# Patent

## Title
Metallophosphate molecular sieves, methods of preparation and use

## Abstract

A new family of crystalline microporous metallophosphates designated AlPO-59 has been synthesized. These metallophosphates are represented by the empirical formula

R+rMm2+EPxSiyOz 

where R is an organoammonium cation such as the ETMA+, M is a framework metal alkaline earth or transition metal of valence 2+, and E is a trivalent framework element such as aluminum or gallium. The AlPO-59 compositions are characterized by a new unique ABC-6 net structure and compositions and have catalytic properties for carrying out various hydrocarbon conversion processes, and separation properties for separating at least one component.

## Background
FIELD OF THE INVENTION
This invention relates to a new family of charged metallophosphate-based molecular sieves designated AlPO-59. They are represented by the empirical formula of:

R+rMm2+EPxSiyOz 

where M is a divalent framework metal such as magnesium or zinc, R is an organoammonium cation such as ethyltrimethylammonium and E is a trivalent framework element such as aluminum or gallium.

BACKGROUND OF THE INVENTION
Zeolites are crystalline aluminosilicate compositions which are microporous and which are formed from corner sharing AlO2− and SiO2 tetrahedra. Numerous zeolites, both naturally occurring and synthetically prepared are used in various industrial processes. Synthetic zeolites are prepared via hydrothermal synthesis employing suitable sources of Si, Al and structure directing agents such as alkali metals, alkaline earth metals, amines, or organoammonium cations. The structure directing agents reside in the pores of the zeolite and are largely responsible for the particular structure that is ultimately formed. These species balance the framework charge associated with aluminum and can also serve as space fillers. Zeolites are characterized by having pore openings of uniform dimensions, having a significant ion exchange capacity, and being capable of reversibly desorbing an adsorbed phase which is dispersed throughout the internal voids of the crystal without significantly displacing any atoms which make up the permanent zeolite crystal structure. Zeolites can be used as catalysts for hydrocarbon conversion reactions, which can take place on outside surfaces of the zeolite as well as on internal surfaces within the pores of the zeolite.
In 1982, Wilson et al. developed aluminophosphate molecular sieves, the so-called AlPOs, which are microporous materials that have many of the same properties of zeolites, but are silica free, composed of AlO2− and PO2+ tetrahedra (See U.S. Pat. No. 4,319,440). Subsequently, charge was introduced to the neutral aluminophosphate frameworks via the substitution of SiO2 tetrahedra for PO2+ tetrahedra to produce the SAPO molecular sieves (See U.S. Pat. No. 44,408,710). Another way to introduce framework charge to neutral aluminophosphates is to substitute [M2+O2]2− tetrahedra for AlO2− tetrahedra, which yield the MeAPO molecular sieves (see U.S. Pat. No. 4,567,039). It is furthermore possible to introduce framework charge on AlPO-based molecular sieves via the introduction both of SiO2 and [M2+O2]2− tetrahedra to the framework, giving MeAPSO molecular sieves (See U.S. Pat. No. 4,973,785).
Applicants have synthesized a new family of charged metallophosphate framework materials that contain a +3 valence metal, such as aluminum or gallium, and additionally at least one of a +2 valence metal (such as magnesium or zinc) and silicon, designated AlPO-59. When the +3 valence metal is Al, this corresponds to SAPO, MeAPO, and MeAPSO compositions. The AlPO-59 materials have a unique topology that falls in the class of structures known as ABC-6 nets (See American Mineralogist, 66, 777-788 (1981)). The microporous AlPO-59 materials can be prepared with the ethyltrimethylammonium (ETMA) structure directing agent.
SUMMARY OF THE INVENTION
As stated, the present invention relates to a new family of metallophosphate molecular sieves designated AlPO-59. Accordingly, one embodiment of the invention is a microporous crystalline material having a three-dimensional framework of at least EO2− and PO2+ tetrahedral units and furthermore, at least one of [M2+O2]2− and SiO2 tetrahedral units and an empirical composition in the as synthesized form and anhydrous basis expressed by an empirical formula of:

R+rMm2+EPxSiyOz 

where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, R is an organoammonium cation selected from the group consisting of ethyltrimethylammonium (ETMA+), choline [Me3NCH2CH2OH]+, trimethylpropylammonium, diethyldimethylammonium (DEDMA+), tetramethylammonium (TMA+), tetraethylammonium (TEA+), tetrapropylammonium (TPA+) and mixtures thereof, “r” is the mole ratio of R to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:

z=(2·m+r+3+5·x+4·y)/2

and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:












TABLE A







2Θ
d(Å)
I/I0 %









7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m










Another embodiment of the invention is a process for preparing the crystalline microporous metallophosphate molecular sieve described above. The process comprises forming a reaction mixture containing reactive sources of R, E, P, one or both of M and Si, and heating the reaction mixture at a temperature of about 60° C. to about 200° C. for a time sufficient to form the molecular sieve, the reaction mixture having a composition expressed in terms of mole ratios of the oxides of:

aR2O:bMO:E2O3:cP2O5:dSiO2:eH2O

where “a” has a value of about 0.75 to about 16, “b” has a value of about 0 to about 2, “c” has a value of about 0.8 to about 8, “d” has a value of about 0 to about 4, and “e” has a value from 30 to 800.

Yet another embodiment of the invention is a hydrocarbon conversion process using the above-described molecular sieve as a catalyst. The process comprises contacting at least one hydrocarbon with the molecular sieve at conversion conditions to generate at least one converted hydrocarbon.
Still another embodiment of the invention is a separation process using the crystalline AlPO-59 material. The process may involve separating mixtures of molecular species or removing contaminants by contacting a fluid with the AlPO-59 molecular sieve. Separation of molecular species can be based either on the molecular size (kinetic diameter) or on the degree of polarity of the molecular species. Removing contaminants may be by ion exchange with the molecular sieve.


DETAILED DESCRIPTION OF THE INVENTION
Applicants have prepared a family of metallophosphate materials whose topological structure is unique. In their paper “Enumeration of 4-connected 3-dimensional nets and classification of framework silicates: the infinite set of ABC-6 nets; the Archimedean and σ-related nets,” Smith and Bennett state “To a first approximation, all silicates belonging to the ABC-6net family have x-ray diffraction patterns which can be indexed on a hexagonal prismatic unit cell with lattice parameters a ̃13.0±0.3 Å and c ̃p×(2.6±0.1 Å).” (See American Mineralogist, 66, 777-788 (1981)). One particular ETMA-Zn—Al—P—O composition of AlPO-59 indexes on a hexagonal unit cell with lattice parameters a=13.387 Å and c=18.091 Å, which is suggests an ABC-6 net structure with the stacking sequence repeating every 7 layers along the c-axis (p=18.091/2.5=7.23). The lattice parameters here are a little larger than those associated with the silicates since Zn2+ is larger than Al3+ or Si4+. This is the first known example of an ABC-6 net structure with 7-layer repeats; hence the topology of AlPO-59 family of materials is unique. The instant microporous crystalline material (AlPO-59) has an empirical composition in the as-synthesized form and on an anhydrous basis expressed by the empirical formula:

R+rMm2+EPxSiyOz 

where M is at least one framework divalent cation and is selected from the group consisting of alkaline earth and transition metals. Specific examples of the M cations include but are not limited to beryllium, magnesium, cobalt (II), manganese, zinc, iron(II), nickel and mixtures thereof. R is an organoammonium cation, examples of which include but are not limited to ethyltrimethylammonium (ETMA+), choline [Me3NCH2CH2OH]+, trimethylpropylammonium, diethyldimethylammonium (DEDMA+), tetramethylammonium (TMA+) tetraethylammonium (TEA+), tetrapropylammonium (TPA+) and mixtures thereof and “r” is the mole ratio of R to E and varies from about 0.1 to about 2.0. The value of “m” is the mole ratio of M to E and varies from 0 to about 1.0, “x” is mole ratio of P to E and varies from 0.5 to about 2.0. The ratio of silicon to E is represented by “y” which varies from about 0 to about 1.0 and “m”+“y”≧0.1. E is a trivalent element which is tetrahedrally coordinated, is present in the framework and is selected from the group consisting of aluminum, gallium, iron(III) and boron. Lastly, “z” is the mole ratio of O to E and is given by the equation:

z=(2·m+r+3+5·x+4·y)/2.

