisting of Mordenite, [Ga- Si-0]-MOR, Maricopaite, Ca-Q, LZ-211 , Na-D, RMA-1 , including mixtures of two or more thereof, wherein preferably the first zeolitic material having an MOR-type framework struc ture comprises Mordenite, wherein more preferably the first zeolitic material having an MOR-type framework structure is Mordenite.
  • the first zeolitic material having an LTA-type framework structure is selected from the group consisting of Linde Type A (zeolite A), Alpha, [AI-Ge-0]-LTA, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd.
  • Linde Type A, ZK-22, ITQ-29, UZM-9 including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21 , Dehyd.
  • Linde Type A, ZK-22, ITQ-29, UZM-9 including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N- A, LZ-215, ZK-4, ZK-21 , ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof.
  • the first zeolitic material having a BEA-type framework structure is selected from the group consisting of zeolite beta, Tschernichite, [B-Si-0]- * BEA, CIT-6, [Ga-Si-0]- * BEA, Beta polymorph B, SSZ-26, SSZ- 33, Beta polymorph A, [Ti-Si-0]- * BEA, and pure silica beta, including mixtures of two or more thereof, preferably from the group consisting of zeolite beta, CIT-6, Beta polymorph B, SSZ-26, SSZ-33, Beta polymorph A, and pure silica beta, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having a BEA-type frame- work structure comprises zeolite beta, preferably zeolite beta obtained from organotem- plate-free synthesis, wherein more preferably the first zeolitic material having a BEA
  • the first zeolitic material having an M FI-type framework structure is selected from the group consisting of Silicalite, ZSM-5, [Fe-Si-0]-MFI, [Ga-Si-0]-MFI, [As-Si-0]-MFI, AMS-1 B, AZ-1, Bor-C, Encilite, Boralite C, FZ-1, LZ-105, Mutinaite, NU-4, NU-5, TS-1, TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, MnS-1, and FeS-1 , including mixtures of two or more thereof, prefera bly from the group consisting of Silicalite, ZSM-5, AMS-1B, AZ-1, Encilite, FZ-1 , LZ-105, Mutinaite, NU-4, NU-5, TS-1, TSZ, TSZ,
  • the first zeolitic material having an FER-type framework structure is selected from the group consisting of Ferrierite, [Ga- Si-0]-FER, [Si-0]-FER, FU-9, ISI-6, NU-23, Sr-D, ZSM-35, and [B-Si-0]-FER, including mixtures of two or more thereof, preferably from the group consisting of Ferrierite, FU-9, ISI-6, NU-23, and ZSM-35, including mixtures of two or more thereof, wherein more pref erably the first zeolitic material having an FER-type framework structure is Ferrierite.
  • any one of embodiments 1 to 12 wherein the first zeolitic material having an TON-type framework structure is selected from the group consisting of Theta-1 , ZSM- 22, ISI-1, KZ-2, and NU-10, including mixtures of two or more thereof, wherein preferably the first zeolitic material having a TON-type framework structure is ZSM-22.
  • the process of any one of embodiments 1 to 13, wherein the first zeolitic material having an MTT-type framework structure is selected from the group consisting of ZSM-23, EU-13, ISI-4, and KZ-1 , including mixtures of two or more thereof, wherein preferably the first zeolitic material having a MTT-type framework structure is ZSM-23.
  • the first zeolitic material having an MEL-type framework structure is selected from the group consisting of Boralite D, SSZ- 46, and ZSM-11 , including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MEL-type framework structure comprises ZSM-11 , wherein more preferably the first zeolitic material having an MEL-type framework structure is ZSM- 11. 16.
  • the first zeolitic material having an MWW-type framework structure is selected from the group consisting of MCM-22, ERB-1 , ITQ-1, PSH-3, and SSZ-25 and MCM-22, including mixtures of two or more there of, wherein more preferably the first zeolitic material having an MWW-type framework structure comprises MCM-22, wherein more preferably the first zeolitic material having an MWW-type framework structure is MCM-22.
  • first zeolitic material having an MFS-type framework structure comprises ZSM-57, wherein more preferably the first zeolitic material having an MFS-type framework structure is ZSM-57.
  • the second zeolitic material ob tained in (iii) has a CFIA-type framework structure
  • the zeolitic material having a CFIA-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,
  • R 1 , R 2 , and R 3 independently from one another stand for optionally substituted and/or optionally branched (Ci-C 6 )alkyl, preferably (Cr C5)alkyl, more preferably (CrC4)alkyl, more preferably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 1 , R 2 , and R 3 inde pendently from one another stand for optionally substituted methyl or ethyl, preferably un substituted 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 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.
  • any one of embodiments 19 to 21 wherein 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-adamantammonium compounds, preferably one or more N,N,N- tri(Ci-C 3 )alkyl-1-adamantammonium compounds, more preferably one or more N,N,N- tri(Ci-C 2 )alkyl-1-adamantammonium compounds, more preferably one or more N,N,N- tri(Ci-C 2 )alkyl-1-adamantammonium and/or one or more /V,/V,/V-tri(Ci-C 2 )alkyl-1- adamantammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-1-adamantammonium, /
  • 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 consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides.
  • R 1 and R 2 independently from one another stand for optionally substituted and/or optionally branched (CrC 6 )alkyl, preferably (CrC5)alkyl, more preferably (C C )alkyl, more preferably (C C3)alkyl, and more preferably for option ally 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 me thyl or ethyl, wherein more preferably R 1 and R 2 independently from one another stand for optionally substituted methyl, preferably unsubstituted methyl.
  • R 3 stands for optionally substituted and/or optionally branched (C C 6 )alkyl, preferably (CrC )alkyl, more preferably (CrC )alkyl, more preferably (CrC3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R 3 stands for optionally substituted ethyl, preferably un substituted ethyl.
  • R 4 stands for optionally hetero cyclic 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 one of embodiments 24 to 27, wherein 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(Cr C2)alkyl-cyclohexylammonium compounds, more preferably one or more compounds se lected from
  • any one of embodiments 24 to 28, wherein 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 consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides.
  • any one of embodiments 18 to 29, wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 7 to 40, preferably of from 9 to 30, more preferably of from 11 to 25, more preferably of from 13 to 22, more preferably of from 15 to 20, more preferably of from 16 to 19, and more preferably of from 17 to 18.
  • the second zeolitic material ob tained in (iii) has an AEI-type framework structure, wherein preferably the zeolitic material having an AEI-type framework structure is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the second zeolitic material obtained in (iii) comprises SSZ-39, and wherein more preferably the second zeolitic material obtained in (iii) is SSZ-39.
  • R 1 and R 2 independently from one another stand for optionally substituted and/or optionally branched (C C 6 )alkyl, preferably (C C )alkyl, more preferably (CrC 4 )alkyl, more preferably (C C3)alkyl, and more preferably for option ally 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 me thyl or ethyl.
  • R 3 and R 4 form a common derivatized or underivatized, preferably underivatized alkyl chain, preferably a common (C 4 - Cs)alkyl chain, more preferably a common (C 4 - C7)alkyl chain, more preferably a common (C 4 - C 6 )alkyl chain, wherein more preferably said common alkyl chain is a derivatized or un derivatized, preferably underivatized C 4 or C alkyl chain, and more preferably a derivat ized or underivatized, preferably underivatized C5 alkyl chain.
  • the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more ammonium compounds selected from the group consisting of derivatized or underivatized, preferably underivatized /V,/V-di(Ci-C 4 )alkyl-3,5-di(Ci-C 4 )alkylpyrrolidinium compounds, /V,/V-di(Ci-C 4 )alkyl-3,5-di(Ci-C 4 )alkylpiperidinium compounds, /V,/V-di(Ci-C 4 )alkyl-3,5-di(Ci- C 4 )alkylhexahydroazepinium compounds, /V,/V-di(Ci-C 4 )alkyl-2,6-di(C C 4 )alkylpyrrolidinium compounds, //
  • any one of embodiments 33 to 36 wherein the /V,/V-dialkyl-2,6- dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the c/s and trans isomers, wherein preferably the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds comprise one or more ammonium compounds select
  • any one of embodiments 33 to 37 wherein the /V,/V-dialkyl-3,5- dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the c/s and trans isomers, wherein preferably the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more ammonium cation R 1 R 2 R 3 R 4 N + - containing compounds are selected from the group consisting of /V,/V-d
  • any one of embodiments 33 to 38, wherein 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 consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides.
  • any one of embodiments 1 to 41 wherein the one or more structure direct ing agents comprises one or more tetraalkylammonium cation R 1 R 2 R 3 R 4 N + -containing compounds, and wherein the mixture prepared in (i) and heated in (iii) displays an R 1 R 2 R 3 R 4 N + : S1O2 molar ratio of the one or more tetraalkylammonium cations to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1.5, pref erably from 0.1 to 0.8, more preferably from 0.3 to 0.5, more preferably from 0.5 to 0.3, more preferably from 0.7 to 0.2, more preferably from 0.8 to 0.15, more preferably from 0.85 to 0.12, more preferably from 0.9 to 0.11 , and more preferably from 0.95 to 0.1.
  • the framework structure of the first zeolitic material displays a YO 2 : X 2 O 3 molar ratio rang ing from 5 to 120, preferably from 8 to 80, more preferably from 10 to 50, more preferably from 15 to 40, more preferably from 20 to 30, more preferably from 22 to 28, and more preferably from 24 to 26.
  • volume of the continuous flow reactor is in the range of from 50 cm 3 to 75 m 3 , preferably from 55 cm 3 to 3 m 3 , more preferably from 60 cm 3 to 1 m 3 , more preferably from 65 cm 3 to 0.7 m 3 , more preferably from 70 cm 3 to 0.3 m 3 , more preferably from 75 cm 3 to 0.1 m 3 , more preferably from 80 to 70,000 cm 3 , more preferably from 85 to 50,000 cm 3 , more preferably from 90 to 30,000 cm 3 , more preferably from 95 to 10,000 cm 3 , more preferably from 100 to 7,000 cm 3 , more preferably from 105 to 5,000 cm 3 , more preferably from 110 to 3,000 cm 3 , more preferably from 115 to 1 ,000 cm 3 , more preferably from 120 to 700 cm 3 , more preferably from 125 to 500 cm 3 , more preferably from 130 to 350 cm 3 , more preferably from 135 to 250 cm 3 ,
  • 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, a continuously oscillating baffled reactor, and combina tions thereof, wherein more preferably the continuous flow reactor is a plain tubular reac tor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor.
  • the continuous flow reactor is a tubular reactor, and wherein at least a portion of the tubular reactor is of a regular cylindri cal 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 4 to 500 mm, more preferably from 4.5 to 200 mm, more preferably from 4.5 to 100 mm, more preferably from 5 to 50 mm, more preferably from 5 to 30 mm, more preferably from 5.5 to 15 mm, more preferably from 5.5 to 10 mm, more preferably from 6 to 8 mm, and more preferably from 6 to 6.5 mm.
  • any one of embodiments 1 to 48, 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 prefer ably from 1 to 1 ,000 m more preferably from 2 to 500 m more preferably from 3 to 200 m, more preferably from 4 to 100 m, more preferably from 4.5 to 50 m, more preferably from 4.5 to 30 m, more preferably from 4 to 20 m, more preferably from 4 to 15 m, more prefer ably from 4.5 to 10 m, and more preferably from 4.5 to 5.5 m.
  • the wall of the continuous flow reactor 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 combi nations and/or alloys of two or more thereof, preferably from the group consisting of Ta,
  • the metallic material comprises a nickel alloy, a nickel-molybdenum al loy, and more preferably a nickel-molybdenum-chromium alloy.
  • any one of embodiments 1 to 50 wherein 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, preferably 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).
  • 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, preferably from the group consisting of fluorinated polyethylenes and mixtures
  • any one of embodiments 1 to 56 wherein the framework of the second zeolitic material obtained in (iii) contains substantially no phosphorous, wherein preferably the second zeolitic material obtained in (iii) contains substantially no phosphorous and/or phosphorous containing compounds.
  • continuous feeding in (ii) is per formed at a liquid hourly space velocity in the range of from 0.05 to 5 IT 1 , preferably from 0.1 to 3 IT 1 , more preferably from 0.2 to 2 IT 1 , more preferably from 0.3 to 1.5 IT 1 , more preferably from 0.4 to 1.2 IT 1 , more preferably from 0.5 to 1 IT 1 , and more preferably from 0.7 to 0.8 IT 1 .
  • any one of embodiments 1 to 60 wherein in (iii) the mixture is heated un der autogenous pressure, wherein preferably the pressure is in the range of from 0.5 to 15 MPa, more preferably in the range of from 1 to 10 MPa, more preferably from 1.5 to 8 MPa, more preferably from 2 to 6 MPa, more preferably from 2.5 to 5.5 MPa, more prefer ably from 3 to 5 MPa, more preferably from 3.5 to 4.5 MPa, and more preferably from 3.8 to 4.2 MPa. 62.
  • 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, wa ter, and mixtures thereof, wherein more preferably the liquid comprises water, and where in 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, wa ter, and mixtures thereof, wherein more preferably the liquid comprises water, and where in more preferably water is used as the liquid, preferably deionized water.
  • drying in (vii) is effected at a temperature in the range from 50 to 220 °C, preferably from 70 to 190 °C, more preferably from 80 to 170 °C, more preferably from 90 to 150 °C, more preferably from 100 to 140 °C, and more preferably from 110 to 130 °C.
  • the lubricating agent comprises one or more fluorinated polymers, preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyethers.
  • the one or more metal ions are selected from the group consisting of ions of alkaline earth metal elements and/or transition metal elements, preferably from the group consisting of ions of metals selected from group Mg, Sr, Zr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more there of, more preferably from the group consisting of Mg, Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Cr, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, and even more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof.
  • the mixture prepared in (i) fur ther comprises seed crystals, wherein preferably the seed crystals comprise a zeolitic ma terial having a CFIA-, AEI-, GME-, and/or M FI-type framework structure, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-type and/or an AEI-type framework structure, wherein more preferably the zeolitic material of the seed crystals is obtainable and/or obtained according to any one of embodiments 1 to 79. 81.
  • zeolitic material having a CHA-type frame work structure comprised 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,
  • zeolitic material having an AEI-type framework structure comprised in the seed crystals is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein preferably the zeolitic material having an AEI-type framework structure comprised in the seed crys tals is SSZ-39.
  • any one of embodiments 80 to 82, wherein the amount of seed crystals in the mixture prepared in (i) and heated in (iii) ranges from 0.1 to 25 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material, preferably from 0.5 to 15 wt.-%, more preferably from 1 to 10 wt.-%, more preferably from 2 to 7 wt.-%, more preferably from 3 to 6 wt.-%, and more preferably from 4 to 5 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material.
  • zeolitic material of embodiment 84 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,
  • zeolitic material of embodiment 84 wherein the zeolitic material has an AEI-type framework structure, wherein preferably the zeolitic material is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the zeolitic material comprises SSZ-39, and wherein more preferably the zeolitic material is SSZ-39.
  • a zeolitic material according to any one of embodiments 84 to 86 as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support, 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 oxi dation 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 conversion reactions, preferably in the conversion of alcohols to olefins, and more preferably in methanol to ole fin (MTO) catalysis; more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NO c , and more preferably for the selective catalytic reduction (SCR) of nitrogen ox ides NO
  • SCR selective
  • Reference Example A Production of an AEI-type zeolite from zeolite Y in a batch process
  • Reference Example B Production of an AEI-type zeolite from zeolite Y in a batch process
  • a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %).
  • 9.380 g of water glass 25 wt.% S1O2, 6.5 wt.% Na 2 0 and 68.5 wt.% water; Wako
  • 0.280 g AEI seed (provided by BASF), which equals to 10 wt.% of the S1O2, were added.
  • the final synthesis gel which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20: 455 H2O (plus 10 wt.% seed on the basis of the S1O2), was transferred to an autoclave.
  • the synthesis was conducted in an air-circulating oven at 210 °C under rotation of the autoclave with 60 rpm.
  • the crystallinity of the resulting product was determined according to XRD as be ing 87 % of AEI-type zeolite.
  • Reference Example C Production of an AEI-type zeolite from zeolite Y in a batch process
  • the synthesis was conducted in an air-circulating oven at 160 °C for 24 h, and the autoclave was rotated with a speed of 20 rpm.
  • the crystallinity of the resulting product was determined according to XRD as being 94 % of AEI-type zeolite, whereby traces of an impurity phase was observed.
  • Reference Example D Production of an AEI-type zeolite from zeolite Y in a batch process
  • a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %).
