Classifications

• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B39/00—Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
  • C01B39/02—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof; Direct preparation thereof; Preparation thereof starting from a reaction mixture containing a crystalline zeolite of another type, or from preformed reactants; After-treatment thereof
  • C01B39/026—After-treatment
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B39/00—Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
  • C01B39/02—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof; Direct preparation thereof; Preparation thereof starting from a reaction mixture containing a crystalline zeolite of another type, or from preformed reactants; After-treatment thereof
  • C01B39/46—Other types characterised by their X-ray diffraction pattern and their defined composition
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2002/00—Crystal-structural characteristics
  • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
  • C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2004/00—Particle morphology
  • C01P2004/01—Particle morphology depicted by an image
  • C01P2004/03—Particle morphology depicted by an image obtained by SEM

Definitions

• This disclosure relates to processes for preparing molecular sieve SSZ-122.
• Molecular sieves are a commercially important class of materials that have distinct crystal structures with defined pore structures that are shown by distinct X-ray diffraction (XRD) patterns and have specific chemical compositions.
• the crystal structure defines cavities and pores that are characteristic of the specific type of molecular sieve .
• Molecular sieves are classified by the Structure Commission of the International Zeolite Association according to the rules of the IUPAC Commission on Zeolite Nomenclature. According to this classification, f ramework-type zeolites and other crystalline microporous molecular sieves, for which a unique structure has been established, are assigned a unique three-letter code and are described, for example, in the " Atlas of Zeolite Framework Types" by Ch. Baerlocher, L.B. McCusker and D.H. Olson (Elsevier, Sixth Revised Edition, 2007) .
• BOG framework type molecular sieves have a three-dimensional channel system of 10- and 12-rings.
• Materials having the BOG framework type include boggsite, ITQ- 47 and SSZ-122.
• an organotemplate-f ree synthetic process for synthesizing an aluminosilicate molecular sieve having a framework structure of SSZ-122, the process comprising: (1) preparing a reaction mixture comprising: (a) a silicon atom source; (b) an aluminum atom source; (c) a source of an alkali metal [M] ; (d) a source of hydroxide ions; (e) water; and (f) seed crystals; and (2) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the aluminosilicate molecular sieve .
• a synthetic organotemplate-f ree aluminosilicate molecular sieve having a framework structure of SSZ-122, wherein the molecular sieve optionally comprises an alkali metal [M] , wherein the molecular sieve is non-calcined .
• FIG. 1 shows a powder X-ray diffraction (XRD) pattern of an as-synthesized SSZ-122 material in accordance with Example 1.
• FIG. 2 shows a Scanning Electron Microscopy (SEM) image of an as-synthesized SSZ-122 material in accordance with Example 1.
• organotemplate designates any conceivable organic material which is suitable for template-mediated synthesis of a molecular sieve material, preferably of a molecular sieve material having a BOG-type framework-structure, and even more preferably which is suitable for the synthesis of SSZ-122.
• organotemplates include l-adamantyl-3-propylimidazolium cation .
• an "organotemplate-f ree" synthetic process relates to a synthetic process wherein the materials used therein are substantially free of organotemplate materials, wherein "substantially" as employed in the present disclosure with respect to the amount of one or more organotemplates contained in the one or more materials used in a synthetic process indicates an amount of 0.001 wt . % or less of one or more organotemplates, such as 0.0005 wt . % or less, or 0.00001 wt . % or less, or 0.000005 wt . % or less, or even 0.000001 wt . % or less thereof.
• organotemplates if at all present in any one of the materials used in the synthetic process, may also be denoted as “impurities” or “trace amounts” within the meaning of the present disclosure.
• organotemplate and “organic structure directing agent” are synonymously used in the present disclosure.
• BOG refers to a BOG topological type as recognized by the International Zeolite Association Structure Commission.
• Molecular sieve SSZ-122 can be synthesized by: (1) preparing a reaction mixture comprising (a) a silicon atom source; (b) an aluminum atom source; (c) a source of an alkali metal [M] ; (d) a source of hydroxide ions; (e) water; and (f) seed crystals; and (2) subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the aluminosilicate molecular sieve.
• the reaction mixture can have a composition, in terms of molar ratios, within the ranges set forth in Table 1:
• silicon atom sources include colloidal suspensions of silica, precipitated silica, fumed silica, alkali metal silicates, tetraalkyl orthosilicates, (e.g., tetraethyl orthosilicate) , and mixtures thereof.
• Examples of aluminum atom sources include hydrated alumina, aluminum hydroxide, alkali metal aluminates, aluminum alkoxides, and water-soluble aluminum salts (e.g., aluminum nitrate) , and mixtures thereof.