The microporous crystalline metallophosphate AlPO-59 is prepared by a hydrothermal crystallization of a reaction mixture prepared by combining reactive sources of R, E, phosphorous, and one or both of M and silicon. A preferred form of the AlPO-59 materials is when E is Al. The sources of aluminum include but are not limited to aluminum alkoxides, precipitated aluminas, aluminum metal, aluminum hydroxide, aluminum salts and alumina sols. Specific examples of aluminum alkoxides include, but are not limited to aluminum ortho sec-butoxide and aluminum ortho isopropoxide. Sources of phosphorus include, but are not limited to, orthophosphoric acid, phosphorus pentoxide, and ammonium dihydrogen phosphate. Sources of silica include but are not limited to tetraethylorthosilicate, colloidal silica, and precipitated silica. Sources of the other E elements include but are not limited to organoammonium borates, boric acid, precipitated gallium oxyhydroxide, gallium sulfate, ferric sulfate, and ferric chloride. Sources of the M metals include the halide salts, nitrate salts, acetate salts, and sulfate salts of the respective alkaline earth and transition metals. R is an organoammonium cation selected from the group consisting of ETMA+ choline, DEDMA+, trimethylpropylammonium, TMA+ tetraethylammonium (TEA+), tetrapropylammonium (TPA+) and mixtures thereof, and the sources include the hydroxide, chloride, bromide, iodide and fluoride compounds. Specific examples include without limitation ethyltrimethylammonium hydroxide, ethyltrimethylammonium chloride, choline hydroxide, choline chloride, diethyldimethylammonium chloride, diethyldimethylammonium hydroxide, tetraethylammonium hydroxide, propyltrimethylammonium chloride and tetramethylammonium chloride. In one embodiment R is ETMA+. In another embodiment, R is a combination of ETMA+ and at least one organoammonium cation selected from the group consisting of choline, DEDMA+, TMA+, trimethylpropylammonium, TEA+, and TPA+.
The reaction mixture containing reactive sources of the desired components can be described in terms of molar ratios of the oxides by the formula:

aR2O:bMO:E2O3:cP2O5:dSiO2:eH2O

where “a” varies from about 0.75 to about 16, “b” varies from about 0 to about 2, “c” varies from about 0.8 to about 8, “d” varies from about 0 to about 4, and “e’ varies from 30 to 800. If alkoxides are used, it is preferred to include a distillation or evaporative step to remove the alcohol hydrolysis products. The reaction mixture is now reacted at a temperature of about 60° C. to about 200° C. and preferably from about 125° C. to about 175° C. for a period of about 1 day to about 3 weeks and preferably for a time of about 2 days to about 10 days in a sealed reaction vessel at autogenous pressure. After crystallization is complete, the solid product is isolated from the heterogeneous mixture by means such as filtration or centrifugation, and then washed with deionized water and dried in air at ambient temperature up to about 100° C. AlPO-59 seeds can optionally be added to the reaction mixture in order to accelerate the formation of the desired microporous composition.

The AlPO-59 aluminophosphate-based material, which is obtained from the above-described process, is characterized by the x-ray diffraction pattern, having at least the d-spacings and relative intensities set forth in Table A below.











TABLE A







2Θ
d(Å)
I/I0 %









7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m










In one embodiment of the invention, the AlPO-59 is thermally stable up to a temperature of at least 400° C., and in another embodiment the AlPO-59 is thermally stable up to a temperature of at least 500° C.
The AlPO-59 may be modified in many ways to tailor it for use in a particular application. Modifications include calcination, ammonia calcinations, ion-exchange, steaming, various acid extractions, ammonium hexafluorosilicate treatment, or any combination thereof, as outlined for the case of UZM-4 in U.S. Pat. No. 6,776,975 B1 which is incorporated by reference in its entirety. Properties that are modified include porosity, adsorption, framework composition, acidity, thermal stability, etc.
As synthesized, the AlPO-59 material will contain some of the exchangeable or charge balancing cations in its pores. These exchangeable cations can be exchanged for other cations, or in the case of organic cations, they can be removed by heating under controlled conditions. A preferred method of removing organic cations from the pores is ammonia calcination. Calcination in air converts the organic cations in the pores to protons, which can, for example, lead to some removal of Al from the framework upon exposure to water vapor. When the calcination is carried out in an ammonia atmosphere, the organic cation in the pore is replaced by NH4+ cation and the framework remains intact (See Studies in Surface Science, (2004) vol. 154, p. 1324-1331). Typical conditions for ammonia calcinations include the use of gaseous anhydrous ammonia flowing at a rate of 1.1 l/min while ramping the sample at 5° C./min to 500° C. and holding at that temperature for a time ranging from 5 minutes to an hour. The resulting ammonium form of AlPO-59 has essentially the diffraction pattern of Table A. The ammonium form of AlPO-59 may then be ion-exchanged to any other form, resulting in a material with a modified composition, AlPO-59M, given by the empirical formula:

M′np+Mm2+EPxSiyOz 

where M is at least one framework metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, M′ is selected from the group consisting of NH4+, H+, alkali metals, alkaline earth metals, rare earth metals and mixtures thereof, “n” is the mole ratio of M′ to E and has a value of about 0.03 to about 2.0, “p” is the weighted average valence of M′, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:

z=(p·n+2·m+3+5·x+4·y)/2

and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:












TABLE A







2Θ
d(Å)
I/I0 %









7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m










When AlPO-59 is calcined in air, there can be loss of metal from the framework, such as Al, which can alter the x-ray diffraction pattern from that observed for the as-synthesized AlPO-59 (See Studies in Surface Science, (2004) vol. 154, p. 1324-1331). Some AlPO-59 compositions may not be stable to air calcination and subsequent exposure to water. Stability to air calcinations is favored by AlPO-59 compositions containing some Si. The stable air calcined AlPO-59 materials, AlPO-59C, are characterized on an anhydrous basis by the empirical formula:

HaMm2+EPxSiyOz 

where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, H is a proton, “a” is the mole ratio of H to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0.05 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:

z=(a+2·m+3+5·x+4·y)/2

and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table B:












TABLE B







2-Θ
d(Å)
I/I0 %









9.42-9.02
9.38-9.80
m-s



12.95-12.49
6.83-7.08
m-s



13.68-13.20
6.47-6.70
vs



15.34-14.90
5.77-5.94
w-m



16.53-15.98
5.36-5.54
w-m



18.71-18.20
4.74-4.87
w-m



21.45-20.88
4.14-4.25
w-s



21.93-21.39
4.05-4.15
w-m



23.14-22.72
3.84-3.91
w-s



25.96-25.35
3.43-3.51
w-m



26.75-26.27
3.33-3.39
m-s



27.25-26.83
3.27-3.32
w-s



29.16-28.68
3.06-3.11
w-m



30.06-29.55
2.97-3.02
w-m



31.82-31.36
2.81-2.85
w-m



33.03-32.53
2.71-2.75
w-m










The crystalline AlPO-59 materials of this invention can be used for separating mixtures of molecular species, removing contaminants through ion exchange and catalyzing various hydrocarbon conversion processes. Separation of molecular species can be based either on the molecular size (kinetic diameter) or on the degree of polarity of the molecular species.
The AlPO-59 compositions of this invention can also be used as a catalyst or catalyst support in various hydrocarbon conversion processes. Hydrocarbon conversion processes are well known in the art and include cracking, hydrocracking, alkylation of both aromatics and isoparaffin, isomerization, polymerization, reforming, hydrogenation, dehydrogenation, transalkylation, dealkylation, hydration, dehydration, hydrotreating, hydrodenitrogenation, hydrodesulfurization, methanol to olefins, methanation and syngas shift process. Specific reaction conditions and the types of feeds which can be used in these processes are set forth in U.S. Pat. No. 4,310,440, U.S. Pat. No. 4,440,871 and U.S. Pat. No. 5,126,308, which are incorporated by reference. Preferred hydrocarbon conversion processes are those in which hydrogen is a component such as hydrotreating or hydrofining, hydrogenation, hydrocracking, hydrodenitrogenation, hydrodesulfurization, etc.
Hydrocracking conditions typically include a temperature in the range of 400° to 1200° F. (204-649° C.), preferably between 600° and 950° F. (316-510° C.). Reaction pressures are in the range of atmospheric to about 3,500 psig (24,132 kPa g), preferably between 200 and 3000 psig (1379-20,685 kPa g). Contact times usually correspond to liquid hourly space velocities (LHSV) in the range of about 0.1 hr−1 to 15 hr−1, preferably between about 0.2 and 3 hr−1. Hydrogen circulation rates are in the range of 1,000 to 50,000 standard cubic feet (scf) per barrel of charge (178-8,888 std. m3/m3), preferably between 2,000 and 30,000 scf per barrel of charge (355-5,333 std. m3/m3). Suitable hydrotreating conditions are generally within the broad ranges of hydrocracking conditions set out above.
The reaction zone effluent is normally removed from the catalyst bed, subjected to partial condensation and vapor-liquid separation and then fractionated to recover the various components thereof. The hydrogen, and if desired some or all of the unconverted heavier materials, are recycled to the reactor. Alternatively, a two-stage flow may be employed with the unconverted material being passed into a second reactor. Catalysts of the subject invention may be used in just one stage of such a process or may be used in both reactor stages.
Catalytic cracking processes are preferably carried out with the AlPO-59 composition using feedstocks such as gas oils, heavy naphthas, deasphalted crude oil residua, etc. with gasoline being the principal desired product. Temperature conditions of 850° to 1100° F., LHSV values of 0.5 to 10 and pressure conditions of from about 0 to 50 psig are suitable.
Alkylation of aromatics usually involves reacting an aromatic (C2 to C12), especially benzene, with a monoolefin to produce a linear alkyl substituted aromatic. The process is carried out at an aromatic:olefin (e.g., benzene:olefin) ratio of between 5:1 and 30:1, a LHSV of about 0.3 to about 6 hr−1, a temperature of about 100° to about 250° C. and pressures of about 200 to about 1000 psig. Further details on apparatus may be found in U.S. Pat. No. 4,870,222 which is incorporated by reference.
Alkylation of isoparaffins with olefins to produce alkylates suitable as motor fuel components is carried out at temperatures of −30° to 40° C., pressures from about atmospheric to about 6,894 kPa (1,000 psig) and a weight hourly space velocity (WHSV) of 0.1 to about 120. Details on paraffin alkylation may be found in U.S. Pat. No. 5,157,196 and U.S. Pat. No. 5,157,197, which are incorporated by reference
The conversion of methanol to olefins is effected by contacting the methanol with the AlPO-59 catalyst at conversion conditions, thereby forming the desired olefins. The methanol can be in the liquid or vapor phase with the vapor phase being preferred. Contacting the methanol with the AlPO-59 catalyst can be done in a continuous mode or a batch mode with a continuous mode being preferred. The amount of time that the methanol is in contact with the AlPO-59 catalyst must be sufficient to convert the methanol to the desired light olefin products. When the process is carried out in a batch process, the contact time varies from about 0.001 hrs to about 1 hr and preferably from about 0.01 hr to about 1.0 hr. The longer contact times are used at lower temperatures while shorter times are used at higher temperatures. Further, when the process is carried out in a continuous mode, the Weight Hourly Space Velocity (WHSV) based on methanol can vary from about 1 hr−1 to about 1000 hr−1 and preferably from about 1 hr−1 to about 100 hr−1.
Generally, the process must be carried out at elevated temperatures in order to form light olefins at a fast enough rate. Thus, the process should be carried out at a temperature of about 300° C. to about 600° C., preferably from about 400° C. to about 550° C. and most preferably from about 450° C. to about 525° C. The process may be carried out over a wide range of pressure including autogenous pressure. Thus, the pressure can vary from about 0 kPa (0 psig) to about 1724 kPa (250 psig) and preferably from about 34 kPa (5 psig) to about 345 kPa (50 psig).
Optionally, the methanol feedstock may be diluted with an inert diluent in order to more efficiently convert the methanol to olefins. Examples of the diluents which may be used are helium, argon, nitrogen, carbon monoxide, carbon dioxide, hydrogen, steam, paraffinic hydrocarbons, e.g., methane, aromatic hydrocarbons, e.g., benzene, toluene and mixtures thereof. The amount of diluent used can vary considerably and is usually from about 5 to about 90 mole percent of the feedstock and preferably from about 25 to about 75 mole percent.
The actual configuration of the reaction zone may be any well known catalyst reaction apparatus known in the art. Thus, a single reaction zone or a number of zones arranged in series or parallel may be used. In such reaction zones the methanol feedstock is flowed through a bed containing the AlPO-59 catalyst. When multiple reaction zones are used, one or more AlPO-59 catalysts may be used in series to produce the desired product mixture. Instead of a fixed bed, a dynamic bed system, e.g., fluidized or moving, may be used. Such a dynamic system would facilitate any regeneration of the AlPO-59 catalyst that may be required. If regeneration is required, the AlPO-59 catalyst can be continuously introduced as a moving bed to a regeneration zone where it can be regenerated by means such as oxidation in an oxygen containing atmosphere to remove carbonaceous materials.
The following examples are presented in illustration of this invention and are not intended as undue limitations on the generally broad scope of the invention as set out in the appended claims. The products will be designated with names that contain the suffix “-59” to indicate the “-59” structure and prefix that reflects the compositional nature of the product, such as “SAPO” for a silicoaluminophosphate, ZAPO for a zinc aluminophosphate, and MAPSO for a magnesium silicoaluminophosphate, etc.
The structure of the AlPO-59 compositions of this invention was determined by x-ray analysis. The x-ray patterns presented in the following examples were obtained using standard x-ray powder diffraction techniques. The radiation source was a high-intensity, x-ray tube operated at 45 kV and 35 mA. The diffraction pattern from the copper K-alpha radiation was obtained by appropriate computer based techniques. Flat compressed powder samples were continuously scanned at 2° to 56° (2θ). Interplanar spacings (d) in Angstrom units were obtained from the position of the diffraction peaks expressed as θ where θ is the Bragg angle as observed from digitized data. Intensities were determined from the integrated area of diffraction peaks after subtracting background, “Io” being the intensity of the strongest line or peak, and “I” being the intensity of each of the other peaks.
As will be understood by those skilled in the art the determination of the parameter 2θ is subject to both human and mechanical error, which in combination can impose an uncertainty of about ±0.4° on each reported value of 2θ. This uncertainty is, of course, also manifested in the reported values of the d-spacings, which are calculated from the 2θ values. This imprecision is general throughout the art and is not sufficient to preclude the differentiation of the present crystalline materials from each other and from the compositions of the prior art. In some of the x-ray patterns reported, the relative intensities of the d-spacings are indicated by the notations vs, s, m, and w which represent very strong, strong, medium, and weak, respectively. In terms of 100×I/Io, the above designations are defined as:

    
    
        w=0-15; m=15-60: s=60-80 and vs=80-100
    
    


In certain instances the purity of a synthesized product may be assessed with reference to its x-ray powder diffraction pattern. Thus, for example, if a sample is stated to be pure, it is intended only that the x-ray pattern of the sample is free of lines attributable to crystalline impurities, not that there are no amorphous materials present.
In order to more fully illustrate the invention, the following examples are set forth. It is to be understood that the examples are only by way of illustration and are not intended as an undue limitation on the broad scope of the invention as set forth in the appended claims.
Example 1
A Teflon beaker was charged with 100.00 g ETMAOH (20 wt. %) and equipped with a high speed stirrer. With stirring, 5.15 g Al(OH)3 (80.0 wt. %) was added slowly in several portions, allowing time for stirring between additions. The addition took about 20 minutes and the reaction mixture was homogenized for an additional 90 minutes, resulting in a solution with a very slight haze. This was followed by the dropwise addition of 14.65 g H3PO4 (85 wt. %), with a pause after every dropperfull was delivered. By the end of the addition, the reaction mixture was a clear solution. Separately, 2.32 g Zn(OAc)2*2H2O was dissolved in 8.00 g de-ionized water. This solution was added dropwise to the reaction mixture, again pausing for stirring after each dropperfull. The resulting clear solution was distributed among 7 Teflon-lined autoclaves and digested at temperatures of 95° C. for 252 hours, and 125, 150 and 175° C. for 84 and 252 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. All of the products besides the 95° C. product were identified as ZAPO-59 via powder x-ray diffraction. Representative diffraction lines for the 150° C., 84 hr product are shown in Table 1. Elemental analysis of this product yielded the empirical composition ETMA0.41Zn0.44AlP1.44O5.75.











TABLE 1







2-Θ
d(Å)
I/I0 %




















4.81
18.38
w



7.58
11.65
w



9.00
9.82
w



9.73
9.08
w



12.36
7.16
m



13.18
6.71
m



14.62
6.05
w



16.00
5.54
m



16.52
5.36
w



18.12
4.89
m



19.58
4.53
m



20.20
4.39
w



20.80
4.27
s



21.02
4.22
m



22.46
3.96
m



22.94
3.87
m



23.66
3.76
w



25.02
3.56
w



25.70
3.46
vs



26.54
3.36
m



28.26
3.16
w



29.00
3.08
w



29.38
3.04
w



30.56
2.92
m



31.14
2.87
m



31.94
2.80
m



32.34
2.77
m



33.38
2.68
w



34.60
2.59
w



35.38
2.54
w



36.04
2.49
w



39.70
2.27
w



41.96
2.15
w



43.18
2.09
w



46.38
1.96
w



48.90
1.86
w



49.42
1.84
w



50.30
1.81
m



54.12
1.69
w



54.70
1.68
w










Example 2
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and equipped with a high speed stirrer. With stirring, 6.86 g Al(OH)3 (78.1 wt. %) was added in several portions, forming a nearly clear solution. Then 23.74 g H3PO4 (85 wt. %) was added quickly by the dropperfull, yielding a clear solution. Separately, 3.01 g Zn(OAc)2*2H2O was dissolved in 15.00 g de-ionized water. This solution was added dropwise with stirring and the reaction mixture remained a clear solution. The reaction mixture was distributed among 7 Teflon-lined autoclaves and digested at temperatures of 95° C. for 158 hours and 125, 150, and 175° C. for 47 and 158 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. All of the samples were identified as ZAPO-59 by powder x-ray diffraction. The characteristic diffraction lines for the 95° C. sample, which was digested for 158 hours, are shown in Table 2. Elemental analysis of this product yielded the empirical formula ETMA0.36Zn0.41AlP1.42O5.64.











TABLE 2







2-Θ
d(Å)
I/I0 %




















7.60
11.62
w



9.04
9.77
vs



9.75
9.07
w



12.40
7.13
m



13.20
6.70
s



14.64
6.04
w



16.02
5.53
m



16.53
5.36
w



18.14
4.89
m



19.64
4.52
w



20.22
4.39
w



20.80
4.27
vs



21.04
4.22
m



22.48
3.95
vs



22.95
3.87
m



25.04
3.55
w



25.74
3.46
s



26.54
3.36
m



28.08
3.18
w



29.02
3.07
w



29.35
3.04
w



30.58
2.92
w



31.12
2.87
m



32.00
2.79
m



32.32
2.77
m



34.67
2.59
w



35.34
2.54
w



36.08
2.49
w



39.72
2.27
w



41.98
2.15
w



43.16
2.09
w



46.36
1.96
w



48.88
1.86
w



49.42
1.84
w



50.32
1.81
m



54.16
1.69
w



54.64
1.68
w










Example 3
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. To this solution 6.86 g Al(OH)3 (78.1 wt. %) was added in several portions with stirring in between each addition, forming a clear solution. Then 23.74 g H3PO4 (85 wt. %) was added quickly via dropper resulting in a clear solution. Separately, 3.42 g Co(OAc)2*4 H2O was dissolved in 15.00 g de-ionized water. This solution was added dropwise with stirring, the reaction mixture becoming a purple solution. The reaction mixture was distributed among 7 Teflon-line autoclaves and digested at temperatures of 95° C. for 158 hours, and at 125, 150, 175° C. for 47 and 158 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. Other than the 95° C. reaction, powder x-ray diffraction showed that the other reactions all gave some CoAPO-59. A pure product was isolated from the 125° C./158 hr reaction. Characteristic diffraction lines for this product are shown below in Table 3. Elemental analysis showed the product to have the empirical formula ETMA0.31Co0.29AlP1.24O5.05.











TABLE 3







2-Θ
d(Å)
I/I0 %




















7.62
11.59
w



9.08
9.74
s



9.79
9.02
w



12.42
7.12
m



13.22
6.69
m



14.67
6.03
w



16.04
5.52
m



16.54
5.35
w



18.14
4.89
m



19.66
4.51
m



20.82
4.26
s



21.10
4.21
m



22.50
3.95
s



22.95
3.87
m



24.97
3.56
w



25.76
3.46
vs



26.58
3.35
m



28.20
3.16
w



29.04
3.07
w



29.44
3.03
w



30.56
2.92
m



31.16
2.87
m



32.02
2.79
m



32.34
2.77
m



33.41
2.68
w



34.64
2.59
w



35.38
2.54
w



36.03
2.49
w



39.75
2.27
w



41.99
2.15
w



43.12
2.10
w



48.92
1.86
w



50.30
1.81
m



54.74
1.68
w










Example 4
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. Then 6.86 g Al(OH)3 (78.1 wt. %) was weighed out and added in several portions, stirring for a few minutes between additions, yielding a clear solution. This was followed by the addition of 18.99 g H3PO4 (85 wt. %) in a fast dropwise manner. The resulting reaction mixture was slightly hazy. Separately, 2.94 g Mg(OAc)2*4H2O was dissolved in 15.00 g de-ionized water. This solution was added slowly, dropwise, to the reaction mixture with stirring. The reaction mixture was further homogenized after the addition was completed, becoming a nearly clear solution. The reaction mixture was distributed among 7 Teflon-lined autoclaves and digested at 95° C. for 156 hours, and 125, 150, and 175° C. for 48 and 156 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. The products from the 125° C./156 hr and 150° C./48 hr were identified as MAPO-59 via powder x-ray diffraction. The characteristic diffraction lines for the 125° C./156 hr product are shown in Table 4 below.