  • 9.380 g of water glass 25 wt.% S1O2, 6.5 wt.% Na 2 0 and 68.5 wt.% water; Wako
  • 0.280 g AEI seed (provided by BASF), which equals to 10 wt.% of the S1O2, was added.
  • the final synthesis gel which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20: 455 H2O (plus 10 wt.% seed on the basis of the S1O2).
  • 4.5 g of this precursor was trans ferred to the tubular reactor, which was placed in an air-circulating oven at 210 °C and rotated with a speed of 60 rpm over a reaction time of 60 min.
  • the crystallinity of the resulting product was determined according to XRD as being 96 % of AEI-type zeolite.
  • the synthesis precursor was treated with a planetary centrifugal mixer (Thinky planetary centrifugal mixer using S1 3 N 4 balls) for 1 min un der a spinning speed of 2000 rpm. And, this treatment cycle was repeated for 6 times. 4.5 g of the final precursor was transferred to the tubular reactor, which was placed in an air-circulating oven at 210 °C and rotated with a speed of 60 rpm over a reaction time of 40 min. The crystal linity of the resulting product was determined according to XRD as being 94 % of AEI-type zeo lite.
  • Reference Example F Production of an GME-type zeolite from zeolite Y in a batch process
  • the synthesis was conducted in an air-circulating oven at 200 °C for 3 h, with a rotation speed of 10 rpm.
  • the resulting product was identified by XRD as be ing a GME-type zeolite.
  • small amounts of AEI-type zeolite were observed.
  • the slurry was stirred at room temperature for 6 h, and thereafter the slurry was filtrated to re cover the K-form zeolite, which was thoroughly washed and dried.
  • the dried K-form zeolite was calcined twice (the sample was washed with hot water in between), and the temperature pro grams for the two calcination procedures was as follows:
  • Calcination procedure 1 heating with a heating ramp of 0.1 °C/min to a temperature of 90 °C over 11 h; heating with a heating ramp of 0.5 °C/min over additional 14 h to a temperature of 500 °C;
  • Calcination procedure 2 heating with a heating ramp of 1 °C/min to a temperature of 150 °C over 11 h; keeping a temperature of 150 °C until a total heating time of 5 h was applied; heating with a heating ramp of 1 °C/min until a temperature of 500 °C is reached; keeping a temperature of 500 °C until a total heating time of 18 h was applied.
  • the K-form of the prepared GME-type zeolite was prepared.
  • Example 1 Continuous production of an AEI-type zeolite from zeolite Y a) Preparation of a synthesis gel
  • AEI-type zeolites purchased from CCG
  • the synthesis gel comprised 24.61 weight-% of zeolite Y, 25.06 weight-% of TMPOH, 49.11 weight-% of sodium hydroxide and 1.23 weight-% of AEI-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.098 TMPOH : 0.355 Na : 10.31 H 2 0.
  • the synthesis gel as prepared according to a) was used. Further, a Teflon tube was used as reactor having a volume of 160 ml and a di ameter of 6.4 mm. The reactor had a length of 6 m, whereby the reactor could be heated over a length of about 5 m. The reactor and the lining to the reactor was filled with about 200 ml per- fluorinated decalin, further a receiver tank was filled with the synthesis gel as prepared accord ing to a). To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 5 bar using nitrogen gas, while the reactor was heated up to a temperature of 200 °C.
  • the temperature of the reactor was recorded using four thermocouples fixed on the outside of the reactor tube.
  • the temperature measured at the reactor inlet was 185 °C, in the middle 202 °C, at the reactor exit 200 °C, and at the heat- exchanger positioned downstream of the reactor 24 °C.
  • the pressure was recorded on top of the receiver tank and also downstream at the exit of the reactor using a pressure indi cator. After reaching the desired temperature, the pressure was increased to 41 bar.
  • Down stream of the heat-exchanger positioned downstream of the reactor a tube with a volume of 1.3 ml is located.
  • a first ball valve is positioned at the intersection of the reactor and the tube and a second ball valve at the end of the tube.
  • the first ball valve opens shortly every 60 seconds allowing to release a volume of 1.3 ml of the zeo lite product suspension from the reactor. Once the first ball valve is closed, the second ball valve opens allowing these 1.3 ml of product suspension to exit the reactor setup into a sepa rate vessel where it is collected. This results in a continuous flow of 1.3 ml/60 s. After a reaction time of about 130 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture was about 130 min.
  • the continuously reacted mixture containing the zeolitic product was filtered and the resulting solids washed with deionized water, subsequently dried at 120 °C for 4 h and then calcined. Calcination was performed by heating the solids to a temperature of 450 °C within 7 h, holding said temperature for 2 h, further heating to a temperature of 500 °C within 30 minutes, holding the temperature of 500 °C for 2 h, further heating to a temperature of 550 °C, and hold ing the temperature of 550 °C for 2 h. According to XRD measurement, the obtained product had a crystallinity of 90 %, of which 66 % were AEI-type zeolite, 31 % MOR-type zeolite, and 3 % ZSM-5 zeolite.
  • Example 2 Continuous production of an AEI-type zeolite from zeolite Y
  • Example 1 Considering the reactor set-up according to Example 1 the continuous production of an AEI- type zeolite was performed starting from zeolite y. A synthesis gel prepared according to Exam ple 1 a) was used. Further, the following conditions were applied in b). The continuous flow was set to 1 .3 ml/45 s. Thus, the first ball valve opens shortly every 45 seconds during the reaction process allowing to release a volume of 1 .3 ml of the zeolite product suspension from the reac tor. The retention time of the reaction mixture in the reactor was about 90 min.
  • the obtained product had a crystallinity of 90 %, of which 65 % were AEI-type zeolite, 33 % MOR-type zeolite, and 2 % ZSM-5 zeolite.
  • Example 3 Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
  • the synthesis gel comprised 16.34 weight-% of zeolite Y, 24.20 weight-% of TM Ad AO H, 58.80 weight-% of sodium hydroxide and 0.66 weight-% of CFIA-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOFI : 0.389 Na : 18.27 FI2O. b) Continuous preparation of a CFIA-type zeolite using the synthesis gel prepared under a)
  • a Teflon tube was used as reactor having a volume of 160 ml and a diameter of 6.4 mm.
  • the reactor had a length of 6 m, whereby the reactor could be heated over a length of about 5 m.
  • the reactor and the lining to the reactor was filled with about 200 ml perfluorinated decalin, further a receiver tank was filled with the synthesis gel as prepared according to a).
  • the synthesis gel was introduced into the reactor and a pressure was set to 3 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C.
  • the temperature of the reactor was recorded using four thermo couples fixed on the outside of the reactor tube.
  • the temperature measured at the reactor inlet was 172 °C, of the middle 195 °C, of the reactor exit 193 °C, and of the heat-exchanger posi tioned downstream of the reactor 24 °C.
  • the pressure was recorded on top of the receiver tank and also downstream at the exit of the reactor using a pressure indicator. After reaching the desired temperature, the pressure was increased to 40.6 bar.
  • Downstream of the heat-exchanger positioned downstream of the reactor a tube with a volume of 1.3 ml is located.
  • a first ball valve is positioned at the intersection of the reactor and the tube and a second ball valve at the end of the tube.
  • the first ball valve opens shortly every 36 seconds allowing to release a volume of 1.3 ml of the zeolite product suspension from the reactor. Once the first ball valve is closed, the second ball valve opens allowing these 1.3 ml of product suspension to exit the reactor setup into a separate vessel where it is collected. This results in a continuous flow of 1.3 ml/36 s. After a reaction time of about 50 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture in the reactor was about 70 min.
  • the continuously reacted mixture containing the zeolitic product was filtered and the resulting solids washed with deionized water, subsequently dried at 120 °C for 4 h and then calcined. Calcination was performed by heating the solids to a temperature of 450 °C within 7 h, holding said temperature for 2 h, further heating to a temperature of 500 °C within 30 minutes, holding the temperature of 500 °C for 2 h, further heating to a temperature of 550 °C, and hold ing the temperature of 550 °C for 2 h. According to XRD measurement, the obtained product had a crystallinity of 90 %, of which 100 % were CHA-type zeolite.
  • the resulting product had a Si content of 33 weight-%, an Al content of 3.7 weight-%, a Na content of 1.5 weight-%, and a C content of 0.03 weight-%.
  • the BET specific surface area was determined as being 637 m 2 /g.
  • Example 4 Continuous production of a CHA-type zeolite from zeolite Y Considering the reactor set-up according to Example 3 the production of a CHA-type zeolite was performed starting from zeolite Y. In particular, the following condition was applied in b). To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 3 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C. The tem perature of the reactor was recorded using four thermocouples fixed on the outside of the reac tor tube.
  • the temperature measured at the reactor inlet was 172 °C, in the middle 195 °C, at the reactor exit 193 °C, and at the heat-exchanger positioned downstream of the reactor 24 °C.
  • the pressure was determined as being 40.6 bar.
  • the continuous flow was set to 1.3 ml/10 s.
  • the first ball valve opens shortly every 10 seconds during the reaction process allowing to re lease a volume of 1.3 ml of the zeolite product suspension from the reactor.
  • the retention time of the reaction mixture in the reactor was about 20 min.
  • the obtained product had a crystallinity of 95 %, of which 100 % were CHA-type zeolite.
  • the resulting product had a Si con tent of 34 weight-%, an Al content of 3.7 weight-%, a Na content of 1.5 weight-%, and a C con tent of 0.03 weight-%.
  • the BET specific surface area was determined as being 638 m 2 /g.
  • Example 5 Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
  • 1175.7 g of an aqueous solution of sodium hydroxide (6 weight-% of sodium hydroxide powder purchased from Sigma Aldrich in deionized water) were mixed with 483.9 g of an aqueous solu tion of Trimethyladamantylammonium hydroxide (20 weight-% in water; TMAdAOH; BASF) in a beaker.
  • 326.9 g of zeolite Y (DY-32 from Quilu having a molar ratio of SiC>2:Al2C>3 of 25) were added thereto under stirring.
  • 13.5 g of CHA-type zeolites (BASF) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel.
  • the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOH : 0.389 Na : 18.27 H 2 0. b) Continuous preparation of a CHA-type zeolite using the synthesis gel prepared under a)
  • a CHA-type zeolite was preformed starting from zeolite Y.
  • the following conditions were applied.
  • the synthesis gel was introduced into the reactor and a pressure was set to 5 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C.
  • the tempera ture of the reactor was recorded using four thermocouples fixed on the outside of the reactor tube.
  • the temperature measured at the reactor inlet was 160 °C, in the middle 192.2 °C, at the reactor exit 191 °C, and at the heat-exchanger positioned downstream of the reactor 24 °C.
  • the pressure was determined as being 40.5 bar.
  • the continuous flow was set to 1.3 ml/17 s.
  • the first ball valve opens shortly every 17 seconds during the reaction process allowing to re- lease a volume of 1 .3 ml of the zeolite product suspension from the reactor.
  • the decalin was removed from the reactor and collection of the product mixture could be started.
  • the retention time of the reaction mixture in the reactor was about 34 min.
  • the obtained product had a crystallinity of 100 %, of which 100 % were CHA-type zeolite.
  • the resulting product had a Si content of 36.2 weight-%, an Al content of 3.9 weight-%, a Na content of 1.7 weight-%, and a C content of 0.06 weight-%.
  • the BET specific surface area was determined as being 580 m 2 /g.
  • Example 6 Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
  • CHA-type zeolites (BASF) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel.
  • the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOH : 0.389 Na : 18.27 H 2 0.
  • the synthesis gel comprised 17.35 weight-% of zeolite Y, 19.51 weight-% of TMAdA-SC>4, 62.44 weight-% of sodium hydroxide and 0.70 weight-% of CHA-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdA-SC>4 : 0.389 Na : 17.12 H 2 0. b) Continuous preparation of an CHA-type zeolite using the synthesis gel prepared under a)
  • the first ball valve opens shortly every 71 seconds during the reaction process allowing to release a volume of 1.3 ml of the zeolite product suspension from the reactor.
  • a reaction time of about 120 min the decalin was removed from the reactor and collection of the product mixture could be started.
  • the retention time of the reaction mixture in the reactor was about 120 min.
  • the obtained product had a crystallinity of 94 %, of which at least 99 % were CHA-type zeolite and less than 1 % zeolite Y.
  • the resulting product had a Si content of 36 weight-%, an Al content of 3.5 weight-%, a Na con tent of 1.4 weight-%, a C content of 0.1 weight-%, and a S content of less than 0.01 weight-%.
  • Example 7 Catalytic testing in selective catalytic reduction (SCR)
  • Impregnation i A sample of uncalcined zeolite powder was impregnated with a Cu nitrate solution using incipient wetness technique; ii. The impregnated sample was sealed and stored for 20 h at 50 °C in an oven; iii. The sample was then dried; iv. Subsequent calcination of a sample was conducted for 5 h at 450 °C.
  • Shaping i A slurry was prepared from a sample obtained from a.iv); ii.
  • the slurry was mixed with pre-milled alumina (TM 100/150; ball-milled with 500 rpm for 10 min) in a weight ratio of the sample to alumina of 70 : 30; iii.
  • the mixture was dried under stirring; iv.
  • the mixture was calcined for 1 h at 550 °C; v.
  • the obtained solids were crushed and sieved to obtain a fraction with an average particle size in the range of 250-500 pm.
  • Aging i. Fresh (as obtained according to b)); ii. Aged for 50 h at a temperature of 650 °C in air comprising 10 % steam; iii. Aged for 16 h at a temperature of 820 °C, 10% steam/air.
  • samples were used being either i. fresh, ii. aged for 50 h at 650 °C, or iii. aged for 16 h at 820 °C in accordance with the aging conditions under c).
  • the following condi tions were applied for the SCR catalytic testing:
  • the feed stream was set to a GFISV of 80000 IT 1 , whereby the feed stream comprised 500 ppm NO, 500 ppm N H3, 5 % H2O, 10 % O2, balanced with N2
  • Figure 1 shows the catalytic performance of the zeolitic materials of the present invention according to Examples 3, 5 and 6, respectively.
  • the temperature [°C] is shown on the abscissa, and the NO x conversion [%] on the ordinate.
  • Circles indicate meas urements in fresh state, diamonds indicate measurements after aging for 50 h at 650 °C, and triangles indicate measurements after aging for 16 h at 820 °C.
  • Figure 2 shows the catalytic performance of the zeolitic materials of the present invention according to Examples 3, 5 and 6, respectively.
  • the upper diagram relates to the NO x conversion determined at 575 °C and the lower diagram relates to the NOx conversion determined at 200 °C.
  • the NO x conversion [%] for the fresh sample is shown on the left, for the sample aged for 50 h at 650 °C in the mid dle, and for the sample aged for 16 h at 820 °C on the right.
  • Figure 3 shows the N O make for Examples 3, 5, and 6, respectively.
  • the temperature [°C] is shown on the abscissa, and the N O make [ppm] on the ordinate.
  • Circles indicate measurements in fresh state, diamonds indicate measurements after aging for 50 h at 650 °C, and triangles indicate measurements after aging for 16 h at 820 °C.

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Abstract

The present invention relates to a continuous process for the preparation of a zeolitic material comprising SiO2 and X2O3 in its framework structure comprising interzeolitic conversion, a zeolitic material obtainable and/or obtained according to said process, and a use of said zeolitic material as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support.

Description

Process for Continuous Interzeolitic Conversion
TECHNICAL FIELD
The present invention relates to a continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure comprising interzeolitic conversion, a zeo litic material obtainable and/or obtained according to said process, and a use of said zeolitic material as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support.
INTRODUCTION
Zeolites are widely used in the technical field of emission control. However, the synthesis there of usually requires long processing times and high investments since zeolites are typically made in batch processes which take a long synthesis time, thus, a large capacity of resources, espe cially reactor allocation.
Y. Hu et al. disclose in Microporous and Mesoporous Materials 2018, 27, pp. 149-154 an ultra fast hydrothermal synthesis of TS-1 zeolite without extra-framework titanium species in a con tinuous flow system particularly using a tubular reactor. As a precursor solution, a mixture com prising tetrapropylammonium hydroxide, tetra-butyl orthotitanate, tetraethyl orthosilicate and water was used.
CN 109336131 A relates to a method for rapidly synthesizing an AEI-type molecular sieve, the method comprising mixing of a templating agent, a water source, an alkali source, an aluminum source, a silicon source and seed crystals. The method further comprises a step of high shear aging of the synthesis mixture and crystallizing thereof at 130 to 150 °C for 3 to 24 h.