• Combined silicon atom and aluminum atom sources can also be used, such as aluminosilicate zeolites (e.g., Y- zeolite) .
• the aluminosilicate zeolite may be used as the sole or predominant source of silicon and aluminum.
• the term "predominant" means greater than 50 mole %, suitably greater than 75 mole % and preferably greater than 90 mole %.
• the alkali metal [M] may be selected from lithium, sodium, potassium, rubidium, and cesium, wherein more preferably the alkali metal is sodium and/or potassium, and wherein even more preferably the alkali metal is sodium.
• any conceivable source for hydroxide ions can be used, wherein the source preferably comprises a metal hydroxide, particularly a hydroxide of an alkali metal [M] , preferably sodium and/or potassium hydroxide, and even more preferably sodium hydroxide.
• seed crystals are provided in step (1) , wherein the seed crystals comprise a molecular sieve material having a BOG-type framework structure.
• the seed crystals can comprise any molecular sieve material having a BOG-type framework structure, provided that a molecular sieve material having a BOG-type framework structure is crystallized in step (2) .
• the seed crystals comprise a molecular sieve selected from the group consisting of boggsite, ITQ-47, SSZ-122, and mixtures thereof, wherein even more preferably the seed crystals preferably comprise SSZ-122.
• any suitable amount of seed crystals can be provided in the mixture according to step (1) , provided that a molecular sieve material having a BOG-type framework structure is crystallized in step (2) .
• the amount of seed crystals contained in the reaction mixture according to step (1) ranges from 0.01 to 30 wt . % (e.g., 0.1 to 20 wt . %, or 0.5 to 10 wt . %) , based on 100 wt . % of SiO2 in the silicon atom source.
• the reaction mixture prepared in step (1) and crystallized in step (2) contain more than an impurity of an organic structure directing agent specifically used in the synthesis of molecular sieve materials having a BOG-type framework structure, in particular specific tetraalkylammonium salts and/or related organotemplates , such as l-adamantyl-3- propylimidazolium salts.
• an impurity can, for example, be caused by organic structure directing agents still present in seed crystals used in the present process.
• Organotemplates contained in seed crystal material may not, however, participate in the crystallization process since they are trapped within the seed crystal framework and therefore may not act structure directing agents within the meaning of the present disclosure.
• the reaction mixture components can be supplied by more than one source. Also, two or more reaction mixture components can be provided by one source.
• the reaction mixture can be prepared by any conceivable means, wherein mixing by agitation is preferred, preferably by means of stirring.
• the reaction mixture can be prepared in batch, continuous, or semi-continuous mode.
• the reaction mixture can be in the form of a solution, a colloidal dispersion (colloidal sol) , gel, or paste, with a gel being preferred.
• Crystallization of the molecular sieve may be carried out under static or stirred conditions in a suitable reactor vessel, such as for example, polypropylene jars or Teflon lined or stainless steel autoclaves placed in a convection oven maintained at a temperature of about 100 to about 200°C for a period of time sufficient for crystallization to occur (e.g., from about 1 day to 21 days, or 1 day to 14 days, or 1 day to 10 days) .
• a suitable reactor vessel such as for example, polypropylene jars or Teflon lined or stainless steel autoclaves placed in a convection oven maintained at a temperature of about 100 to about 200°C for a period of time sufficient for crystallization to occur (e.g., from about 1 day to 21 days, or 1 day to 14 days, or 1 day to 10 days) .
• the solid product is separated from the reaction mixture by standard separation techniques such as filtration or centrifugation.
• the recovered crystals are water-washed and then dried, for several seconds to a few minutes (e.g., from 5 seconds to 10 minutes for flash drying) or several hours (e.g., from 4 to 24 hours for oven drying at 75°C to 150°C) , to obtain as-synthesized molecular sieve crystals.
• the drying step can be performed at atmospheric pressure or under vacuum.
• the molecular sieve crystallized in step (2) can optionally be subject to at least one step of an ionexchange procedure, wherein the term "ion-exchange" according to the present disclosure generally refers to non-framework ionic elements and/or molecules contained in the molecular sieve material.
• the non-framework ionic element comprises an alkali metal [M] preferably comprised in the molecular sieve.
• any conceivable ion-exchange procedure with all possible ionic elements and/or molecules can be conducted on the molecular sieve, with the exception of organic structure directing agents specifically used in the synthesis of molecular sieve materials having a BOG-type framework structure.
• organic structure directing agents specifically used in the synthesis of molecular sieve materials having a BOG-type framework structure.
• ionic elements at least one cation and/or cationic element is employed which may be selected from the group consisting of H + , NH4 + , Sc, Zr, Cr, Mo, W, Fe, Co, Ni, Cu, Zn, Ru, Rh, Rd, Ag, Os, Ir, Pt, Au, and mixtures thereof.