TABLE 4







2-Θ
d(Å)
I/I0 %




















7.60
11.62
w



9.04
9.78
m



9.78
9.03
w



12.35
7.16
m



13.14
6.73
m



14.66
6.04
w



15.94
5.55
m



16.52
5.36
w



18.08
4.90
m



19.71
4.50
m



20.15
4.40
w



20.72
4.28
s



21.02
4.22
m



21.63
4.11
w



22.42
3.96
s



22.86
3.89
m



23.61
3.77
w



25.02
3.56
w



25.72
3.46
vs



26.46
3.37
m



27.99
3.19
w



28.22
3.16
w



28.98
3.08
w



29.31
3.04
w



30.54
2.92
m



31.04
2.88
m



31.94
2.80
m



32.24
2.77
m



33.38
2.68
w



34.62
2.59
w



34.94
2.57
w



35.26
2.54
w



36.00
2.49
w



39.64
2.27
w



40.17
2.24
w



41.87
2.16
w



43.09
2.10
w



44.96
2.01
w



46.25
1.96
w



48.73
1.87
w



50.24
1.81
m



50.94
1.79
w



54.02
1.70
w



54.46
1.68
w










Example 5
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. To this solution 7.42 g Ludox AS-40 (40 wt. % SiO2) was added and the mixture stirred briefly. The suspension was transferred to a Teflon bottle and was digested at 95° C. for 45 minutes to dissolve the silica. The solution was placed back into the Teflon beaker and stirred while cooling. Next, 24.69 g Al(OH)3 (78.1 wt. %) was added in several portions taking time to homogenize the reaction mixture after each addition. By the end of the additions, the reaction mixture is a white suspension. This was followed by the dropwise addition of 28.50 g H3PO4 (85 wt. %) over a period of 5 minutes with stirring. Following the addition, the white suspension was homogenized for an additional 50 minutes. The reaction mixture was distributed among 6 Teflon-lined autoclaves and digested at 175 and 200° C. at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water, and dried at room temperature. The product digested at 175° C. for 202 hours was identified as SAPO-59 via powder x-ray diffraction. The characteristic diffraction lines for the SAPO-59 product are shown in Table 5a below. Elemental analysis showed the product to have the empirical formula ETMA0.27AlP0.71Si0.27O3.95.
A portion of the solid was calcined by heating at a rate of 2° C./min to 500° C. in N2 and holding 60 minutes in N2. The feed was then switched to dry air, and the temperature was maintained at 500° C. for 3 hours. The calcined product was analyzed by powder x-ray diffraction. The characteristic diffraction lines for calcined SAPO-59 are shown below in Table 5b.












TABLE 5









Table 5a

Table 5b















2-Θ
d(Å)
I/I0 %
2-Θ
d(Å)
I/I0 % 


















7.64
11.56
w






9.08
9.73
m
9.13
9.68
s



9.86
8.97
w



12.46
7.10
m
12.62
7.01
s



13.22
6.69
m
13.32
6.64
vs



14.80
5.98
w
15.03
5.89
m



16.06
5.52
m
16.18
5.47
m



16.64
5.32
w
16.92
5.24
w



18.20
4.87
m
18.38
4.82
m



19.78
4.49
m
20.12
4.41
m



20.82
4.26
m
21.04
4.22
m



21.20
4.19
m
21.58
4.11
m



21.82
4.07
w



22.54
3.94
m
22.82
3.89
m



22.96
3.87
m



24.24
3.67
w*
24.16
3.68
w*



25.12
3.54
w
25.48
3.49
m



25.94
3.43
vs
26.38
3.38
s



26.58
3.35
m
26.92
3.31
m



28.12
3.17
w



28.42
3.14
w
28.84
3.09
w



29.20
3.06
w



29.44
3.03
w
29.70
3.01
m



30.78
2.90
m



31.18
2.87
m
31.48
2.84
m



32.16
2.78
m



32.40
2.76
w
32.74
2.73
m



33.58
2.67
w



34.89
2.57
w



35.38
2.54
w



35.74
2.51
w



36.28
2.47
w



39.88
2.26
w



42.20
2.14
w



43.34
2.09
w



46.50
1.95
w



48.90
1.86
w



50.54
1.80
w



51.34
1.78
w



54.40
1.69
w



54.72
1.68
w







*slight SOD impurity






Example 6
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. To this solution 7.43 g Ludox AS-40 (40 wt. % SiO2) was added and the mixture stirred briefly. The reaction mixture was transferred to a Teflon bottle and digested at 95° C. for 45 minutes to dissolve the SiO2. The resulting clear solution was transferred back to the beaker and stirred to cool. An 18.25 g portion of Al(OH)3 (84.5 wt. %) was added a little at a time with time to stir in between additions. A white suspension resulted which was homogenized further for 25 minutes. Next, 28.50 g H3PO4 (85 wt. %) was added dropwise over a 30 minute period. The resulting white suspension was homogenized further for another 30 minutes before it was distributed among 6 Teflon-lined autoclaves and digested at 150 and 175° C. for 94, 189, and 301 hours at autogenous pressures. The reaction products were isolated by centrifugation, washed with de-ionized water, and dried at room temperature. The products from the 150° C. reactions and the 175° C./94 hour reaction were identified as SAPO-59 by powder x-ray diffraction. Characteristic diffraction lines for the 175° C./94 hour product are given in Table 6 below.









TABLE 6





2-Θ
d (Å)
I/I0 %

















7.57
11.68
w


9.02
9.80
s


9.72
9.09
w


12.38
7.14
m


13.14
6.73
m


14.68
6.03
w


15.96
5.55
m


16.54
5.36
w


18.10
4.90
m


19.70
4.50
m


20.72
4.28
vs


21.10
4.21
m


21.66
4.10
w


22.42
3.96
s


22.88
3.88
m


23.66
3.76
w


25.06
3.55
w


25.78
3.45
s


26.48
3.36
m


28.04
3.18
w


28.30
3.15
w


29.06
3.07
w


29.30
3.05
w


30.62
2.92
m


31.06
2.88
m


32.02
2.79
m


32.28
2.77
m


33.48
2.67
w


35.28
2.54
w


36.14
2.48
w


39.70
2.27
w


40.18
2.24
w


42.02
2.15
w


43.20
2.09
w


46.36
1.96
w


48.78
1.87
w


50.36
1.81
m


54.20
1.69
w


54.52
1.68
w









Example 7
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. To this solution 2.97 g Ludox AS-40 (40 wt. % SiO2) was added and stirred briefly. The suspension was transferred to a Teflon bottle and digested at 95° C. for an hour to dissolve the silica. The reaction mixture was transferred back to the beaker and stirred to cool. Then commenced the addition of 18.25 g Al(OH)3 (84.5 wt. %) a little at a time, allowing time for homogenization in between additions. Following the Al(OH)3 addition, the reaction mixture was homogenized for 30 minutes. Next, 28.50 g H3PO4 (85 wt. %) was added dropwise and allowed to stir for 10 minutes. Separately, 4.34 g Zn(OAc)2*2H2O was dissolved in 18.25 g de-ionized water. This solution was added dropwise to the reaction mixture with continued stirring. The final reaction mixture, a white suspension, was distributed among 6 Teflon-lined autoclaves and digested at 150 and 175° C. for 93, 188, and 301 hours. The products were isolated by centrifugation, washed with de-ionized water, and dried at room temperature. The products from the 150° C. reactions and the 175° C./93 hr reaction were identified as ZAPSO-59 via powder x-ray diffraction. The characteristic diffraction lines for the 175° C./93 hr product are given in Table 7 below.