CN 109319804 A relates to a preparation method for a SSZ-13 zeolite under super/subcritical conditions, in particular at a temperature in the range of from 270 to 380 °C and a pressure in the range of from 12 to 35 MPa. Further, CN 109319804 A discloses a device for the continuous preparation of an SSZ-13 zeolite.
DE 3029787 A1 relates to a continuous process for preparing zeolites. EP 0402801 A2 relates 20 to a method for the preparation of crystalline and zeolitic aluminosilicates. Further, US 4374093 discloses a continuous-stream zeolite crystallization apparatus particularly comprising a combination of a tubular reactor, a central stirring element, ingress and egress means, and recovery vessels. Furthermore, US 6656447 B1 discloses a continuous process for the prepara tion of a molecular sieve. Thus, it was an object to provide an improved process for preparing a zeolitic material, in partic ular with respect to the process efficiency. In particular, it was an object of the present invention to provide a process for preparing a zeolitic material having a significantly reduced synthesis time.
Said object was surprisingly solved by the present invention where it has been particularly found that when using a zeolitic material having a distinct framework structure type in a continuous process a zeolitic material having a different framework structure type can be obtained especial ly in a comparatively reduced synthesis time. Thus, a zeolitic material can be prepared via the process of the present invention within a comparatively reduced synthesis time. In particular, the synthesis time can be reduced from more than 20 h according to a common preparation process to less than 1 h according to the process of the present invention. As an example, the present invention provides a method for preparing a CHA-type zeolite via a continuous interzeo- litic conversion. In particular, CHA-type zeolites are commonly known for their broad field of application, in particular as a catalytic material.
Therefore, the present invention relates to a continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein X stands for a trivalent element, said process comprising
(i) preparing a mixture comprising one or more solvents, one or more structure directing agents, and a first zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein preferably the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 independently from one another stand for alkyl;
(ii) continuously feeding the mixture prepared in (i) into a continuous flow reactor; and
(iii) heating the mixture in the continuous flow reactor for obtaining a second zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein the second zeolitic material obtained in (iii) has a different type of framework structure than the first zeolitic material contained in the mixture prepared in (i), wherein the mixture is heated to a temperature in the range of from 70 to 300 °C; wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture pre pared in (i) is in the range of from 3 to 50, preferably of from 6 to 35, more preferably of from 8 to 25, more preferably of from 10 to 20, more preferably of from 11 to 17, more preferably of from 12 to 16, and more preferably of from 13 to 15.
No restriction applies to the framework structure type of the first zeolitic material such that it can have any known framework structure type. It is preferred that the first zeolitic material has an FAU-, GIS-, MOR-, LTA-, FER-, TON-, MTT-, BEA-, MEL-, MWW-, MFS-, and/or M FI-type framework structure, more preferably an FAU-, GIS-, BEA-, and/or M FI-type framework struc ture, more preferably an FAU- and/or BEA-type framework structure, and more preferably an FAU-type framework structure. Also, no restriction applies to the framework structure type of the second zeolitic material such that it can have any known framework structure type. It is preferred that the second zeolitic ma terial has a CHA-, AEI-, GME-, and/or M FI-type framework structure, preferably a CHA- and/or AEI-type framework structure.
It is preferred that the one or more solvents in the mixture prepared in (i) comprise water, pref erably distilled water, wherein more preferably water is contained as the one or more solvents in the mixture prepared in (i), preferably distilled water.
It is preferred that the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein said at least one source for OH- more preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH- is sodium hydroxide.
It is particularly preferred that the first zeolitic material has an FAU-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an FAU-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of ZSM-3, Faujasite, [Al-Ge- 0]-FAU, CSZ-1 , ECR-30, Zeolite X, Zeolite Y, LZ-210, SAPO-37, ZSM-20, Na-X, US-Y, Na-Y, [Ga-Ge-0]-FAU, Li-LSX, [Ga-AI-Si-0]-FAU, and [Ga-Si-0]-FAU, including mixtures of two or more thereof, more preferably from the group consisting of ZSM-3, Faujasite, CSZ-1 , ECR-30, Zeolite X, Zeolite Y, LZ-210, ZSM-20, Na-X, US-Y, Na-Y, and Li-LSX, including mixtures of two or more thereof, more preferably from the group consisting of Faujasite, Zeolite X, Zeolite Y, Na-X, US-Y, and Na-Y, including mixtures of two or more thereof, more preferably from the group consisting of Faujasite, Zeolite X, and Zeolite Y, including mixtures of two or more there of, wherein more preferably the first zeolitic material having an FAU-type framework structure comprises zeolite X and/or zeolite Y, preferably zeolite Y.
It is more particularly preferred that the first zeolitic material having an FAU-type framework structure is zeolite X and/or zeolite Y, more preferably zeolite Y.
It is particularly preferred that the first zeolitic material has an GIS-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an GIS-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of zeolite P, TMA-gismondine, Na- P1 , Amicite, Gobbinsite, High-silica Na-P, Na-P2, SAPO-43, Gismondine, MAPSO-43, MAPSO- 43, Garronite, Synthetic amicite, Synthetic garronite, Synthetic gobbinsite, [Ga-Si-Oj-GIS, Syn thetic Ca-garronite, Low-silica Na-P (MAP), [AI-Ge-Oj-GIS, including mixtures of two or more thereof, more preferably from the group consisting of zeolite P, TMA-gismondine, Na-P1 , Amici te, Gobbinsite, High-silica Na-P, Na-P2, Gismondine, Garronite, Synthetic amicite, Synthetic garronite, Synthetic gobbinsite, [Ga-Si-Oj-GIS, Synthetic Ca-garronite, [AI-Ge-Oj-GIS, including mixtures of two or more thereof, more preferably from the group consisting of zeolite P, TMA- gismondine, Na-P1 , Amicite, Gobbinsite, High-silica Na-P, Na-P2, Gismondine, Garronite, Syn thetic amicite, Synthetic garronite, Synthetic gobbinsite, Synthetic Ca-garronite, including mix tures of two or more thereof, more preferably from the group consisting of zeolite P, Na-P1 , High-silica Na-P, Na-P2, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having a GIS-type framework structure comprises zeolite P.
It is more particularly preferred that the first zeolitic material having a GIS-type framework struc ture is zeolite P.
It is particularly preferred that the first zeolitic material has an MOR-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an MOR-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Mordenite, [Ga-Si-0]-MOR, Maricopaite, Ca-Q, LZ-211, Na-D, RMA-1, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MOR-type framework structure comprises Mordenite.
It is more particularly preferred that the first zeolitic material having an MOR-type framework structure is Mordenite.
It is particularly preferred that the first zeolitic material has an LTA-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an LTA-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Linde Type A (zeolite A), Alpha, [AI-Ge-0]-LTA, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd. Linde Type A (dehyd. zeo lite A), ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd. Linde Type A, ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21, Dehyd. Linde Type A, ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21 , ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof.
It is particularly preferred that the first zeolitic material has an BEA-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an BEA-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of zeolite beta, Tschernichite, [B-Si-0]-*BEA, CIT-6, [Ga-Si-0]-*BEA, Beta polymorph B, SSZ-26, SSZ-33, Beta polymorph A, [Ti-Si-0]-*BEA, and pure silica beta, including mixtures of two or more thereof, more preferably from the group consisting of zeolite beta, CIT-6, Beta polymorph B, SSZ-26, SSZ-33, Beta pol ymorph A, and pure silica beta, including mixtures of two or more thereof, wherein more prefer ably the first zeolitic material having a BEA-type framework structure comprises zeolite beta, preferably zeolite beta obtained from organotemplate-free synthesis. It is more particularly preferred that the first zeolitic material having a BEA-type framework struc ture is zeolite beta, more preferably zeolite beta obtained from organotemplate mediated syn thesis or obtained from organotemplate-free synthesis, and more preferably zeolite beta ob tained from organotemplate-free synthesis.
It is particularly preferred that the first zeolitic material has an M FI-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an M FI-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Silicalite, ZSM-5, [Fe-Si-0]-MFI, [Ga-Si-0]-MFI, [As-Si-0]-MFI, AMS-1 B, AZ-1 , Bor-C, Encilite, Boralite C, FZ-1 , LZ-105, Mu- tinaite, NU-4, NU-5, TS-1 , TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, MnS- 1 , and FeS-1 , including mixtures of two or more thereof, more preferably from the group consist ing of Silicalite, ZSM-5, AMS-1 B, AZ-1 , Encilite, FZ-1 , LZ-105, Mutinaite, NU-4, NU-5, TS-1 , TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, and ZMQ-TB, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an M FI-type framework structure comprises Silicalite and/or ZSM-5, preferably ZSM-5.
It is more particularly preferred that the first zeolitic material having an M FI-type framework structure is zeolite Silicalite and/or ZSM-5, preferably ZSM-5.
It is particularly preferred that the first zeolitic material has an FER-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an FER-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Ferrierite, [Ga-Si-0]-FER, [Si-0]-FER, FU-9, ISI-6, NU-23, Sr-D, ZSM-35, and [B-Si-0]-FER, including mixtures of two or more thereof, more preferably from the group consisting of Ferrierite, FU-9, ISI-6, NU-23, and ZSM-35, including mixtures of two or more thereof.
It is more particularly preferred that the first zeolitic material having an FER-type framework structure is Ferrierite.
It is particularly preferred that the first zeolitic material has an TON-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an TON-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Theta-1 , ZSM-22, ISI-1 , KZ-2, and NU-10, including mixtures of two or more thereof.
It is more particularly preferred that the first zeolitic material having a TON-type framework structure is ZSM-22.
It is particularly preferred that the first zeolitic material has an MTT-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an MTT-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of ZSM-23, EU-13, ISI-4, and KZ-1 , including mixtures of two or more thereof.
It is more particularly preferred that the first zeolitic material having a MTT-type framework structure is ZSM-23.
It is particularly preferred that the first zeolitic material has an MEL-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an MEL-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of Boralite D, SSZ-46, and ZSM-11 , including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MEL-type framework structure comprises ZSM-11.
It is more particularly preferred that the first zeolitic material having an MEL-type framework structure is ZSM-11.
It is particularly preferred that the first zeolitic material has an MWW-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an MWW-type framework structure, it is preferred that the first zeolitic material is selected from the group consisting of MCM-22, ERB-1 , ITQ-1 , PSH-3, and SSZ-25 and MCM-22, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MWW-type framework structure comprises MCM- 22.
It is more particularly preferred that the first zeolitic material having an MWW-type framework structure is MCM-22.
It is particularly preferred that the first zeolitic material has an MFS-type framework structure, also in combination with another framework structure type as an intergrowth zeolitic material. In the case where the first zeolitic material has an MFS-type framework structure, it is preferred that the first zeolitic material comprises ZSM-57.
It is more particularly preferred that the first zeolitic material having an MFS-type framework structure is ZSM-57.
It is particularly preferred that the second zeolitic material obtained in (iii) has an CHA-type framework structure, also in combination with another framework structure type as an inter growth zeolitic material. In the case where the second zeolitic material obtained in (iii) has an CHA-type framework structure, it is preferred that the second zeolitic material obtained in (iii) has 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 con sisting 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 second zeolitic mate rial obtained in (iii) comprises chabazite and/or SSZ-13, preferably SSZ-13.
It is more particularly preferred that the second zeolitic material obtained in (iii) is chabazite and/or SSZ-13, more preferably SSZ-13.
In the case where the second zeolitic material obtained in (iii) has an CHA-type framework structure, it is preferred that the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, more preferably for 1 -adamantyl.
In the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, it is preferred that R1, R2, and R3 independently from one another stand for optionally substitut ed and/or optionally branched (CrC6)alkyl, more preferably (CrC5)alkyl, more preferably (Ci- C4)alkyl, more preferably (Ci-Cs)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R1 , R2, and R3 independently from one another stand for option ally substituted methyl or ethyl, preferably unsubstituted methyl or ethyl, wherein more prefera bly R1, R2, and R3 independently from one another stand for optionally substituted methyl, pref erably unsubstituted methyl.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, it is preferred that R4 stands for optionally heterocyclic and/or optionally substituted adamantyl and/or benzyl, more preferably for optionally heterocyclic and/or optionally substituted 1- adamantyl, more preferably for optionally substituted adamantyl and/or benzyl, more preferably for optionally substituted 1 -adamantyl, more preferably for unsubstituted adamantyl and/or ben zyl, and more preferably for unsubstituted 1-adamantyl.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds comprise one or more /V,/V,/V-tri(Ci-C4)alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C3)alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V-tri(CrC2)alkyl-1-adamantammonium compounds, more preferably one or more /V,/V,/V-tri(Ci-C2)alkyl-1-adamantammonium and/or one or more /V,/V,/V-tri(C C2)alkyl-1- adamantammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-1-adamantammonium, /V,/V-diethyl-/V-methyl-1-adamantammonium, N,N- dimethyl-/V-ethyl-1-adamantammonium, /V,/V,/V-trimethyl-1-adamantammonium compounds, 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,/V-trimethyl-1- adamantammonium compounds.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds are salts, more preferably one or more salts selected from the group consisting of hal ides, 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 sulfates, and more preferably tetraalkylammonium hydroxides.
Alternatively, it is preferred that the one or more structure directing agents comprises 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 the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that R1 and R2 independently from one another stand for optionally substituted and/or optionally branched (CrC6)alkyl, more preferably (Ci-C5)alkyl, more preferably (CrC^alkyl, more prefera bly (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 independent ly from one another stand for optionally substituted methyl, preferably unsubstituted methyl.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that R3 stands for optionally substituted and/or optionally branched (Ci-C6)alkyl, more preferably (Ci-C5)alkyl, more preferably (CrC^alkyl, more preferably (Ci-C3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R3 stands for optionally substi tuted ethyl, preferably unsubstituted ethyl. Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that R4 stands for optionally heterocyclic and/or optionally substituted 5- to 8-membered cyclo alkyl, more 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 sub stituted 6-membered cycloalkyl, preferably optionally substituted cyclohexyl, and more prefera bly unsubstituted cyclohexyl.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for cycloalkyl, 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, more 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 /V,/V,/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 compounds.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, more preferably one or more salts selected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more preferably from the group con sisting of bromide, chloride, hydroxide, sulfate, and mixtures of two or more thereof, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides.
In the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, or where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one an other stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that the FI2O : S1O2 mo lar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 7 to 40, more preferably of from 9 to 30, more preferably of from 11 to 25, more preferably of from 13 to 22, more preferably of from 15 to 20, more preferably of from 16 to 19, and more preferably of from 17 to 18.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 inde pendently from one another stand for alkyl, and wherein R4 stands for adamantyl and/or benzyl, or where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, and R3 independently from one an other stand for alkyl, and wherein R4 stands for cycloalkyl, it is preferred that continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 IT1 , more pref erably from 0.1 to 3 IT1 , more preferably from 0.2 to 2 IT1 , more preferably from 0.3 to 1 .5 IT1 , more preferably from 0.4 to 1.2 IT1 , more preferably from 0.5 to 0.9 IT1 , and more preferably from 0.6 to 0.7 hr1.
It is preferred that the second zeolitic material obtained in (iii) has an AEI-type framework struc ture, wherein more preferably the zeolitic material having an AEI-type framework structure is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the second zeolitic material obtained in (iii) comprises SSZ-39, and wherein more preferably the second zeolitic material obtained in (iii) is SSZ-39.
In the case where the second zeolitic material obtained in (iii) has an AEI-type framework struc ture, it is preferred that the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain.