• a calcination step involves the heating of the molecular sieve material crystallized according to step (2) above a temperature of 500°C.
• the molecular sieve crystallized according to step (2) is not subject in a subsequent step to a temperature exceeding 450°C, or 350°C, or 300°C, or 250°C, or even 200°C.
• the product obtainable by the presently described process is a synthetic aluminosilicate molecular sieve having the framework structure of SSZ-122.
• an "organotemplate-f ree" molecular sieve relates to a molecular sieve which is substantially free of organotemplate materials, wherein “substantially”, as employed in the present disclosure with respect to the amount of one or more organotemplates contained in the molecular sieve, indicates an amount of 0.001 wt . % or less of one or more organotemplates, such as 0.0005 wt . % or less, or 0.00001 wt . % or less, or 0.000005 wt . % or less, or even 0.000001 wt . % or less thereof.
• the amounts of one or more organotemplates, if at all present in the molecular sieve may also be denoted as "impurities" or "trace amounts" within the meaning of the present disclosure.
• the molecular sieve does not contain more than an impurity of an organic structure directing agent specifically used in the synthesis of molecular sieve materials having a BOG-type framework structure, in particular specific tetraalkylammonium salts and/or related organotemplates such l-adamantyl-3- propylimidazolium salts.
• an impurity can, for example, be caused by organic structure directing agents still present in seed crystals used in the present process.
• the organotemplate-f ree molecular sieve can have a S1O2/A12O3 molar ratio of at least 10 (e.g., 10 to 100, or 10 to 60, or 15 to 100, or 15 to 60, or 15 to 40, or 20 to 100, or 20 to 60, or 20 to 40, or 25 to 100, or 25 to 60, or 25 to 40) .
• the organotemplate-f ree zeolitic material comprises an alkali metal [M] as nonframework elements
• the M:SiO2 molar ratio can be in a range of from greater than 0 to 0.1.
• the molecular sieve comprises sodium and/or potassium as non-framework elements.
• At least a portion of the alkali metal [M] optionally present in the molecular sieve is substituted by at least one cation and/or cationic element.
• the cation and/or cationic element may be selected from the group consisting of H + , NH4 + , Sc, Zr, Cr, Mo, W, Fe, Co, Ni, Cu, Zn, Ru, Rh, Rd, Ag, Os, Ir, Pt, Au, and mixtures thereof.
• the powder XRD spectra of the molecular sieve product obtainable by the present process is consistent with other materials having a BOG-type framework structure.
• Powder XRD patterns representative of BOG framework type molecular sieves can be referenced in the "Collection of Simulated XRD Powder Patterns for Zeolites" by M.M.J. Treacy and J.B. Higgins (Elsevier, Fifth Revised Edition, 2007) .
• the powder XRD patterns presented herein were determined by standard techniques. The radiation was the K-alpha/doublet of copper.
• EXAMPLE 1 Synthesis of SSZ-122 [041] 0.90 g of 50% NaOH solution, 5.00 g of deionized water and 0.096 g of Reheis F-2000 hydrated alumina (53% AI2O3, 47% H2O) were mixed together in a Teflon liner. The resulting gel was stirred until the alumina was completely dissolved. Then, 5.00 g of 30% LUDOX® HS-30 colloidal silica was added to the solution. The gel was stirred until it became homogeneous. Then, 0.15 g of as-synthesized SSZ-122 seed crystals were added to the solution and the gel was further stirred.
• the liner was then capped and placed within a Parr Steel autoclave reactor.
• the autoclave was then put in an oven heated at 135°C for 10 days.
• the solid products were recovered from the cooled reactor by centrifugation, washed with deionized water and dried at 95°C.
• the resulting product was analyzed by powder XRD and SEM.
• the powder X-ray diffraction of the product is shown in FIG. 1 and indicates that the material is a pure SSZ-122 molecular sieve.
• the SEM image is depicted in FIG. 2 and shows a uniform field of crystals.
• the product had a S1O2/A12O3 molar ratio of 26.3, according to TCP elemental analysis.
• the product had a S1O2/A12O3 molar ratio of 34.8, according to TCP elemental analysis.
• the product had a S1O2/A12O3 molar ratio of 23.7, according to TCP elemental analysis.
• Example 1 The as-synthesized product of Example 1 was calcined inside a muffle furnace under a flow of air heated to 540°C at a rate of l°C/minute and held at 540°C for 5 hours, cooled and then analyzed by powder XRD.
• the powder XRD pattern indicated that the material remains stable after calcination.

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• 2022
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