TABLE 7





2-Θ
d (Å)
I/I0 %

















7.59
11.64
w


9.06
9.76
s


12.38
7.14
w


13.18
6.71
m


14.70
6.02
w


15.96
5.55
m


16.54
5.35
w


18.10
4.90
m


19.74
4.49
m


20.20
4.39
w


20.76
4.28
vs


21.06
4.21
m


22.48
3.95
s


22.92
3.88
m


25.08
3.55
w


25.80
3.45
s


26.50
3.36
m


28.08
3.18
w


29.09
3.07
w


29.40
3.04
w


30.70
2.91
m


31.12
2.87
m


31.98
2.80
m


32.30
2.77
m


34.73
2.58
w


35.29
2.54
w


36.14
2.48
w


39.74
2.27
w


42.04
2.15
w


43.06
2.10
w


46.37
1.96
w


48.82
1.86
w


50.36
1.81
m


54.60
1.68
w









Example 8
A Teflon beaker was charged with 130.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. To this solution 7.43 g Ludox AS-40 (40 wt. % SiO2) was added and the mixture was stirred briefly. The reaction mixture was transferred to a Teflon bottle and digested at 95° C. for an hour to dissolve the SiO2. The solution was transferred back to the beaker and stirred to cool. Separately aluminum isopropoxide (AIP) (98 wt. %) was ground to a powder. A total of 41.21 g of the powdered AIP was added to the reaction mixture over about an hour with vigorous stirring. After an hour of further homogenization, the solution was nearly clear. Then 28.50 g H3PO4 (85 wt. %) was added dropwise. Over the course of the addition, the reaction mixture became cloudy. Separately, 4.34 g Zn(OAc)2*2H2O was dissolved in 14.00 g de-ionized water. This solution was added dropwise with vigorous stirring and homogenized further post addition. The resulting reaction mixture maintained a slight turbidity and was then distributed among 8 Teflon-lined autoclaves, digested at 125, 150, 175 and 200° C. for 58 and 173 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. The products isolated from the reactions carried out at 125, 150 and 175° C. were identified as ZAPSO-59 by powder x-ray diffraction. The characteristic diffraction lines for the 150° C./173 hr product are given below in Table 8.









TABLE 8





2-Θ
d (Å)
I/I0 %

















7.60
11.63
w


9.08
9.73
s


12.44
7.11
m


13.23
6.69
m


14.78
5.99
w


16.04
5.52
m


16.60
5.34
w


18.18
4.88
m


19.76
4.49
m


20.79
4.27
vs


21.18
4.19
m


22.52
3.94
vs


22.96
3.87
m


25.12
3.54
w


25.92
3.44
s


26.54
3.36
m


28.12
3.17
w


28.38
3.14
w


29.16
3.06
w


29.37
3.04
w


30.78
2.90
m


31.16
2.87
m


32.14
2.78
m


33.59
2.67
w


35.38
2.54
w


36.26
2.48
w


40.32
2.24
w


42.18
2.14
w


43.16
2.09
w


46.42
1.95
w


48.89
1.86
w


50.46
1.81
m


54.27
1.69
w


54.62
1.68
w









Example 9
A Teflon beaker was charged with 250.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. Next, 14.28 g Ludox AS-40 (40 wt. % SiO2) was added to the solution, which was stirred briefly, transferred to a Teflon bottle and digested at 95° C. for 90 minutes to dissolve the silica. The resulting solution was transferred back to the beaker and stirred to cool. Then 34.87 g Al(OH)3 (85.07 wt. %) was added in small portions taking time to stir between additions. Once the addition was completed, the reaction mixture was stirred for an additional 90 minutes resulting in a white suspension. Then 54.80 g H3PO4 (85 wt. %) was added dropwise with vigorous stirring. A thin white gel formed that was homogenized for an additional 50 minutes. The reaction mixture was then distributed among 3Teflon-lined autoclaves, all of which were digested at 165° C. for 70 hours at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water, and dried at room temperature. The products were identified as SAPO-59 via powder x-ray diffraction. Characteristic diffraction lines for the SAPO-59 product are shown in Table 9.









TABLE 9





2-Θ
d (Å)
I/I0 %

















7.59
11.64
w


9.04
9.77
m


12.40
7.13
m


13.18
6.71
m


14.68
6.03
w


15.98
5.54
m


16.56
5.35
w


18.10
4.90
m


19.74
4.49
m


20.78
4.27
s


21.12
4.20
m


21.74
4.09
w


22.48
3.95
s


22.90
3.88
m


25.00
3.56
w


25.86
3.44
vs


26.52
3.36
m


28.10
3.17
w


28.34
3.15
w


29.14
3.06
m


30.70
2.91
m


31.07
2.88
m


32.06
2.79
m


32.32
2.77
m


33.52
2.67
w


34.88
2.57
w


35.32
2.54
w


36.20
2.48
w


40.22
2.24
w


42.10
2.14
w


43.27
2.09
w


48.82
1.87
w


50.46
1.81
m


54.26
1.69
w


54.62
1.68
w









Example 10
A Teflon beaker was charged with 13.00 g ETMAOH (20 wt. %) and placed under a high speed stirrer. A 6.29 g portion of Al(OH)3 (85.07 wt. %) was added to the solution in several additions with vigorous stirring. This resulted in a cloudy suspension. Then 23.75 g H3PO4 (85 wt. %) was added to the reaction mixture in a dropwise fashion, the reaction mixture maintaining a cloudy appearance. Separately, 2.94 g Mg(OAc)2*4H2O was dissolved in 10.08 g de-ionized water. This solution was added dropwise and the resulting cloudy reaction mixture was homogenized for an additional 45 minutes, resulting in a homogenous reaction mixture. The reaction mixture was distributed among 6 Teflon-lined autoclaves and digested at 175 or 200° C. at autogenous pressures. The products were isolated by centrifugation, washed with de-ionized water and dried at room temperature. The products from the 175° C./46 and 93 hour digestions were identified as MAPO-59 by powder x-ray diffraction. The characteristic lines for the product are shown below in Table 10.