In the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that R1 and R2 independently from one another stand for optionally substi tuted and/or optionally branched (Ci-C6)alkyl, more preferably (CrC5)alkyl, more preferably (Cr C^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.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that R3 and R4 form a common derivatized or underivatized, more prefera bly underivatized alkyl chain, preferably a common (C4 - Cs)alkyl chain, more preferably a common (C - C7)alkyl chain, more preferably a common (C - Ce)alkyl chain. It is particularly preferred that said common alkyl chain is a derivatized or underivatized, more preferably un- derivatized C or C alkyl chain, and more preferably a derivatized or underivatized, preferably underivatized C alkyl chain.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more ammonium compounds selected from the group consisting of derivatized or underivatized, more preferably underivatized /V, /V-d i (C i -C4) al ky I-3 , 5-d i (C i - C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C )alkyl-3,5-di(Ci-C )alkylpiperidinium compounds, /V,/V-di(Ci-C4)alkyl-3,5-di(Ci-C4)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C4)alkyl-2,6- di(Ci-C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylpiperidinium com pounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylhexahydroazepinium compounds, and mixtures of two or more thereof, preferably from the group consisting of /V,/V-di(Ci-C4)alkyl-3,5-di(Cr C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C4)alkyl-3,5-di(Ci-C4)alkylpiperidinium compounds, /V,/V-di(Ci-C4)alkyl-3,5-di(Ci-C4)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C4)alkyl-2,6- di(Ci-C )alkylpyrrolidinium compounds, /V,/V-di(Ci-C )alkyl-2,6-di(Ci-C )alkylpiperidinium com pounds, /V,/V-di(Ci-C )alkyl-2,6-di(Ci-C )alkylhexahydroazepinium compounds, and mixtures of two or more thereof, more preferably from the group consisting of /V, /V-d i (C i -C3)a I ky I-3 , 5-d i (C i - C3)alkylpyrrolidinium compounds, /V,/V-di(Ci-C3)alkyl-3,5-di(Ci-C3)alkylpiperidinium compounds, /V,/V-di(Ci-C3)alkyl-3,5-di(Ci-C3)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C3)alkyl-2,6- di(Ci-C3)alkylpyrrolidinium compounds, /V,/V-di(Ci-C3)alkyl-2,6-di(Ci-C3)alkylpiperidinium com pounds, /V,/V-di(Ci-C3)alkyl-2,6-di(Ci-C3)alkylhexahydroazepinium compounds, and mixtures of two or more thereof, more preferably from the group consisting of /V, /V-d i (C i -C2)a I ky I-3 , 5-d i (C i - C2)alkylpyrrolidinium compounds, /V,/V-di(Ci-C2)alkyl-3,5-di(Ci-C2)alkylpiperidinium compounds, /V,/V-di(Ci-C2)alkyl-3,5-di(Ci-C2)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C2)alkyl-2,6- di(Ci-C2)alkylpyrrolidinium compounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci-C2)alkylpiperidinium com pounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci-C2)alkylhexahydroazepinium compounds, and mixtures of two or more thereof, more preferably from the group consisting of /V, /V-d i (C i -C2)a I ky I-3 , 5-d i (C i - C2)alkylpiperidinium compounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci-C2)alkylpiperidinium 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-3,5- dimethylpiperidinium and/or /V,/V-diethyl-2,6-dimethylpiperidinium compounds.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the cis and trans isomers, wherein preferably the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more tetraalkylammonium cat- ion R1R2R3R4N+-containing compounds comprise one or more ammonium compounds selected from the group consisting of derivatized or underivatized, preferably underivatized /V,/V-di(C C2)alkyl- s-2,6-di(Ci-C2)alkylpiperidinium compounds, 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-diethyl-c7s-2,6-dimethylpiperidinium compounds.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the cis and trans isomers, wherein preferably the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5- dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more ammonium cation R1R2R3R4N+-containing compounds are selected from the group consisting of N,N- di(Cr C2)alkyl- s-3,5-di(Ci-C2)alkylpiperidinium compounds, and mixtures of two or more thereof, wherein more preferably the one or more ammonium cation containing compounds comprise one or more /V,/V-dimethyl-c/s-3,5-dimethylpiperidinium compounds.
Further in the case where the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 in dependently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain, it is preferred that the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, more preferably one or more salts selected from the group consisting of halides, sulfate, nitrate, phosphate, acetate, and mixtures of two or more thereof, more prefera bly 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 sulfates, and more preferably tetraalkylammonium hydroxides.
Further in the case where the second zeolitic material obtained in (iii) has an AEI-type frame work structure, it is preferred that the FI2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 4 to 30, more preferably of from 5 to 23, more preferably of from 6 to 18, more preferably of from 7 to 15, more preferably of from 8 to 13, more preferably of from 9 to 12, and more preferably of from 10 to 11.
Further in the case where the second zeolitic material obtained in (iii) has an AEI-type frame work structure, it is preferred that continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 1 IT1 , more preferably from 0.1 to 0.8 IT1 , more preferably from 0.2 to 0.7 IT1 , more preferably from 0.3 to 0.65 IT1 , more preferably from 0.35 to 0.6 IT1 , more preferably from 0.4 to 0.55 IT1 , and more preferably from 0.45 to 0.5 IT1. It is preferred that the mixture prepared in (i) and heated in (iii) displays an R1R2R3R4N+ : S1O2 molar ratio of the one or more tetraalkylammonium cations to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1.5, more preferably from 0.1 to 0.8, more preferably from 0.3 to 0.5, more preferably from 0.5 to 0.3, more preferably from 0.7 to 0.2, more preferably from 0.8 to 0.15, more preferably from 0.85 to 0.12, more preferably from 0.9 to 0.11 , and more preferably from 0.95 to 0.1.
It is preferred that independently from one another, the framework structure of the first zeolitic material displays a YO2 : X2O3 molar ratio ranging from 5 to 120, more preferably from 8 to 80, more preferably from 10 to 50, more preferably from 15 to 40, more preferably from 20 to 30, more preferably from 22 to 28, and more preferably from 24 to 26.
It is preferred that the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein the mixture displays an OH- : S1O2 molar ratio of hydroxide to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1 , more prefera bly from 0.1 to 0.7, more preferably from 0.3 to 0.6, more preferably from 0.4 to 0.55, more preferably from 0.45 to 0.5, more preferably from 0.46 to 0.49, and more preferably from 0.47 to 0.48.
It is preferred that X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, X more preferably being Al and/or B, and more preferably being Al.
It is preferred that the volume of the continuous flow reactor is in the range of from 50 cm3 to 75 m3, more preferably from 55 cm3 to 3 m3, more preferably from 60 cm3 to 1 m3, more preferably from 65 cm3 to 0.7 m3, more preferably from 70 cm3 to 0.3 m3, more preferably from 75 cm3 to 0.1 m3, more preferably from 80 to 70,000 cm3, more preferably from 85 to 50,000 cm3, more preferably from 90 to 30,000 cm3, more preferably from 95 to 10,000 cm3, more preferably from 100 to 7,000 cm3, more preferably from 105 to 5,000 cm3, more preferably from 110 to 3,000 cm3, more preferably from 115 to 1 ,000 cm3, more preferably from 120 to 700 cm3, more prefer ably from 125 to 500 cm3, more preferably from 130 to 350 cm3, more preferably from 135 to 250 cm3, more preferably from 140 to 200 cm3, more preferably from 145 to 180 cm3, more preferably from 150 to 170 cm3, and more preferably from 155 to 165 cm3.
It is preferred that the continuous flow reactor is selected among a tubular reactor, a ring reac tor, and a continuously oscillating reactor, more preferably among a plain tubular reactor, a tub ular membrane reactor, a tubular reactor with Coanda effect, a ring reactor, a continuously os cillating baffled reactor, and combinations thereof, 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.
It is preferred that the continuous flow reactor is a tubular reactor, and wherein at least a portion of the tubular reactor is of a regular cylindrical form having a constant inner diameter perpen dicular 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 4 to 500 mm, more prefera bly from 4.5 to 200 mm, more preferably from 4.5 to 100 mm, more preferably from 5 to 50 mm, more preferably from 5 to 30 mm, more preferably from 5.5 to 15 mm, more preferably from 5.5 to 10 mm, more preferably from 6 to 8 mm, and more preferably from 6 to 6.5 mm.
It is preferred that the continuous flow reactor has a length in the range of from 0.2 to 5,000 m, more preferably from 0.5 to 3,000 m, more preferably from 1 to 1 ,000 m more preferably from 2 to 500 m more preferably from 3 to 200 m, more preferably from 4 to 100 m, more preferably from 4.5 to 50 m, more preferably from 4.5 to 30 m, more preferably from 4 to 20 m, more pref erably from 4 to 15 m, more preferably from 4.5 to 10 m, and more preferably from 4.5 to 5.5 m.
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 selected from the group consisting of Ta,
Cr, Fe, Ni, Cu, Al, Mo, and combinations and/or alloys of two or more thereof, more 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 wherein preferably the metallic material comprises a nickel alloy, a nick- el-molybdenum alloy, and more preferably a nickel-molybdenum-chromium alloy.
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 more 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 mix tures of two or more thereof, preferably 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).
Alternatively, the walls of the continuous flow reactor may comprise, preferably consist of, 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, preferably 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).
It is preferred that the continuous flow reactor is straight and/or comprises one or more curves with respect to the direction of flow, wherein more preferably the continuous flow reactor is straight and/or has a coiled form with respect to the direction of flow.
It is preferred that the walls of the continuous flow reactor are subject to vibration during crystal lization in (iii). It is preferred that the continuous flow reactor consists of a single stage.
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 (iii), wherein more preferably no matter is add ed, wherein more preferably no matter is added and no matter is removed from the reaction mixture during its passage through the continuous flow reactor in (iii).
It is preferred that the mixture prepared in (i) contains substantially no phosphorous and/or phosphorous containing compounds.
It is preferred that the framework of the second zeolitic material obtained in (iii) contains sub stantially no phosphorous, wherein more preferably the second zeolitic material obtained in (iii) contains substantially no phosphorous and/or phosphorous containing compounds.
It is preferred that continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 IT1 , more preferably from 0.1 to 3 IT1 , more preferably from 0.2 to 2 IT1 , more preferably from 0.3 to 1.5 IT1 , more preferably from 0.4 to 1.2 IT1 , more preferably from 0.5 to 1 IT1 , and more preferably from 0.7 to 0.8 IT1.
It is preferred that in (ii) the mixture prepared in (i) 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 prefer ably 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.
It is preferred that in (iii) the mixture is heated to a temperature in the range of from 90 to 280 °C, more preferably of from 120 to 250 °C, more preferably of from 140 to 230 °C, more preferably of from 160 to 220 °C, more preferably of from 180 to 210 °C, and more preferably of from 190 to 200 °C.
It is preferred that in (iii) the mixture is heated under autogenous pressure, wherein more pref erably the pressure is in the range of from 0.5 to 15 MPa, more preferably in the range of from 1 to 10 MPa, more preferably from 1.5 to 8 MPa, more preferably from 2 to 6 MPa, more prefera bly from 2.5 to 5.5 MPa, more preferably from 3 to 5 MPa, more preferably from 3.5 to 4.5 MPa, and more preferably from 3.8 to 4.2 MPa.
It is preferred that prior to (ii) the mixture prepared in (i) is aged at a temperature in the range of from 40 to 120 °C, preferably from 50 to 110 °C, more preferably from 60 to 105 °C, more pref erably from 70 to 100 °C, more preferably from 75 to 95 °C, and more preferably from 80 to 90 °C. It is preferred that prior to (ii) the mixture prepared in (i) is aged for a duration ranging from 1 to 72 h, more preferably from 6 to 60 h, more preferably from 12 to 54 h, more preferably from 14 to 42 h, more preferably from 16 to 36 h, more preferably from 18 to 32 h, and more preferably from 20 to 28 h.
It is preferred that (i) includes a step of milling the mixture prior to and/or during continuous feeding in (ii).
It is preferred that the mixture prepared in (i) is directly fed to the continuous flow reactor in (ii), wherein while being fed to the continuous flow reactor in (ii), the mixture prepared in (i) is pre heated, more preferably to a temperature in the range of from 90 to 280 °C, preferably of from 120 to 250 °C, more preferably of from 140 to 230 °C, more preferably of from 160 to 220 °C, more preferably of from 180 to 210 °C, and more preferably of from 190 to 200 °C.
The process may comprise further process steps. It is preferred that the process further com prises
(iv) treating the reaction product effluent continuously exiting the reactor in (iii) with a liquid comprising one or more solvents and/or via expansion of the reaction product effluent; and/or, more preferably and,
(v) isolating the second zeolitic material obtained in (iii) or (iv); and/or, more preferably and,
(vi) washing the second zeolitic material obtained in (iii), (iv) or (v); and/or, more preferably and,
(vii) drying the second zeolitic material obtained in (iii), (iv), (v), or (vi); and/or, more preferably and,
(viii) calcining the second zeolitic material obtained in (iii), (iv), (v), (vi), or (vii).
In the case where the process further comprises (iv), it is preferred that in (iv) the liquid com prises one or more solvents selected from the group consisting of polar protic solvents and mix tures thereof, more 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.
In the case where the process further comprises (vii), it is preferred that drying in (vii) is effected at a temperature in the range from 50 to 220 °C, more preferably from 70 to 190 °C, more pref erably from 80 to 170 °C, more preferably from 90 to 150 °C, more preferably from 100 to 140 °C, and more preferably from 110 to 130 °C.
In the case where the process further comprises (v), it is preferred that the supernatant obtained from the isolation of the zeolitic material in (v), 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. In the case where the process further comprises (v), and optionally (iv), it is preferred that in (v) isolating the zeolitic material includes a step of spray-drying the second zeolitic material ob tained in (iii) or (iv).
In the case where the process further comprises (vii), and optionally (iv), (v), and/or (vi), it is preferred that in (vii) drying of the zeolitic material includes a step of spray-drying the second zeolitic material obtained in (iii), (iv), (v), or (vi).
It is preferred that the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, wherein the lubricating agent more preferably com prises one or more fluorinated compounds.
In the case where the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, it is preferred that the lubricating agent comprises one or more fluorinated polymers, more preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyethers.
Further in the case where the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent, it is preferred that the lubricating agent com prises one or more fluorocarbons, more preferably one or more perfluorocarbons, more prefer ably the lubricating agent comprises perfluorodecalin.
It is preferred that the mixture crystallized in (iii) in the continuous flow reactor is mechanically agitated, wherein more 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 reac tor 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.
As disclosed above, the process may comprise further process steps. It is preferred that the process further comprises
(ix) subjecting the zeolitic material obtained in (v), (vi), (vii), or (viii) to an ion-exchange proce dure, wherein at least one ionic non-framework element or compound contained in the zeolitic material is ion-exchanged against one or more metal ions.
In the case where the process further comprises (ix), it is preferred that in (ix) the step of sub jecting the zeolitic material to an ion-exchange procedure includes the steps of (ix.a) subjecting the zeolitic material obtained in (v), (vi), (vii), or (viii) to an ion-exchange proce dure, wherein at least one ionic non-framework element or compound contained in the zeolitic material is ion-exchanged against NFU+;
(ix.b) calcining the ion-exchanged zeolitic material obtained in (ix.a) for obtaining the H-form of the zeolitic material; and
(ix.c) subjecting the zeolitic material obtained in (ix.b) to an ion-exchange procedure, wherein H+ contained in the zeolitic material as ionic non-framework element is ion-exchanged against one or more metal ions.
In the case where the process further comprises (ix.a), (ix.b), and (ix.c), it is preferred that the one or more metal ions are selected from the group consisting of ions of alkaline earth metal elements and/or transition metal elements, more preferably from the group consisting of ions of metals selected from group Mg, Sr, Zr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Cr, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, and even more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof.
In the case where the process further comprises (viii) and/or (ix.b), it is preferred that the calcin ing in (viii) and/or (ix.b) is effected at a temperature in the range from 250 to 800 °C, more pref erably from 300 to 750 °C, more preferably from 350 to 700 °C, more preferably from 400 to 650 °C, more preferably from 450 to 600 °C, and more preferably from 500 to 550 °C.
Further in the case where the process further comprises (viii) and/or (ix.b), it is preferred that calcining in (viii) and/or (ix.b) is conducted for a period in the range of from 0.5 to 15 h, more preferably from 1 to 12 h, more preferably from 2 to 10 h, more preferably from 2.5 to 9 h, more preferably from 3 to 7 h, more preferably from 3.5 to 6.5 h, more preferably from 4 to 6 h, and more preferably from 4.5 to 5.5 h.
It is preferred that the mixture prepared in (i) further comprises seed crystals, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-, AEI-, GME-, and/or M FI-type framework structure, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-type and/or an AEI-type framework structure, wherein more preferably the zeolitic material of the seed crystals is obtainable and/or obtained according to any one of the embodiments disclosed herein.
In the case where the mixture prepared in (i) further comprises seed crystals, it is preferred that the seed crystals comprises a zeolitic material having a CFIA-type framework structure. In the case where the seed crystals comprises a zeolitic material having a CFIA-type framework struc ture, it is preferred that the zeolitic material comprised 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| [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. It is particularly preferred that the zeolitic material having a CHA-type framework structure comprised in the seed crystals is chabazite and/or SSZ-13, more preferably SSZ-13.
In the case where the mixture prepared in (i) further comprises seed crystals, it is alternatively preferred that the seed crystals comprises a zeolitic material having a AEI-type framework struc ture. In the case where the seed crystals comprises a zeolitic material having a AEI-type framework structure, it is preferred that the zeolitic material comprised in the seed crystals is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof. It is particularly preferred that the zeolitic material having an AEI-type framework structure comprised in the seed crystals is SSZ-39.
In the case where the mixture prepared in (i) further comprises seed crystals, it is preferred that the amount of seed crystals in the mixture prepared in (i) and heated in (iii) ranges from 0.1 to 25 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material, more preferably from 0.5 to 15 wt.-%, more preferably from 1 to 10 wt.-%, more preferably from 2 to 7 wt.-%, more preferably from 3 to 6 wt.-%, and more preferably from 4 to 5 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material.
Further, the present invention relates to a zeolitic material as obtainable and/or obtained ac cording to the process of any one of the embodiments disclosed herein.
It is preferred that the zeolitic material has a CHA-type framework structure, wherein more pref erably 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| [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 consist ing 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, preferably SSZ-13. IT is particularly preferred that the zeolitic material is chabazite and/or SSZ-13, more preferably SSZ- 13. Alternatively, it is preferred that the zeolitic material has an AEI-type framework structure, wherein more preferably the zeolitic material is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the zeolitic material comprises SSZ-39. It is particularly preferred that the zeolitic material is SSZ-39.
Yet further, the present invention relates to a use of a zeolitic material according to any one of the embodiments disclosed herein as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support, more preferably as a catalyst for the selective catalyt ic reduction (SCR) of nitrogen oxides NOx; for the storage and/or adsorption of CO2; for the oxi dation of N H3, in particular for the oxidation of N H3 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 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 unit bar(abs) refers to an absolute pressure wherein 1 bar equals 105 Pa.
The present invention is further illustrated by the following set of embodiments and combina tions of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for ex ample in the context of a term such as "The process of any one of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the word ing of this term is to be understood by the skilled person as being synonymous to "The process of any one 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 suit ably structured part of the description directed to general and preferred aspects of the present invention.
1. A continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein X stands for a trivalent element, said process compris ing
(i) preparing a mixture comprising one or more solvents, one or more structure direct ing agents, and a first zeolitic material comprising S1O2 and X2O3 in its framework struc ture, wherein preferably the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 independently from one another stand for alkyl;
(ii) continuously feeding the mixture prepared in (i) into a continuous flow reactor; and
(iii) heating the mixture in the continuous flow reactor for obtaining a second zeolitic ma terial comprising S1O2 and X2O3 in its framework structure, wherein the second zeolitic material obtained in (iii) has a different type of framework structure than the first zeolitic material contained in the mixture prepared in (i), wherein the mixture is heated to a tern- perature in the range of from 70 to 300 °C; wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 3 to 50, preferably of from 6 to 35, more preferably of from 8 to 25, more preferably of from 10 to 20, more preferably of from 11 to 17, more preferably of from 12 to 16, and more preferably of from 13 to 15. The process of embodiment 1 , wherein the first zeolitic material has an FAU-, GIS-, MOR- , LTA-, FER-, TON-, MTT-, BEA-, MEL-, MWW-, MFS-, and/or M FI-type framework struc ture, preferably an FAU-, GIS-, BEA-, and/or M FI-type framework structure, more prefera bly an FAU- and/or BEA-type framework structure, and more preferably an FAU-type framework structure. The process of embodiment 1 or 2, wherein the second zeolitic material has a CFIA-, AEI-, GME-, and/or M FI-type framework structure, preferably a CFIA- and/or AEI-type frame work structure. The process of any one of embodiments 1 to 3, wherein the one or more solvents in the mixture prepared in (i) comprise water, preferably distilled water, wherein more preferably water is contained as the one or more solvents in the mixture prepared in (i), preferably distilled water. The process of any one of embodiments 1 to 4, wherein the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein said at least one source for OH~ preferably comprises a metal hydroxide, more preferably a hydroxide of an alkali metal M, more preferably sodium and/or potassium hydroxide, and more preferably sodium hydroxide, wherein more preferably the at least one source for OH~ is sodium hy droxide. The process of any one of embodiments 1 to 5, wherein the first zeolitic material having an FAU-type framework structure is selected from the group consisting of ZSM-3, Faujasite, [AI-Ge-0]-FAU, CSZ-1, ECR-30, Zeolite X, Zeolite Y, LZ-210, SAPO-37, ZSM- 20, Na-X, US-Y, Na-Y, [Ga-Ge-0]-FAU, Li-LSX, [Ga-AI-Si-0]-FAU, and [Ga-Si-0]-FAU, including mixtures of two or more thereof, preferably from the group consisting of ZSM-3, Faujasite, CSZ-1, ECR-30, Zeolite X, Zeolite Y, LZ-210, ZSM-20, Na-X, US-Y, Na-Y, and Li-LSX, including mixtures of two or more thereof, more preferably from the group consist ing of Faujasite, Zeolite X, Zeolite Y, Na-X, US-Y, and Na-Y, including mixtures of two or more thereof, more preferably from the group consisting of Faujasite, Zeolite X, and Zeo lite Y, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an FAU-type framework structure comprises zeolite X and/or zeolite Y, preferably zeolite Y, wherein more preferably the first zeolitic material having an FAU-type framework structure is zeolite X and/or zeolite Y, preferably zeolite Y. The process of any one of embodiments 1 to 6, wherein the first zeolitic material having a GIS-type framework structure is selected from the group consisting of zeolite P, TMA- gismondine, Na-P1, Amicite, Gobbinsite, High-silica Na-P, Na-P2, SAPO-43, Gismondine, MAPSO-43, MAPSO-43, Garronite, Synthetic amicite, Synthetic garronite, Synthetic gob binsite, [Ga-Si-0]-GIS, Synthetic Ca-garronite, Low-silica Na-P (MAP), [AI-Ge-0]-GIS, in cluding mixtures of two or more thereof, preferably from the group consisting of zeolite P, TMA-gismondine, Na-P1 , Amicite, Gobbinsite, High-silica Na-P, Na-P2, Gismondine, Gar ronite, Synthetic amicite, Synthetic garronite, Synthetic gobbinsite, [Ga-Si-0]-GIS, Syn thetic Ca-garronite, [AI-Ge-0]-GIS, including mixtures of two or more thereof, more pref erably from the group consisting of zeolite P, TMA-gismondine, Na-P1 , Amicite, Gob binsite, High-silica Na-P, Na-P2, Gismondine, Garronite, Synthetic amicite, Synthetic gar ronite, Synthetic gobbinsite, Synthetic Ca-garronite, including mixtures of two or more thereof, more preferably from the group consisting of zeolite P, Na-P1 , High-silica Na-P, Na-P2, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having a GIS-type framework structure comprises zeolite P, wherein more pref erably the first zeolitic material having a GIS-type framework structure is zeolite P. The process of any one of embodiments 1 to 7, wherein the first zeolitic material having an MOR-type framework structure is selected from the group consisting of Mordenite, [Ga- Si-0]-MOR, Maricopaite, Ca-Q, LZ-211 , Na-D, RMA-1 , including mixtures of two or more thereof, wherein preferably the first zeolitic material having an MOR-type framework struc ture comprises Mordenite, wherein more preferably the first zeolitic material having an MOR-type framework structure is Mordenite. The process of any one of embodiments 1 to 8, wherein the first zeolitic material having an LTA-type framework structure is selected from the group consisting of Linde Type A (zeolite A), Alpha, [AI-Ge-0]-LTA, N-A, LZ-215, SAPO-42, ZK-4, ZK-21, Dehyd. Linde Type A (dehyd. zeolite A), ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, SAPO- 42, ZK-4, ZK-21 , Dehyd. Linde Type A, ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N-A, LZ-215, ZK-4, ZK-21 , Dehyd. Linde Type A, ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof, more preferably from the group consisting of Linde Type A, Alpha, N- A, LZ-215, ZK-4, ZK-21 , ZK-22, ITQ-29, UZM-9, including mixtures of two or more thereof. The process of any one of embodiments 1 to 9, wherein the first zeolitic material having a BEA-type framework structure is selected from the group consisting of zeolite beta, Tschernichite, [B-Si-0]-*BEA, CIT-6, [Ga-Si-0]-*BEA, Beta polymorph B, SSZ-26, SSZ- 33, Beta polymorph A, [Ti-Si-0]-*BEA, and pure silica beta, including mixtures of two or more thereof, preferably from the group consisting of zeolite beta, CIT-6, Beta polymorph B, SSZ-26, SSZ-33, Beta polymorph A, and pure silica beta, including mixtures of two or more thereof, wherein more preferably the first zeolitic material having a BEA-type frame- work structure comprises zeolite beta, preferably zeolite beta obtained from organotem- plate-free synthesis, wherein more preferably the first zeolitic material having a BEA-type framework structure is zeolite beta, preferably zeolite beta obtained from organotemplate mediated synthesis or obtained from organotemplate-free synthesis, and more preferably zeolite beta obtained from organotemplate-free synthesis. The process of any one of embodiments 1 to 10, wherein the first zeolitic material having an M FI-type framework structure is selected from the group consisting of Silicalite, ZSM-5, [Fe-Si-0]-MFI, [Ga-Si-0]-MFI, [As-Si-0]-MFI, AMS-1 B, AZ-1, Bor-C, Encilite, Boralite C, FZ-1, LZ-105, Mutinaite, NU-4, NU-5, TS-1, TSZ, TSZ-III, TZ-01 , USC-4, USI-108, ZBH, ZKQ-1 B, ZMQ-TB, MnS-1, and FeS-1 , including mixtures of two or more thereof, prefera bly from the group consisting of Silicalite, ZSM-5, AMS-1B, AZ-1, Encilite, FZ-1 , LZ-105, Mutinaite, NU-4, NU-5, TS-1, TSZ, TSZ-III, TZ-01, USC-4, USI-108, ZBH, ZKQ-1B, and ZMQ-TB, including mixtures of two or more thereof, wherein more preferably the first zeo litic material having an M FI-type framework structure comprises Silicalite and/or ZSM-5, preferably ZSM-5, wherein more preferably the first zeolitic material having an M FI-type framework structure is zeolite Silicalite and/or ZSM-5, preferably ZSM-5. The process of any one of embodiments 1 to 11 , wherein the first zeolitic material having an FER-type framework structure is selected from the group consisting of Ferrierite, [Ga- Si-0]-FER, [Si-0]-FER, FU-9, ISI-6, NU-23, Sr-D, ZSM-35, and [B-Si-0]-FER, including mixtures of two or more thereof, preferably from the group consisting of Ferrierite, FU-9, ISI-6, NU-23, and ZSM-35, including mixtures of two or more thereof, wherein more pref erably the first zeolitic material having an FER-type framework structure is Ferrierite. The process of any one of embodiments 1 to 12, wherein the first zeolitic material having an TON-type framework structure is selected from the group consisting of Theta-1 , ZSM- 22, ISI-1, KZ-2, and NU-10, including mixtures of two or more thereof, wherein preferably the first zeolitic material having a TON-type framework structure is ZSM-22. The process of any one of embodiments 1 to 13, wherein the first zeolitic material having an MTT-type framework structure is selected from the group consisting of ZSM-23, EU-13, ISI-4, and KZ-1 , including mixtures of two or more thereof, wherein preferably the first zeolitic material having a MTT-type framework structure is ZSM-23. The process of any one of embodiments 1 to 14, wherein the first zeolitic material having an MEL-type framework structure is selected from the group consisting of Boralite D, SSZ- 46, and ZSM-11 , including mixtures of two or more thereof, wherein more preferably the first zeolitic material having an MEL-type framework structure comprises ZSM-11 , wherein more preferably the first zeolitic material having an MEL-type framework structure is ZSM- 11. 16. The process of any one of embodiments 1 to 15, wherein the first zeolitic material having an MWW-type framework structure is selected from the group consisting of MCM-22, ERB-1 , ITQ-1, PSH-3, and SSZ-25 and MCM-22, including mixtures of two or more there of, wherein more preferably the first zeolitic material having an MWW-type framework structure comprises MCM-22, wherein more preferably the first zeolitic material having an MWW-type framework structure is MCM-22.
17. The process of any one of embodiments 1 to 16, wherein the first zeolitic material having an MFS-type framework structure comprises ZSM-57, wherein more preferably the first zeolitic material having an MFS-type framework structure is ZSM-57.
18. The process of any one of embodiments 1 to 17, wherein the second zeolitic material ob tained in (iii) has a CFIA-type framework structure, wherein preferably the zeolitic material having a CFIA-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 con sisting 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 sec ond zeolitic material obtained in (iii) comprises chabazite and/or SSZ-13, preferably SSZ- 13, and wherein more preferably the second zeolitic material obtained in (iii) is chabazite and/or SSZ-13, preferably SSZ-13.
19. The process of embodiment 18, wherein the one or more structure directing agents com prises 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.