TABLE 10





2-Θ
d (Å)
I/I0 %

















7.56
11.68
w


9.00
9.82
m


9.70
9.11
w


12.32
7.18
m


13.13
6.74
w


14.60
6.06
w


15.94
5.56
m


16.46
5.38
w


18.07
4.90
m


19.52
4.54
m


20.23
4.39
w


20.72
4.28
m


20.92
4.24
m


21.56
4.12
w


22.38
3.97
m


22.86
3.89
w


24.89
3.58
w


25.60
3.48
vs


26.46
3.37
w


28.18
3.16
w


28.92
3.08
w


30.41
2.94
m


31.04
2.88
w


31.88
2.81
m


32.16
2.78
w


34.52
2.60
w


35.29
2.54
w


35.96
2.50
w


41.78
2.16
w


42.94
2.10
w


48.69
1.87
w


50.14
1.82
m


54.47
1.68
w









Example 11
A 288.38 g portion of ETMAOH (20 wt. %) was placed into a Teflon bottle equipped with a magnetic stir bar. Then 16.47 g of Ludox AS-40 colloidal silica (40 wt. % SiO2) was added to the Teflon bottle. The bottle was sealed, mixed well and transferred to a 100° C. oven and digested for 1.5 hours to dissolve the silica. The solution was then transferred to a beaker, placed under a high speed stirrer and 54.47 g alumina (51.3 wt % Al2O3) was added. Once the addition was completed, the reaction mixture was homogenized for an additional 40 minutes. While continuing to mix, 63.28 g H3PO4 (85 wt. %) was added to the reaction mixture. The reaction mixture was homogenized for an additional 70 minutes. The final mixture was a white gel. The reaction mixture was transferred to a 600 cc autoclave. While stirring at  ̃200 rpm, the autoclave was ramped to 165° C. over a period of 3 hours and held at 165° C. for 72 hours. The reaction product was then collected and washed with deionized water by centrifugation. The solid product was then dried at 100° C. The reaction product was identified as SAPO-59 by powder x-ray diffraction. The characteristic diffraction lines for the product are given in Table 11a below. Elemental analysis showed the as-synthesized product to have the empirical formula ETMA0.29AlP0.69Si0.28O3.93.
A portion of the solid was calcined by heating at a rate of 2° C./min to 500° C. in N2 and holding 60 minutes in N2. The feed was then switched to dry air, and the temperature was maintained at 500° C. for 3 hours. The calcined product was analyzed by powder x-ray diffraction. The characteristic diffraction lines for calcined SAPO-59 are shown below in Table 11b.
Table 11









TABLE 11a





2-Θ
d (Å)
I/I0 %

















7.53
11.74
w


8.94
9.88
s


12.34
7.17
m


13.12
6.74
s


14.62
6.05
w


15.94
5.56
m


16.55
5.35
w


18.08
4.90
m


19.74
4.49
m


20.74
4.28
vs


21.12
4.20
m


21.73
4.09
w


22.44
3.96
vs


22.88
3.88
w


24.99
3.56
w


25.84
3.45
vs


26.50
3.36
m


28.08
3.17
w


28.34
3.15
w


29.06
3.07
w


30.70
2.91
w


31.08
2.88
m


32.06
2.79
m


34.92
2.57
w


35.35
2.54
w


36.06
2.49
w


42.22
2.14
m


43.12
2.10
w


48.88
1.86
w


50.56
1.80
m


54.66
1.68
w


















TABLE 11b





2-Θ
d (Å)
I/I0 %

















9.32
9.48
m


12.84
6.89
m


13.56
6.53
vs


15.20
5.82
w


16.40
5.40
w


18.56
4.78
w


21.26
4.18
m


21.72
4.09
m


23.00
3.86
m


23.40
3.80
m


25.74
3.46
w


26.62
3.35
m


27.12
3.29
m


29.01
3.08
w


29.90
2.99
m


31.68
2.82
m


32.84
2.73
m

## Claims

1. A hydrocarbon conversion process comprising contacting a hydrocarbon stream with a catalyst at hydrocarbon conversion conditions to generate at least one converted product, wherein the catalyst is selected from the group consisting of a microporous crystalline AlPO-59 material, a microporous crystalline AlPO-59M material, a microporous crystalline AlPO-59-C material, or mixtures thereof, where AlPO-59 has a three-dimensional framework of EO2−, PO2+ and at least one of [M2+O2]2− and SiO2 tetrahedral units and an empirical composition in the as synthesized and anhydrous basis expressed by an empirical formula of:


RrMm2+EPxSiyOz 

where M is at least one framework cation of valence 2+ selected from the group consisting of alkaline earth and transition metals, “m” is the mole ratio of M to E and varies from 0 to about 1.0, R is an organoammonium cation selected from the group of ethyltrimethylammonium (ETMA+), choline, diethyldimethylammonium (DEDMA+), trimethylpropylammonium, tetramethylammonium (TMA+), tetraethylammonium (TEA+), tetrapropylammonium (TPA+) and mixtures thereof, “r” is the mole ratio of R to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is the mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(2·m+r+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:











TABLE A






2-Θ
d (Å)
I/I0 %








7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m








the microporous crystalline AlPO-59M material comprises a three-dimensional framework of EO2−, PO2+ and at least one of [M2+O2]2− and SiO2 tetrahedral units the composition given by the empirical formula:


M′np+Mm2+EPxSiyOz 


where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, M′ is selected from the group consisting of NH4+, H+, alkali metals, alkaline earth metals, rare earth metals, and mixtures thereof, “n” is the mole ratio of M′ to E and has a value of about 0.03 to about 2.0, “p” is the weighted average valence of M′, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(p·n+2·m+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:











TABLE A






2-Θ
d (Å)
I/I0 %








7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m








and the microporous crystalline AlPO-59C material comprises a three-dimensional framework of EO2−, PO2+, SiO2 and optionally [M2+O2]2− tetrahedral units characterized by the empirical formula:


HaMm2+EPxSiyOz 


where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, H is a proton, “a” is the mole ratio of H to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0.05 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(a+2·m+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table B:











TABLE B






2-Θ
d (Å)
I/I0 %








9.42-9.02
9.38-9.80
m-s



12.95-12.49
6.83-7.08
m-s



13.68-13.20
6.47-6.70
vs



15.34-14.90
5.77-5.94
w-m



16.53-15.98
5.36-5.54
w-m



18.71-18.20
4.74-4.87
w-m



21.45-20.88
4.14-4.25
w-s



21.93-21.39
4.05-4.15
w-m



23.14-22.72
3.84-3.91
w-s



25.96-25.35
3.43-3.51
w-m



26.75-26.27
3.33-3.39
m-s



27.25-26.83
3.27-3.32
w-s



29.16-28.68
3.06-3.11
w-m



30.06-29.55
2.97-3.02
w-m



31.82-31.36
2.81-2.85
w-m



33.03-32.53
2.71-2.75
w-m

2. The process of claim 1 wherein the hydrocarbon conversion process is selected from the group consisting of cracking, hydrocracking, alkylation, isomerization, polymerization, reforming, hydrogenation, dehydrogenation, transalkylation, dealkylation, hydration, dehydration, hydrotreating, hydrofining, hydrodenitrogenation, hydrodesulfurization, methanol to olefins, methanation, syngas shift process, olefin dimerization, oligomerization, dewaxing, and combinations thereof.

3. The process of claim 1 wherein the hydrocarbon conversion process is hydrocracking or hydrotreating and wherein the hydrocracking or hydrotreating is operated at a temperature in the range of about 400° to about 1200° F. (204-649° C.) and a pressure in the range of atmospheric to about 3,500 psig (24,132 kPa g).

4. The process of claim 3 wherein the hydrocracking or hydrotreating is operated at liquid hourly space velocities (LHSV) in the range of about 0.1 hr−1 to 15 hr−1.

5. The process of claim 3 wherein the hydrocracking or hydrotreating is operated at hydrogen circulation rates in the range of 1,000 to 50,000 standard cubic feet (scf) per barrel of charge (178-8,888 std. m3/m3).