20. The process of embodiment 19, wherein R1 , R2, and R3 independently from one another stand for optionally substituted and/or optionally branched (Ci-C6)alkyl, preferably (Cr C5)alkyl, more preferably (CrC4)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. The process of embodiment 19 or 20, 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. The process of any one of embodiments 19 to 21 , wherein the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more /V,/V,/V-tri(Ci-C4)alkyl-1-adamantammonium compounds, preferably one or more N,N,N- tri(Ci-C3)alkyl-1-adamantammonium compounds, more preferably one or more N,N,N- tri(Ci-C2)alkyl-1-adamantammonium compounds, more preferably one or more N,N,N- tri(Ci-C2)alkyl-1-adamantammonium and/or one or more /V,/V,/V-tri(Ci-C2)alkyl-1- adamantammonium compounds, more preferably one or more compounds selected from /V,/V,/V-triethyl-1-adamantammonium, /V,/V-diethyl-/V-methyl-1-adamantammonium, N,N- dimethyl-/V -ethyl-1 -adamantammonium, N, N,N -trimethyl-1 -adamantammonium 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 N,N,N -trimethyl-1 -adamantammonium compounds. The process of any one of embodiments 19 to 22, wherein the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, preferably one or more salts selected from the group consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides. The process of embodiment 18, wherein the one or more structure directing agents com prises 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. The process of embodiment 24, wherein R1 and R2 independently from one another stand for optionally substituted and/or optionally branched (CrC6)alkyl, preferably (CrC5)alkyl, more preferably (C C )alkyl, more preferably (C 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. The process of embodiment 24 or 25, wherein R3 stands for optionally substituted and/or optionally branched (C C6)alkyl, preferably (CrC )alkyl, more preferably (CrC )alkyl, more preferably (CrC3)alkyl, and more preferably for optionally substituted methyl or ethyl, wherein more preferably R3 stands for optionally substituted ethyl, preferably un substituted ethyl. The process of any one of embodiments 24 to 26, wherein R4 stands for optionally hetero cyclic 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. The process of any one of embodiments 24 to 27, wherein 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(Cr C2)alkyl-cyclohexylammonium compounds, more preferably one or more compounds se lected from /V,/V,/V-triethyl-cyclohexylammonium, /V,/V-diethyl-/V-methyl- cyclohexylammonium, /V,/V-dimethyl-/V-ethyl-cyclohexylammonium, N, N,N -trim ethyl - cyclohexylammonium 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 /V,/V-dimethyl-/V-ethyl-cyclohexylammonium compounds. The process of any one of embodiments 24 to 28, wherein the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, preferably one or more salts selected from the group consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides. The process of any one of embodiments 18 to 29, wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 7 to 40, preferably of from 9 to 30, more preferably of from 11 to 25, more preferably of from 13 to 22, more preferably of from 15 to 20, more preferably of from 16 to 19, and more preferably of from 17 to 18. The process of any one of embodiments 18 to 30, wherein continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 IT1 , preferably from 0.1 to 3 IT1 , more preferably from 0.2 to 2 IT1 , more preferably from 0.3 to 1.5 IT1 , more preferably from 0.4 to 1.2 IT1 , more preferably from 0.5 to 0.9 IT1 , and more prefera bly from 0.6 to 0.7 IT1. The process of any one of embodiments 1 to 17, wherein the second zeolitic material ob tained in (iii) has an AEI-type framework structure, wherein preferably the zeolitic material having an AEI-type framework structure is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the second zeolitic material obtained in (iii) comprises SSZ-39, and wherein more preferably the second zeolitic material obtained in (iii) is SSZ-39. The process of embodiment 32, wherein the one or more structure directing agents com prises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, wherein R1, R2, R3 and R4 independently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain. The process of embodiment 33, wherein R1 and R2 independently from one another stand for optionally substituted and/or optionally branched (C C6)alkyl, preferably (C C )alkyl, more preferably (CrC4)alkyl, more preferably (C 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. The process of embodiment 33 or 34, wherein R3 and R4 form a common derivatized or underivatized, preferably underivatized alkyl chain, preferably a common (C4 - Cs)alkyl chain, more preferably a common (C4 - C7)alkyl chain, more preferably a common (C4 - C6)alkyl chain, wherein more preferably said common alkyl chain is a derivatized or un derivatized, preferably underivatized C4 or C alkyl chain, and more preferably a derivat ized or underivatized, preferably underivatized C5 alkyl chain. The process of any one of embodiments 33 to 35, wherein the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more ammonium compounds selected from the group consisting of derivatized or underivatized, preferably underivatized /V,/V-di(Ci-C4)alkyl-3,5-di(Ci-C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C4)alkyl-3,5-di(Ci-C4)alkylpiperidinium compounds, /V,/V-di(Ci-C4)alkyl-3,5-di(Ci- C4)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C4)alkyl-2,6-di(C C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylpiperidinium com pounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylhexahydroazepinium compounds, and mix tures of two or more thereof, preferably from the group consisting of /V,/V-di(Ci-C4)alkyl- 3,5-di(Ci-C4)alkylpyrrolidinium compounds, /V,/V-di(Ci-C )alkyl-3,5-di(Cr C4)alkylpiperidinium compounds, /V,/V-di(Ci-C )alkyl-3,5-di(Ci- C^alkylhexahydroazepinium compounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci- C^alkylpyrrolidinium compounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylpiperidinium com pounds, /V,/V-di(Ci-C4)alkyl-2,6-di(Ci-C4)alkylhexahydroazepinium compounds, and mix tures of two or more thereof, more preferably from the group consisting of /V,/V-di(Cr C3)alkyl-3,5-di(Ci-C3)alkylpyrrolidinium compounds, TV, 7V-d i (C i -C3)a I ky I-3 , 5-d i (C i - C3)alkylpiperidinium compounds, /V,/V-di(Ci-C3)alkyl-3,5-di(Ci- C3)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C3)alkyl-2,6-di(C C3)alkylpyrrolidinium compounds, /V,/V-di(Ci-C3)alkyl-2,6-di(Ci-C3)alkylpiperidinium com pounds, /V,/V-di(Ci-C3)alkyl-2,6-di(Ci-C3)alkylhexahydroazepinium compounds, and mix tures of two or more thereof, more preferably from the group consisting of /V,/V-di(Cr C2)alkyl-3,5-di(Ci-C2)alkylpyrrolidinium compounds, TV, 7V-d i (C i -C2)a I ky i-3 , 5-d i (C i - C2)alkylpiperidinium compounds, /V,/V-di(Ci-C2)alkyl-3,5-di(Ci- C2)alkylhexahydroazepinium compounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci- C2)alkylpyrrolidinium compounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci-C2)alkylpiperidinium com pounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci-C2)alkylhexahydroazepinium compounds, and mix tures of two or more thereof, more preferably from the group consisting of /V,/V-di(C C2)alkyl-3,5-di(Ci-C2)alkylpiperidinium compounds, /V,/V-di(Ci-C2)alkyl-2,6-di(Ci- C2)alkylpiperidinium compounds, and mixtures of two or more thereof, wherein more pref erably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more /V,/V-dimethyl-3,5-dimethylpiperidinium and/or TV, 7V-d i ethy I- , 6- dimethylpiperidinium compounds. The process of any one of embodiments 33 to 36, wherein the /V,/V-dialkyl-2,6- dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the c/s and trans isomers, wherein preferably the /V,/V-dialkyl-2,6-dialkylpyrrolidinium compounds, /V,/V-dialkyl-2,6-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-2,6-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds comprise one or more ammonium compounds select ed from the group consisting of derivatized or underivatized, preferably underivatized N,N- di(Ci-C2)alkyl- s-2,6-di(Ci-C2)alkylpiperidinium compounds, 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-diethyl-c7s-2,6- dimethylpiperidinium compounds. The process of any one of embodiments 33 to 37, wherein the /V,/V-dialkyl-3,5- dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, the trans configuration, or contain a mixture of the c/s and trans isomers, wherein preferably the /V,/V-dialkyl-3,5-dialkylpyrrolidinium compounds, /V,/V-dialkyl-3,5-dialkylpiperidinium compounds, and/or /V,/V-dialkyl-3,5-dialkylhexahydroazepinium compounds display the cis configuration, wherein more preferably the one or more ammonium cation R1R2R3R4N+- containing compounds are selected from the group consisting of /V,/V-di(Ci-C2)alkyl-c7s- 3,5-di(Ci-C2)alkylpiperidinium compounds, and mixtures of two or more thereof, wherein more preferably the one or more ammonium cation containing compounds comprise one or more /V,/V-dimethyl-c/s-3,5-dimethylpiperidinium compounds. The process of any one of embodiments 33 to 38, wherein the one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds are salts, preferably one or more salts selected from the group consisting 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 com pounds are tetraalkylammonium hydroxides and/or sulfates, and more preferably tetraalkylammonium hydroxides. The process of any one of embodiments 32 to 39, wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 4 to 30, preferably of from 5 to 23, more preferably of from 6 to 18, more preferably of from 7 to 15, more preferably of from 8 to 13, more preferably of from 9 to 12, and more prefer ably of from 10 to 11. The process of any one of embodiments 32 to 40, wherein continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 1 IT1 , preferably from 0.1 to 0.8 IT1 , more preferably from 0.2 to 0.7 IT1 , more preferably from 0.3 to 0.65 hr 1, more preferably from 0.35 to 0.6 hr1, more preferably from 0.4 to 0.55 hr1, and more preferably from 0.45 to 0.5 hr1. The process of any one of embodiments 1 to 41 , wherein the one or more structure direct ing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing compounds, and wherein the mixture prepared in (i) and heated in (iii) displays an R1R2R3R4N+ : S1O2 molar ratio of the one or more tetraalkylammonium cations to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1.5, pref erably from 0.1 to 0.8, more preferably from 0.3 to 0.5, more preferably from 0.5 to 0.3, more preferably from 0.7 to 0.2, more preferably from 0.8 to 0.15, more preferably from 0.85 to 0.12, more preferably from 0.9 to 0.11 , and more preferably from 0.95 to 0.1. The process of any one of embodiments 1 to 42, wherein independently from one another, the framework structure of the first zeolitic material displays a YO2 : X2O3 molar ratio rang ing from 5 to 120, preferably from 8 to 80, more preferably from 10 to 50, more preferably from 15 to 40, more preferably from 20 to 30, more preferably from 22 to 28, and more preferably from 24 to 26.
44. The process of any one of embodiments 1 to 43, wherein the mixture prepared in (i) and heated in (iii) further comprises at least one source for OH-, wherein the mixture displays an OH~ : S1O2 molar ratio of hydroxide to S1O2 in the framework structure of the first zeolit- ic material in the range of from 0.05 to 1 , preferably from 0.1 to 0.7, more preferably from 0.3 to 0.6, more preferably from 0.4 to 0.55, more preferably from 0.45 to 0.5, more pref erably from 0.46 to 0.49, and more preferably from 0.47 to 0.48.
45. The process of any one of embodiments 1 to 44, wherein X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, X preferably being Al and/or B, and more preferably being Al.
46. The process of any one of embodiments 1 to 45, wherein the volume of the continuous flow reactor is in the range of from 50 cm3 to 75 m3, preferably from 55 cm3 to 3 m3, more preferably from 60 cm3 to 1 m3, more preferably from 65 cm3 to 0.7 m3, more preferably from 70 cm3 to 0.3 m3, more preferably from 75 cm3 to 0.1 m3, more preferably from 80 to 70,000 cm3, more preferably from 85 to 50,000 cm3, more preferably from 90 to 30,000 cm3, more preferably from 95 to 10,000 cm3, more preferably from 100 to 7,000 cm3, more preferably from 105 to 5,000 cm3, more preferably from 110 to 3,000 cm3, more preferably from 115 to 1 ,000 cm3, more preferably from 120 to 700 cm3, more preferably from 125 to 500 cm3, more preferably from 130 to 350 cm3, more preferably from 135 to 250 cm3, more preferably from 140 to 200 cm3, more preferably from 145 to 180 cm3, more prefera bly from 150 to 170 cm3, and more preferably from 155 to 165 cm3.
47. The process of any one of embodiments 1 to 46, wherein 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, a continuously oscillating baffled reactor, and combina tions thereof, wherein more preferably the continuous flow reactor is a plain tubular reac tor and/or a ring reactor, wherein more preferably the continuous flow reactor is a plain tubular reactor.
48. The process of any one of embodiments 1 to 47, wherein the continuous flow reactor is a tubular reactor, and wherein at least a portion of the tubular reactor is of a regular cylindri cal 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 4 to 500 mm, more preferably from 4.5 to 200 mm, more preferably from 4.5 to 100 mm, more preferably from 5 to 50 mm, more preferably from 5 to 30 mm, more preferably from 5.5 to 15 mm, more preferably from 5.5 to 10 mm, more preferably from 6 to 8 mm, and more preferably from 6 to 6.5 mm.
49. The process of any one of embodiments 1 to 48, 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 prefer ably from 1 to 1 ,000 m more preferably from 2 to 500 m more preferably from 3 to 200 m, more preferably from 4 to 100 m, more preferably from 4.5 to 50 m, more preferably from 4.5 to 30 m, more preferably from 4 to 20 m, more preferably from 4 to 15 m, more prefer ably from 4.5 to 10 m, and more preferably from 4.5 to 5.5 m.
50. The process of any one of embodiments 1 to 49, wherein the wall of the continuous flow reactor 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 combi nations 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 wherein preferably the metallic material comprises a nickel alloy, a nickel-molybdenum al loy, and more preferably a nickel-molybdenum-chromium alloy.
51. The process of any one of embodiments 1 to 50, wherein 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, preferably 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).
52. The process of any one of embodiments 1 to 51 , 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.
53. The process of any one of embodiments 1 to 52, wherein the walls of the continuous flow reactor are subject to vibration during crystallization in (iii).
54. The process of any one of embodiments 1 to 53, wherein the continuous flow reactor con sists of a single stage. The process of any one of embodiments 1 to 54, wherein no matter is added to and/or removed from the reaction mixture during its passage through the continuous flow reactor in (iii), 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 (iii). The process of any one of embodiments 1 to 55, wherein the mixture prepared in (i) con tains substantially no phosphorous and/or phosphorous containing compounds. The process of any one of embodiments 1 to 56, wherein the framework of the second zeolitic material obtained in (iii) contains substantially no phosphorous, wherein preferably the second zeolitic material obtained in (iii) contains substantially no phosphorous and/or phosphorous containing compounds. The process of any one of embodiments 1 to 57, wherein continuous feeding in (ii) is per formed at a liquid hourly space velocity in the range of from 0.05 to 5 IT1 , preferably from 0.1 to 3 IT1 , more preferably from 0.2 to 2 IT1 , more preferably from 0.3 to 1.5 IT1 , more preferably from 0.4 to 1.2 IT1 , more preferably from 0.5 to 1 IT1 , and more preferably from 0.7 to 0.8 IT1. The process of any one of embodiments 1 to 58, wherein in (ii) the mixture prepared in (i) 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 one of embodiments 1 to 59, wherein in (iii) the mixture is heated to a temperature in the range of from 90 to 280°C, preferably of from 120 to 250°C, more pref erably of from 140 to 230°C, more preferably of from 160 to 220°C, more preferably of from 180 to 210°C, and more preferably of from 190 to 200°C. The process of any one of embodiments 1 to 60, wherein in (iii) the mixture is heated un der autogenous pressure, wherein preferably the pressure is in the range of from 0.5 to 15 MPa, more preferably in the range of from 1 to 10 MPa, more preferably from 1.5 to 8 MPa, more preferably from 2 to 6 MPa, more preferably from 2.5 to 5.5 MPa, more prefer ably from 3 to 5 MPa, more preferably from 3.5 to 4.5 MPa, and more preferably from 3.8 to 4.2 MPa. 62. The process of any one of embodiments 1 to 61 , wherein prior to (ii) the mixture prepared in (i) is aged at a temperature in the range of from 40 to 120 °C, preferably from 50 to 110 °C, more preferably from 60 to 105 °C, more preferably from 70 to 100 °C, more pref erably from 75 to 95 °C, and more preferably from 80 to 90 °C.
63. The process of any one of embodiments 1 to 62, wherein prior to (ii) the mixture prepared in (i) is aged for a duration ranging from 1 to 72 h, more preferably from 6 to 60 h, more preferably from 12 to 54 h, more preferably from 14 to 42 h, more preferably from 16 to 36 h, more preferably from 18 to 32 h, and more preferably from 20 to 28 h.
64. The process of any one of embodiments 1 to 63, wherein (i) includes a step of milling the mixture prior to and/or during continuous feeding in (ii).
65. The process of any one of embodiments 1 to 64, wherein the mixture prepared in (i) is directly fed to the continuous flow reactor in (ii), wherein while being fed to the continuous flow reactor in (ii), the mixture prepared in (i) is pre-heated, preferably to a temperature in the range of from 90 to 280 °C, preferably of from 120 to 250 °C, more preferably of from 140 to 230 °C, more preferably of from 160 to 220 °C, more preferably of from 180 to 210 °C, and more preferably of from 190 to 200 °C.
66. The process of any one of embodiments 1 to 65, wherein the process further comprises
(iv) treating the reaction product effluent continuously exiting the reactor in (iii) with a liquid comprising one or more solvents and/or via expansion of the reaction product efflu ent; and/or, preferably and,
(v) isolating the second zeolitic material obtained in (iii) or (iv); and/or, preferably and,
(vi) washing the second zeolitic material obtained in (iii), (iv) or (v); and/or, preferably and,
(vii) drying the second zeolitic material obtained in (iii), (iv), (v), or (vi); and/or, preferably and,
(viii) calcining the second zeolitic material obtained in (iii), (iv), (v), (vi), or (vii).
67. The process of embodiment 66, wherein in (iv) 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, wa ter, and mixtures thereof, wherein more preferably the liquid comprises water, and where in more preferably water is used as the liquid, preferably deionized water. 68. The process of embodiment 66 or 67, wherein drying in (vii) is effected at a temperature in the range from 50 to 220 °C, preferably from 70 to 190 °C, more preferably from 80 to 170 °C, more preferably from 90 to 150 °C, more preferably from 100 to 140 °C, and more preferably from 110 to 130 °C.
69. The process of any one of embodiments 66 to 68, wherein the supernatant obtained from the isolation of the zeolitic material in (v), 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.
70. The process of any one of embodiments 66 to 69, wherein in (v) isolating the zeolitic ma terial includes a step of spray-drying the second zeolitic material obtained in (iii) or (iv), and/or wherein in (vii) drying of the zeolitic material includes a step of spray-drying the second zeolitic material obtained in (iii), (iv), (v), or (vi).
71. The process of any one of embodiments 1 to 70, wherein the mixture constituting the feed crystallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aque ous phase comprising water, and the second liquid phase comprises a lubricating agent, wherein the lubricating agent preferably comprises one or more fluorinated compounds.
72. The process of embodiment 71 , wherein the lubricating agent comprises one or more fluorinated polymers, preferably one or more fluorinated polyethers, and more preferably one or more perfluorinated polyethers.
73. The process of embodiment 71 or 72, wherein the lubricating agent comprises one or more fluorocarbons, preferably one or more perfluorocarbons, more preferably the lubri cating agent comprises perfluorodecalin.
74. The process of any one of embodiments 1 to 73, wherein the mixture crystallized in (iii) in the continuous flow reactor is mechanically agitated, wherein preferably mechanical agita tion 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.
75. The process of any one of embodiments 1 to 74, wherein the process further comprises (ix) subjecting the zeolitic material obtained in (v), (vi), (vii), or (viii) to an ion-exchange procedure, wherein at least one ionic non-framework element or compound contained in the zeolitic material is ion-exchanged against one or more metal ions. The process of embodiment 75, wherein in (ix) the step of subjecting the zeolitic material to an ion-exchange procedure includes the steps of
(ix.a) subjecting the zeolitic material obtained in (v), (vi), (vii), or (viii) to an ion-exchange procedure, wherein at least one ionic non-framework element or compound contained in the zeolitic material is ion-exchanged against NfV;
(ix.b) calcining the ion-exchanged zeolitic material obtained in (ix.a) for obtaining the in form of the zeolitic material;
(ix.c) subjecting the zeolitic material obtained in (ix.b) to an ion-exchange procedure, wherein H+ contained in the zeolitic material as ionic non-framework element is ion- exchanged against one or more metal ions. The process of embodiment 76, wherein the one or more metal ions are selected from the group consisting of ions of alkaline earth metal elements and/or transition metal elements, preferably from the group consisting of ions of metals selected from group Mg, Sr, Zr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and mixtures of two or more there of, more preferably from the group consisting of Mg, Sr, Cr, Mo, Fe, Co, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, more preferably from the group consisting of Mg, Cr, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof, and even more preferably from the group consisting of Mg, Mo, Fe, Ni, Cu, Zn, Ag, and mixtures of two or more thereof. The process of any one of embodiments 66 to 77, wherein the calcining in (viii) and/or (ix.b) is effected at a temperature in the range from 250 to 800 °C, preferably from 300 to 750 °C, more preferably from 350 to 700 °C, more preferably from 400 to 650 °C, more preferably from 450 to 600 °C, and more preferably from 500 to 550 °C. The process of any one of embodiments 66 to 78, wherein calcining in (viii) and/or (ix.b) is conducted for a period in the range of from 0.5 to 15 h, preferably from 1 to 12 h, more preferably from 2 to 10 h, more preferably from 2.5 to 9 h, more preferably from 3 to 7 h, more preferably from 3.5 to 6.5 h, more preferably from 4 to 6 h, and more preferably from 4.5 to 5.5 h. The process of any one of embodiments 1 to 79, wherein the mixture prepared in (i) fur ther comprises seed crystals, wherein preferably the seed crystals comprise a zeolitic ma terial having a CFIA-, AEI-, GME-, and/or M FI-type framework structure, wherein more preferably the seed crystals comprise a zeolitic material having a CFIA-type and/or an AEI-type framework structure, wherein more preferably the zeolitic material of the seed crystals is obtainable and/or obtained according to any one of embodiments 1 to 79. 81. The process of embodiment 80, wherein the zeolitic material having a CHA-type frame work structure comprised 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, prefer ably 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 having a CHA-type framework structure comprised in the seed crystals is chabazite and/or SSZ-13, preferably SSZ-13.
82. The process of embodiment 80 or 81 , wherein the zeolitic material having an AEI-type framework structure comprised in the seed crystals is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein preferably the zeolitic material having an AEI-type framework structure comprised in the seed crys tals is SSZ-39.
83. The process of any one of embodiments 80 to 82, wherein the amount of seed crystals in the mixture prepared in (i) and heated in (iii) ranges from 0.1 to 25 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material, preferably from 0.5 to 15 wt.-%, more preferably from 1 to 10 wt.-%, more preferably from 2 to 7 wt.-%, more preferably from 3 to 6 wt.-%, and more preferably from 4 to 5 wt.-% based on 100 wt.-% of S1O2 in the framework structure of the first zeolitic material.
84. A zeolitic material as obtainable and/or obtained according to the process of any one of embodiments 1 to 83.
85. The zeolitic material of embodiment 84, 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, includ ing mixtures of two or more thereof, more preferably from the group consisting of Chaba zite, SSZ-13, and SSZ-62, including mixtures of two or three thereof, wherein more pref- erably the zeolitic material comprises chabazite and/or SSZ-13, preferably SSZ-13, and wherein more preferably the zeolitic material is chabazite and/or SSZ-13, preferably SSZ- 13.
86. The zeolitic material of embodiment 84, wherein the zeolitic material has an AEI-type framework structure, wherein preferably the zeolitic material is selected from the group consisting of SSZ-39, SAPO-18, SIZ-8, including mixtures of two or more thereof, wherein more preferably the zeolitic material comprises SSZ-39, and wherein more preferably the zeolitic material is SSZ-39.
87. Use of a zeolitic material according to any one of embodiments 84 to 86 as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support, 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 oxi dation 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 conversion reactions, preferably in the conversion of alcohols to olefins, and more preferably in methanol to ole fin (MTO) catalysis; more preferably for the selective catalytic reduction (SCR) of nitrogen oxides NOc, and more preferably for the selective catalytic reduction (SCR) of nitrogen ox ides NOc in exhaust gas from a combustion engine, preferably from a diesel engine or from a lean burn gasoline engine.
EXPERIMENTAL SECTION
The present invention is further illustrated by the following examples and reference examples.
For evaluating the composition of a synthesis gel most suitable as starting material for a contin uous production, the following batch processes were performed according to Reference Exam ples A-F.
Reference Example A: Production of an AEI-type zeolite from zeolite Y in a batch process
0.504 g of Y zeolite (Tosoh HSZ 320HOA, SiC>2/Al2C>3=5.5) was added to 3.745 g of a solution of the 1 ,1 ,3,5 - tetramethylpiperidinium hydroxide (20 wt. %). To this suspension, 9.380 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was then added. The final synthesis gel, which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20:
455 H2O, was transferred to an autoclave. The synthesis was conducted three times in parallel in an air-circulating oven and under the following conditions: (i) at 160 °C for 24 h under rotation of the autoclave with 20 rpm; (ii) at 200 °C for 16 h under rotation of the autoclave with 20 rpm; and (iii) at 210 °C for 3 h under rotation of the autoclave with 60 rpm. The crystallinity of the resulting products was determined according to XRD as being 100 % for (i), 94 % for (iii), and 94 % for (iii), of AEI-type zeolite, respectively.
Reference Example B: Production of an AEI-type zeolite from zeolite Y in a batch process
0.504 g of Y zeolite (Tosoh HSZ 320HOA, SiC>2/Al2C>3=5.5) was added to 3.745 g of a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %). To this suspension, 9.380 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was then added. Thereafter, 0.280 g AEI seed (provided by BASF), which equals to 10 wt.% of the S1O2, were added. The final synthesis gel, which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20: 455 H2O (plus 10 wt.% seed on the basis of the S1O2), was transferred to an autoclave. The synthesis was conducted in an air-circulating oven at 210 °C under rotation of the autoclave with 60 rpm. The crystallinity of the resulting product was determined according to XRD as be ing 87 % of AEI-type zeolite.
Reference Example C: Production of an AEI-type zeolite from zeolite Y in a batch process
0.490 g of Y zeolite (Tosoh HSZ 320HOA, SiC>2/Al2C>3=5.5) was added into a solution consisting of 3.640 g of a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %) and 0.113 g of water. To this suspension, 4.865 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was added, which was followed by the addition of 3.780 g of another water glass (28 wt.% S1O2, 9 wt.% Na20 and 63 wt.% water; Wako). The final synthesis gel, which had a molar composition of 43 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.8 Na20: 434 H2O, was transferred to an autoclave for the synthesis. The synthesis was conducted in an air-circulating oven at 160 °C for 24 h, and the autoclave was rotated with a speed of 20 rpm. The crystallinity of the resulting product was determined according to XRD as being 94 % of AEI-type zeolite, whereby traces of an impurity phase was observed.
Reference Example D: Production of an AEI-type zeolite from zeolite Y in a batch process
0.504 g of Y zeolite (Tosoh HSZ 320HOA, SiC>2/Al2C>3=5.5) was added to 3.745 g of a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %). To this suspension, 9.380 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was then added. Thereafter, 0.280 g AEI seed (provided by BASF), which equals to 10 wt.% of the S1O2, was added. The final synthesis gel, which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20: 455 H2O (plus 10 wt.% seed on the basis of the S1O2). 4.5 g of this precursor was trans ferred to the tubular reactor, which was placed in an air-circulating oven at 210 °C and rotated with a speed of 60 rpm over a reaction time of 60 min. The crystallinity of the resulting product was determined according to XRD as being 96 % of AEI-type zeolite.
Reference Example E: Production of an AEI-type zeolite from zeolite Y in a batch process 0.504 g of Y zeolite (Tosoh HSZ 320HOA, SiC>2/Al2C>3=5.5) was added to 3.745 g of a solution of 1 ,1 , 3, 5 - tetramethylpiperidinium hydroxide (20 wt. %). To this suspension, 9.380 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was then added. Thereafter, 0.280 g AEI seed (provided by BASF), which equals to 10 wt.% of the S1O2, is added. The final synthesis gel, which had a molar composition of 43.0 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.0 Na20:
455 H2O (plus 10 wt.% seed on the basis of the S1O2). The synthesis precursor was treated with a planetary centrifugal mixer (Thinky planetary centrifugal mixer using S13N4 balls) for 1 min un der a spinning speed of 2000 rpm. And, this treatment cycle was repeated for 6 times. 4.5 g of the final precursor was transferred to the tubular reactor, which was placed in an air-circulating oven at 210 °C and rotated with a speed of 60 rpm over a reaction time of 40 min. The crystal linity of the resulting product was determined according to XRD as being 94 % of AEI-type zeo lite.
Reference Example F: Production of an GME-type zeolite from zeolite Y in a batch process
0.630 g of Y zeolite (Tosoh FISZ 320FIOA, SiC>2/Al2C>3=5.5) was added into a solution consisting of 4.680 g of a solution of 1 ,1 ,3,5 - tetramethylpiperidinium hydroxide (20 wt. %) and 1.206 g of water. To this suspension, 3.420 g of water glass (25 wt.% S1O2, 6.5 wt.% Na20 and 68.5 wt.% water; Wako) was added, which was followed by the addition of 6.615 g of another water glass (28 wt.% S1O2, 9 wt.% Na20 and 63 wt.% water; Wako). The final synthesis precursor, which had a molar composition of 40.3 S1O2: 1.0 AI2O3: 4.2 OSDA: 10.4 Na20: 444 FI2O, is transferred to the autoclave for the synthesis. The synthesis was conducted in an air-circulating oven at 200 °C for 3 h, with a rotation speed of 10 rpm. The resulting product was identified by XRD as be ing a GME-type zeolite. In the case where the production of a GME-type zeolite was performed without rotation or under rotation with 60 rpm, small amounts of AEI-type zeolite were observed.
1 g of the GME-type zeolite product was mixed into 2.1 g of KCI aqueous solution (2 mol/kg).
The slurry was stirred at room temperature for 6 h, and thereafter the slurry was filtrated to re cover the K-form zeolite, which was thoroughly washed and dried. The dried K-form zeolite was calcined twice (the sample was washed with hot water in between), and the temperature pro grams for the two calcination procedures was as follows:
Calcination procedure 1 : heating with a heating ramp of 0.1 °C/min to a temperature of 90 °C over 11 h; heating with a heating ramp of 0.5 °C/min over additional 14 h to a temperature of 500 °C;
Calcination procedure 2: heating with a heating ramp of 1 °C/min to a temperature of 150 °C over 11 h; keeping a temperature of 150 °C until a total heating time of 5 h was applied; heating with a heating ramp of 1 °C/min until a temperature of 500 °C is reached; keeping a temperature of 500 °C until a total heating time of 18 h was applied. Thus, the K-form of the prepared GME-type zeolite was prepared.
Example 1 : Continuous production of an AEI-type zeolite from zeolite Y a) Preparation of a synthesis gel
343.8 g of an aqueous solution of sodium hydroxide (10 weight- % of sodium hydroxide powder purchased from Sigma Aldrich in deionized water) were mixed with 175.4 g of an aqueous solu tion of N,N-dimethyl-3,5-dimethylpiperidinium hydroxide (21.2 weight-% in water; TMPOH; pur chased from CCG with a trans-isomer content of 14.9 %) in a beaker. 172.3 g of zeolite Y (DY- 32 from Quilu having a molar ratio of SiC>2:Al2C>3 of 25) were added thereto under stirring. Then, 8.6 g of AEI-type zeolites (purchased from CCG) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel. The synthesis gel comprised 24.61 weight-% of zeolite Y, 25.06 weight-% of TMPOH, 49.11 weight-% of sodium hydroxide and 1.23 weight-% of AEI-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.098 TMPOH : 0.355 Na : 10.31 H20. b) Continuous preparation of an AEI-type zeolite using the synthesis gel prepared under a)
For the continuous preparation of an AEI-type zeolite the synthesis gel as prepared according to a) was used. Further, a Teflon tube was used as reactor having a volume of 160 ml and a di ameter of 6.4 mm. The reactor had a length of 6 m, whereby the reactor could be heated over a length of about 5 m. The reactor and the lining to the reactor was filled with about 200 ml per- fluorinated decalin, further a receiver tank was filled with the synthesis gel as prepared accord ing to a). To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 5 bar using nitrogen gas, while the reactor was heated up to a temperature of 200 °C. In order to monitor the reaction progress, the temperature of the reactor was recorded using four thermocouples fixed on the outside of the reactor tube. The temperature measured at the reactor inlet was 185 °C, in the middle 202 °C, at the reactor exit 200 °C, and at the heat- exchanger positioned downstream of the reactor 24 °C. In addition, the pressure was recorded on top of the receiver tank and also downstream at the exit of the reactor using a pressure indi cator. After reaching the desired temperature, the pressure was increased to 41 bar. Down stream of the heat-exchanger positioned downstream of the reactor a tube with a volume of 1.3 ml is located. In addition thereto, a first ball valve is positioned at the intersection of the reactor and the tube and a second ball valve at the end of the tube. During the reaction process, the first ball valve opens shortly every 60 seconds allowing to release a volume of 1.3 ml of the zeo lite product suspension from the reactor. Once the first ball valve is closed, the second ball valve opens allowing these 1.3 ml of product suspension to exit the reactor setup into a sepa rate vessel where it is collected. This results in a continuous flow of 1.3 ml/60 s. After a reaction time of about 130 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture was about 130 min. For work-up, the continuously reacted mixture containing the zeolitic product was filtered and the resulting solids washed with deionized water, subsequently dried at 120 °C for 4 h and then calcined. Calcination was performed by heating the solids to a temperature of 450 °C within 7 h, holding said temperature for 2 h, further heating to a temperature of 500 °C within 30 minutes, holding the temperature of 500 °C for 2 h, further heating to a temperature of 550 °C, and hold ing the temperature of 550 °C for 2 h. According to XRD measurement, the obtained product had a crystallinity of 90 %, of which 66 % were AEI-type zeolite, 31 % MOR-type zeolite, and 3 % ZSM-5 zeolite.
Example 2: Continuous production of an AEI-type zeolite from zeolite Y
Considering the reactor set-up according to Example 1 the continuous production of an AEI- type zeolite was performed starting from zeolite y. A synthesis gel prepared according to Exam ple 1 a) was used. Further, the following conditions were applied in b). The continuous flow was set to 1 .3 ml/45 s. Thus, the first ball valve opens shortly every 45 seconds during the reaction process allowing to release a volume of 1 .3 ml of the zeolite product suspension from the reac tor. The retention time of the reaction mixture in the reactor was about 90 min.
According to XRD measurement, the obtained product had a crystallinity of 90 %, of which 65 % were AEI-type zeolite, 33 % MOR-type zeolite, and 2 % ZSM-5 zeolite.
Example 3: Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
235.2 g of an aqueous solution of sodium hydroxide (6 weight-% of sodium hydroxide powder purchased from Sigma Aldrich in deionized water) were mixed with 96.8 g of an aqueous solu tion of Trimethyladamantylammonium hydroxide (20 weight-% in water; TMAdAOH; BASF) in a beaker. 65.4 g of zeolite Y (DY-32 from Quilu having a molar ratio of SiC>2:Al2C>3 of 25) were added thereto under stirring. Then, 2.7 g of CH A-type zeolites (BASF) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel. The synthesis gel comprised 16.34 weight-% of zeolite Y, 24.20 weight-% of TM Ad AO H, 58.80 weight-% of sodium hydroxide and 0.66 weight-% of CFIA-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOFI : 0.389 Na : 18.27 FI2O. b) Continuous preparation of a CFIA-type zeolite using the synthesis gel prepared under a)
For the continuous preparation of a CFIA-type zeolite the synthesis gel as prepared according to a) was used.