6. The process of claim 1 further comprising removing an effluent comprising the at least one converted product, fractionating the effluent, and recovering at least one converted product.

7. The process of claim 6 further comprising subjecting the effluent to partial condensation and vapor-liquid separation prior to fractionation.

8. The process of claim 6 further comprising recycling at least a portion of the effluent to the catalyst.

9. The process of claim 1 wherein the hydrocarbon conversion process comprises two stage operation and the catalyst is present in at least one of the two stages.

10. The process of claim 1 wherein the hydrocarbon conversion process is catalytic cracking operated at a temperature in the range of about 850° to about 1100° F., LHSV values of 0.5 to 10 and a pressure in the range of from about 0 to about 50 psig.

11. The process of claim 10 wherein the hydrocarbon stream is selected from the group consisting of gas oils, heavy naphthas, and deasphalted crude oil residua.

12. The process of claim 1 wherein the hydrocarbon conversion process is alkylation of aromatics and the converted product is at least one linear alkyl substituted aromatic, and wherein the process is operated at an aromatic:olefin mole ratio of between 5:1 and 30:1, a LHSV of about 0.3 to about 6 hr−1, a temperature of about 100° to about 250° C. and a pressure of about 200 to about 1000 psig.

13. The process of claim 1 wherein the hydrocarbon conversion process is alkylation of isoparaffins with olefins and the converted product is at least one alkylate suitable as a motor fuel component, and wherein the process is operated at a temperature of from about −30° to 40° C., a pressure from about atmospheric to about 6,894 kPa (1,000 psig) and a weight hourly space velocity (WHSV) of 0.1 to about 120.

14. The process of claim 1 wherein the hydrocarbon conversion process is the conversion of methanol to olefins wherein the process is operated at a temperature of about 300° C. to about 600° C. and a pressure from about 0 kPa (0 psig) to about 1724 kPa (250 psig).

15. The process of claim 14 wherein the methanol is in the liquid or vapor phase and the operation is in a continuous or batch mode.

16. The process of claim 14 wherein the methanol is diluted with a diluent selected from the group consisting of helium, argon, nitrogen, carbon monoxide, carbon dioxide, hydrogen, steam, at least one paraffinic hydrocarbon, at least one aromatic hydrocarbon, and mixtures thereof.

17. The process of claim 1 wherein the catalyst is located in one or more catalyst zones arranged in series or parallel configuration, and wherein the catalyst may be in fixed beds or fluidized beds.

18. The process of claim 1 further comprising regenerating the catalyst.

19. A separation process comprising contacting at least two components with a material to generate at least one separated component, wherein the material is selected from the group consisting of a microporous crystalline AlPO-59 material, a microporous crystalline AlPO-59M material, a microporous crystalline AlPO-59-C material, or mixtures thereof, where AlPO-59 has a three-dimensional framework of EO2−, PO2+ and at least one of [M2+O2]2− and SiO2 tetrahedral units and an empirical composition in the as synthesized and anhydrous basis expressed by an empirical formula of:


RrMm2+EPxSiyOz 

where M is at least one framework cation of valence 2+ selected from the group consisting of alkaline earth and transition metals, “m” is the mole ratio of M to E and varies from 0 to about 1.0, R is an organoammonium cation selected from the group of ethyltrimethylammonium (ETMA+), choline, diethyldimethylammonium (DEDMA+), trimethylpropylammonium, tetramethylammonium (TMA+), tetraethylammonium (TEA+), tetrapropylammonium (TPA+) and mixtures thereof, “r” is the mole ratio of R to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is the mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(2·m+r+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:











TABLE A






2-Θ
d (Å)
I/I0 %








7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m








the microporous crystalline AlPO-59M material comprises a three-dimensional framework of EO2−, PO2+ and at least one of [M2+O2]2− and SiO2 tetrahedral units the composition given by the empirical formula:


M′np+Mm2+EPxSiyOz 


where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, M′ is selected from the group consisting of NH4+, H+, alkali metals, alkaline earth metals, rare earth metals and mixtures thereof, “n” is the mole ratio of M′ to E and has a value of about 0.03 to about 2.0, “p” is the weighted average valence of M′, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(p·n+2·m+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:











TABLE A






2-Θ
d (Å)
I/I0 %








7.69-7.48
11.48-11.81
w



9.15-8.88
9.66-9.95
m-vs



12.55-12.25
7.05-7.22
m



13.30-13.07
6.65-6.77
w-s



14.90-14.51
5.94-6.10
w



16.13-15.87
5.49-5.58
m



16.75-16.37
5.29-5.41
w



18.28-18.02
4.85-4.92
m



19.94-19.41
4.45-4.57
w-m



20.88-20.64
4.25-4.30
m-vs



21.34-20.79
4.16-4.27
m



22.67-22.26
3.92-3.99
m-vs



23.08-22.78
3.85-3.90
w-s



25.28-24.78
3.52-3.59
w



26.11-25.43
3.41-3.50
s-vs



26.67-26.35
3.34-3.38
w-m



28.40-27.86
3.14-3.20
w



29.36-28.78
3.04-3.10
w-m



30.92-30.27
2.89-2.95
w-m



31.36-30.92
2.85-2.89
w-m



32.29-31.70
2.77-2.82
m



35.60-35.02
2.52-2.56
w-m



36.50-35.45
2.46-2.53
w



42.40-41.58
2.13-2.17
w-m



43.69-42.61
2.07-2.12
w



49.21-48.65
1.85-1.87
w



50.98-49.79
1.79-1.83
w-m



55.30-54.23
1.66-1.69
w-m








and the microporous crystalline AlPO-59C material comprises a three-dimensional framework of EO2−, PO2+ and at least one of [M2+O2]2− and SiO2 tetrahedral units characterized by the empirical formula:


HaMm2+EPxSiyOz 


where M is at least one metal cation of valence +2 selected from the group consisting of Be2+, Mg2+, Zn2+, Co2+, Mn2+, Fe2+, Ni2+, “m” is the mole ratio of M to E and varies from 0 to about 1.0, H is a proton, “a” is the mole ratio of H to E and has a value of about 0.1 to about 2.0, E is a trivalent element selected from the group consisting of aluminum, gallium, iron, boron and mixtures thereof, “x” is mole ratio of P to E and varies from 0.5 to about 2.0, “y” is the mole ratio of Si to E and varies from 0.05 to about 1.0, “m”+“y”≧0.1, and “z” is the mole ratio of O to E and has a value determined by the equation:


z=(a+2·m+3+5·x+4·y)/2


and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table B:











TABLE B






2-Θ
d (Å)
I/I0 %








9.42-9.02
9.38-9.80
m-s



12.95-12.49
6.83-7.08
m-s



13.68-13.20
6.47-6.70
vs



15.34-14.90
5.77-5.94
w-m



16.53-15.98
5.36-5.54
w-m



18.71-18.20
4.74-4.87
w-m



21.45-20.88
4.14-4.25
w-s



21.93-21.39
4.05-4.15
w-m



23.14-22.72
3.84-3.91
w-s



25.96-25.35
3.43-3.51
w-m



26.75-26.27
3.33-3.39
m-s



27.25-26.83
3.27-3.32
w-s



29.16-28.68
3.06-3.11
w-m



30.06-29.55
2.97-3.02
w-m



31.82-31.36
2.81-2.85
w-m



33.03-32.53
2.71-2.75
w-m.

20. The process of claim 19 wherein the separation is based on molecular size of the components, degree of polarity of the components, or ion exchange of the components with the material.