Further, a Teflon tube was used as reactor having a volume of 160 ml and a diameter of 6.4 mm. The reactor had a length of 6 m, whereby the reactor could be heated over a length of about 5 m. The reactor and the lining to the reactor was filled with about 200 ml perfluorinated decalin, further a receiver tank was filled with the synthesis gel as prepared according to a). To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 3 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C. In order to monitor the reaction progress, the temperature of the reactor was recorded using four thermo couples fixed on the outside of the reactor tube. The temperature measured at the reactor inlet was 172 °C, of the middle 195 °C, of the reactor exit 193 °C, and of the heat-exchanger posi tioned downstream of the reactor 24 °C. In addition, the pressure was recorded on top of the receiver tank and also downstream at the exit of the reactor using a pressure indicator. After reaching the desired temperature, the pressure was increased to 40.6 bar. Downstream of the heat-exchanger positioned downstream of the reactor a tube with a volume of 1.3 ml is located. In addition thereto, a first ball valve is positioned at the intersection of the reactor and the tube and a second ball valve at the end of the tube. During the reaction process, the first ball valve opens shortly every 36 seconds allowing to release a volume of 1.3 ml of the zeolite product suspension from the reactor. Once the first ball valve is closed, the second ball valve opens allowing these 1.3 ml of product suspension to exit the reactor setup into a separate vessel where it is collected. This results in a continuous flow of 1.3 ml/36 s. After a reaction time of about 50 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture in the reactor was about 70 min. For work-up, the continuously reacted mixture containing the zeolitic product was filtered and the resulting solids washed with deionized water, subsequently dried at 120 °C for 4 h and then calcined. Calcination was performed by heating the solids to a temperature of 450 °C within 7 h, holding said temperature for 2 h, further heating to a temperature of 500 °C within 30 minutes, holding the temperature of 500 °C for 2 h, further heating to a temperature of 550 °C, and hold ing the temperature of 550 °C for 2 h. According to XRD measurement, the obtained product had a crystallinity of 90 %, of which 100 % were CHA-type zeolite. According to elemental anal ysis, the resulting product had a Si content of 33 weight-%, an Al content of 3.7 weight-%, a Na content of 1.5 weight-%, and a C content of 0.03 weight-%. The BET specific surface area was determined as being 637 m2/g. c) Preparation of an ammonium exchanged CHA-type zeolite
In a 500 ml flask, 80 g de-ionzied water, 20 g of the product of b), and 80 g of an aqueous solu tion of ammonium nitrate were mixed (54 weight-% in water). The mixture was then heated to 80 °C and stirred at said temperature for 1 h. Subsequently, the resulting mixture was filtered and the solids washed with water until a conductivity in the wash water was about 19 pS. Thus, 30.3 g of solids were obtained that were dried at a temperature of 120 °C overnight. 18.7 g of solids were obtained which were calcined at a temperature of 450 °C for 6 h. According to ele mental analysis, the resulting product had a Si content of 38 weight-%, an Al content of 4.1 weight-%, and a Na content of less than 0.01 weight-%.
Example 4: Continuous production of a CHA-type zeolite from zeolite Y Considering the reactor set-up according to Example 3 the production of a CHA-type zeolite was performed starting from zeolite Y. In particular, the following condition was applied in b). To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 3 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C. The tem perature of the reactor was recorded using four thermocouples fixed on the outside of the reac tor tube. The temperature measured at the reactor inlet was 172 °C, in the middle 195 °C, at the reactor exit 193 °C, and at the heat-exchanger positioned downstream of the reactor 24 °C. The pressure was determined as being 40.6 bar. The continuous flow was set to 1.3 ml/10 s. Thus, the first ball valve opens shortly every 10 seconds during the reaction process allowing to re lease a volume of 1.3 ml of the zeolite product suspension from the reactor. The retention time of the reaction mixture in the reactor was about 20 min.
According to XRD measurement, the obtained product had a crystallinity of 95 %, of which 100 % were CHA-type zeolite. According to elemental analysis, the resulting product had a Si con tent of 34 weight-%, an Al content of 3.7 weight-%, a Na content of 1.5 weight-%, and a C con tent of 0.03 weight-%. The BET specific surface area was determined as being 638 m2/g.
Example 5: Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
1175.7 g of an aqueous solution of sodium hydroxide (6 weight-% of sodium hydroxide powder purchased from Sigma Aldrich in deionized water) were mixed with 483.9 g of an aqueous solu tion of Trimethyladamantylammonium hydroxide (20 weight-% in water; TMAdAOH; BASF) in a beaker. 326.9 g of zeolite Y (DY-32 from Quilu having a molar ratio of SiC>2:Al2C>3 of 25) were added thereto under stirring. Then, 13.5 g of CHA-type zeolites (BASF) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel. The synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOH : 0.389 Na : 18.27 H20. b) Continuous preparation of a CHA-type zeolite using the synthesis gel prepared under a)
Considering the reactor set-up according to Example 3 under item b) a CHA-type zeolite was preformed starting from zeolite Y. In particular, the following conditions were applied. To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 5 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C. The tempera ture of the reactor was recorded using four thermocouples fixed on the outside of the reactor tube. The temperature measured at the reactor inlet was 160 °C, in the middle 192.2 °C, at the reactor exit 191 °C, and at the heat-exchanger positioned downstream of the reactor 24 °C. The pressure was determined as being 40.5 bar. The continuous flow was set to 1.3 ml/17 s. Thus, the first ball valve opens shortly every 17 seconds during the reaction process allowing to re- lease a volume of 1 .3 ml of the zeolite product suspension from the reactor. After a reaction time of about 34 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture in the reactor was about 34 min.
According to XRD measurement, the obtained product had a crystallinity of 100 %, of which 100 % were CHA-type zeolite. According to elemental analysis, the resulting product had a Si content of 36.2 weight-%, an Al content of 3.9 weight-%, a Na content of 1.7 weight-%, and a C content of 0.06 weight-%. The BET specific surface area was determined as being 580 m2/g. c) Preparation of an ammonium exchanged CHA-type zeolite
In a 500 ml flask, 80 g de-ionized water, 20 g of the product of b), and 80 g of an aqueous solu tion of ammonium nitrate were mixed (54 weight-% in water). The mixture was then heated to 80 °C and stirred at said temperature for 1 h. Subsequently, the resulting mixture was filtered and the solids washed with water until a conductivity in the wash water was about 19 pS. Thus, 305.5 g of solids were obtained that were dried at a temperature of 120 °C overnight. 193 g of solids were obtained which were calcined at a temperature of 450 °C for 6 h. According to ele mental analysis, the resulting product had a Si content of 38 weight-%, an Al content of 3.7 weight-%, and a Na content of less than 0.01 weight-%.
Example 6: Continuous production of a CHA-type zeolite from zeolite Y a) Preparation of a synthesis gel
249.8 g of an aqueous solution of sodium hydroxide (6 weight-% of sodium hydroxide powder purchased from Sigma Aldrich in deionized water) were mixed with 78.2 g of an aqueous solu tion of Trimethyladamantylammonium sulfate (30.2 weight-% in water; TMAdA-SC ; BASF) in a beaker. 69.5 g of zeolite Y (DY-32 from Quilu having a molar ratio of SiC>2:Al2C>3 of 25) were added thereto under stirring. Then, 3.1 g of CHA-type zeolites (BASF) were added as seeds and the mixture was stirred for further 20 min at room temperature for obtaining a synthesis gel. The synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdAOH : 0.389 Na : 18.27 H20.
The synthesis gel comprised 17.35 weight-% of zeolite Y, 19.51 weight-% of TMAdA-SC>4, 62.44 weight-% of sodium hydroxide and 0.70 weight-% of CHA-type zeolites. Further, the synthesis gel had the following molar ratios: 1 Si : 0.080 Al : 0.101 TMAdA-SC>4 : 0.389 Na : 17.12 H20. b) Continuous preparation of an CHA-type zeolite using the synthesis gel prepared under a)
Considering the reactor set-up according to Example 3 under item b) preparation of a CHA-type zeolite was performed starting from zeolite y. In particular, the following conditions were applied. To start the reaction, the synthesis gel was introduced into the reactor and a pressure was set to 3 bar using nitrogen gas, while the reactor was heated up to a temperature of 190 °C. The temperature of the reactor was recorded using four thermocouples fixed on the outside of the reactor tube. The temperature measured at the reactor inlet was 178 °C, in the middle 190.2 °C, at the reactor exit 192 °C, and at the heat-exchanger positioned downstream of the reactor 24 °C. The pressure was determined as being 40.2 bar. The continuous flow was set to 1.3 ml/71 s. Thus, the first ball valve opens shortly every 71 seconds during the reaction process allowing to release a volume of 1.3 ml of the zeolite product suspension from the reactor. After a reaction time of about 120 min, the decalin was removed from the reactor and collection of the product mixture could be started. The retention time of the reaction mixture in the reactor was about 120 min.
According to XRD measurement, the obtained product had a crystallinity of 94 %, of which at least 99 % were CHA-type zeolite and less than 1 % zeolite Y. According to elemental analysis, the resulting product had a Si content of 36 weight-%, an Al content of 3.5 weight-%, a Na con tent of 1.4 weight-%, a C content of 0.1 weight-%, and a S content of less than 0.01 weight-%. c) Preparation of an ammonium exchanged CHA-type zeolite
In a 500 ml flask, 60 g de-ionzied water, 15 g of the product of b), and 60 g of an aqueous solu tion of ammonium nitrate were mixed (54 weight-% in water). The mixture was then heated to 80 °C and stirred at said temperature for 1 h. Subsequently, the resulting mixture was filtered and the solids washed with water until a conductivity in the wash water was about 19 pS. Thus, 21 g of solids were obtained that were dried at a temperature of 120 °C overnight. 15.1 g of sol ids were obtained which were calcined at a temperature of 450 °C for 6 h. According to ele mental analysis, the resulting product had a Si content of 38 weight-%, an Al content of 3.7 weight-%, and a Na content of less than 0.01 weight-%.
Example 7: Catalytic testing in selective catalytic reduction (SCR)
For catalytic testing in selective catalytic reduction, the following procedure was applied. a) Impregnation i. A sample of uncalcined zeolite powder was impregnated with a Cu nitrate solution using incipient wetness technique; ii. The impregnated sample was sealed and stored for 20 h at 50 °C in an oven; iii. The sample was then dried; iv. Subsequent calcination of a sample was conducted for 5 h at 450 °C. b) Shaping i. A slurry was prepared from a sample obtained from a.iv); ii. The slurry was mixed with pre-milled alumina (TM 100/150; ball-milled with 500 rpm for 10 min) in a weight ratio of the sample to alumina of 70 : 30; iii. The mixture was dried under stirring; iv. The mixture was calcined for 1 h at 550 °C; v. Then, the obtained solids were crushed and sieved to obtain a fraction with an average particle size in the range of 250-500 pm. c) Aging i. Fresh (as obtained according to b)); ii. Aged for 50 h at a temperature of 650 °C in air comprising 10 % steam; iii. Aged for 16 h at a temperature of 820 °C, 10% steam/air. d) Test conditions for standard SCR (selective catalytic reduction):
For catalytic testing, samples were used being either i. fresh, ii. aged for 50 h at 650 °C, or iii. aged for 16 h at 820 °C in accordance with the aging conditions under c). The following condi tions were applied for the SCR catalytic testing:
• Per reactor, 120 mg of a sample were diluted with corundum to a volume of approxi mately 1 ml;
• The feed stream was set to a GFISV of 80000 IT1, whereby the feed stream comprised 500 ppm NO, 500 ppm N H3, 5 % H2O, 10 % O2, balanced with N2
• Different temperature settings were tested:
• 200, 400, and 575 °C (first run for degreening)
• 175, 200, 225, 250, 450, 550, and 575 °C
The results from catalyst testing, in particular with respect to the NOx conversion, are shown in Figure 1 . As can be gathered from the results in Figure 1 , the samples show excellent proper ties with respect to the NOx conversion even after aging. In particular, the NOx conversion reached a high level at temperatures about 200 °C and stayed at a high level.
In Figure 2, further results from catalyst testing, in particular at temperatures of 200 and 575 °C, respectively, are shown. Generally, the results as shown in Figure 1 were confirmed. In particu lar the fresh samples displayed excellent properties with respect to the NOx conversion. Further, even after aging the NOx conversion stayed at a high level.
Further results from catalyst testing, in particular with respect to N2O formation, are shown in Figure 3. Thus, it can be gathered from Figure 3 that also with respect to the N2O formation, the examples of the present invention show excellent results.
Brief description of figures
Figure 1 : shows the catalytic performance of the zeolitic materials of the present invention according to Examples 3, 5 and 6, respectively. The temperature [°C] is shown on the abscissa, and the NOx conversion [%] on the ordinate. Circles indicate meas urements in fresh state, diamonds indicate measurements after aging for 50 h at 650 °C, and triangles indicate measurements after aging for 16 h at 820 °C.
Figure 2: shows the catalytic performance of the zeolitic materials of the present invention according to Examples 3, 5 and 6, respectively. The upper diagram relates to the NOx conversion determined at 575 °C and the lower diagram relates to the NOx conversion determined at 200 °C. In each diagram, the NOx conversion [%] for the fresh sample is shown on the left, for the sample aged for 50 h at 650 °C in the mid dle, and for the sample aged for 16 h at 820 °C on the right.
Figure 3: shows the N O make for Examples 3, 5, and 6, respectively. The temperature [°C] is shown on the abscissa, and the N O make [ppm] on the ordinate. Circles indicate measurements in fresh state, diamonds indicate measurements after aging for 50 h at 650 °C, and triangles indicate measurements after aging for 16 h at 820 °C.
Cited literature
- Y. Hu et al. “Ultrafast synthesis of TS-1 without extra-framework titanium species in a con tinuous flow system” in Microporous and Mesoporous Materials 2018, vol. 270, pp. 149- 154
- CN 109336131 A
- CN 109319804 A
- DE 3029787 A1
- EP 0402801 A2
- US 4374093
- US 6656447 B1

Claims

Claims
1. A continuous process for the preparation of a zeolitic material comprising S1O2 and X2O3 in its framework structure, wherein X stands for a trivalent element, said process compris ing
(i) preparing a mixture comprising one or more solvents, one or more structure direct ing agents, and a first zeolitic material comprising S1O2 and X2O3 in its framework struc ture;
(ii) continuously feeding the mixture prepared in (i) into a continuous flow reactor; and
(iii) heating the mixture in the continuous flow reactor for obtaining a second zeolitic ma terial comprising S1O2 and X2O3 in its framework structure, wherein the second zeolitic material obtained in (iii) has a different type of framework structure than the first zeolitic material contained in the mixture prepared in (i), wherein the mixture is heated to a tem perature in the range of from 70 to 300 °C; wherein the H2O : S1O2 molar ratio of water to S1O2 calculated as the oxide in the mixture prepared in (i) is in the range of from 3 to 50.
2. The process of claim 1 , wherein the first zeolitic material has an FAU-, GIS-, MOR-, LTA-, FER-, TON-, MTT-, BEA-, MEL-, MWW-, MFS-, and/or M FI-type framework structure.
3. The process of claim 1 or 2, wherein the second zeolitic material has a CFIA-, AEI-, GME-, and/or M FI-type framework structure.
4. The process of any one of claims 1 to 3, wherein the mixture prepared in (i) and heated in (iii) further comprises at least one source for OFb.
5. The process of any one of claims 1 to 4, wherein the second zeolitic material obtained in (iii) has a CFIA-type framework structure, and wherein the one or more structure directing agents comprises 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, or wherein the one or more structure directing agents comprises 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.
6. The process of any one of claims 1 to 4, wherein the second zeolitic material obtained in (iii) has an AEI-type framework structure, and wherein the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds, wherein R1, R2, R3 and R4 independently from one another stand for alkyl, and wherein R3 and R4 form a common alkyl chain.
7. The process of any one of claims 1 to 6, wherein the one or more structure directing agents comprises one or more tetraalkylammonium cation R1R2R3R4N+-containing com pounds, and wherein the mixture prepared in (i) and heated in (iii) displays an R1R2R3R4N+ : SiC>2 molar ratio of the one or more tetraalkylammonium cations to S1O2 in the framework structure of the first zeolitic material in the range of from 0.05 to 1.5.
8. The process of any one of claims 1 to 7, wherein independently from one another, the framework structure of the first zeolitic material displays a YO2 : X2O3 molar ratio is in the range of from 5 to 120.
9. The process of any one of claims 1 to 8, wherein X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof.
10. The process of any one of claims 1 to 9, wherein the continuous flow reactor is selected among a tubular reactor, a ring reactor, and a continuously oscillating reactor.
11. The process of any one of claims 1 to 10, wherein continuous feeding in (ii) is performed at a liquid hourly space velocity in the range of from 0.05 to 5 tv1.
12. The process of any one of claims 1 to 11 , wherein the mixture constituting the feed crys tallized in (iii) consists of two liquid phases, wherein the first liquid phase is an aqueous phase comprising water, and the second liquid phase comprises a lubricating agent.
13. The process of any one of claims 1 to 12, wherein the mixture prepared in (i) further com prises seed crystals.
14. A zeolitic material as obtainable and/or obtained according to the process of any one of claims 1 to 13.
15. Use of a zeolitic material according to claim 14 as a molecular sieve, as an adsorbent, for ion-exchange, or as a catalyst and/or as a catalyst support.
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