SYNTHETIC CRYSTALLINE ALUMINOSILICATE COMPOSITION AND METHOD FOR THE PRODUCTION THEREOF

Abstract: A synthetic crystalline aluminosilicate composition has the following chemical composition (in terms of molar ratios of oxides); 0.5-3M₂/ n O:Al₂O₃:15-30SiO₂:0-50H₂O wherein M represents a metallic cation and n is the valence of the metallic cation and also having an X-ray powder diffrac­ tion pattern having d-spacing as shown in the following Table. Interplanar Spacing, d(Å) Relative Intensity 13.59 ± 0.2 Strong 9.15 ± 0.15 Very Strong 6.55 ± 0.07 Strong 4.51 ± 0.03 Strong 3.97 ± 0.03 Very Strong 3.46 ± 0.02 Strong 3.37 ± 0.02 Strong 3.22 ± 0.02 Strong The novel composition is made by maintaining an aqueous solution containing dissolved SiO₂; Al₂O₃; Na₂O and the metal M in specified ranges of molar ratios at 150 to 200°C under autogeneous pressure for 10 to 40 hours. By the practice of this invention, crystalline aluminosili­ cate of the modernite type possessing a high silica content is produced which is of high commercial value, for example, as a catalyst or molecular sieve.

Description: DESCRIPTION OF THE INVENTION The present invention relates to a crystalline aluminosilicate composition and a method for the production thereof. More particularly, the present invention relates to mordenite having a high silica content and a novel method for the production thereof. More particularly, the present invention relates to a crystals line aluminosilicate composition having a high catalytic activity, acid resistance and thermal stability and also having a mordenite framework structure of a high silica/ alumina ratio. Mordenite, which is one of crystalline aluminosilicate zeolites, has an alurninosilicate framework which is based on an infinitely extending threedimensional network of SiO4 and A104 tetrahedra linked to each other by sharing all of the oxygens. In mordenite, the main channels are al2-membered oxygen ring and the other channels are an 8-membered oxygen. ring generally having the following chemical formula: Na20 A1203 lOSiO2 * 6H20 Like other minerals comprising crystalline aluminosilicate, mordenite releases its intercrystalline water without the breaking of the crystalline structure if it is heated to a temperature of about 300-4000C, thereby forming the main channels having dimension of 6 x 7 . Because of the existence of these channels, therefore, synthetic mordenite is used as catalyst and catalyst carrier for the cracking of various. hydrocarbons and also as an effective-adsorbent like numerous other crystalline aluminosilicates. However, when synthetic mordenite is to be used for catalytic dewaxing, production of. aromatic compounds and production. of hydrocarbons by alcohol conversion, the activity thereof must be further improved by treating the same with a mineral acid to remove aluminum, thereby increasing the silica/alumina ratio. However, the amount of aluminum which can be removed is limited from the viewpoint of thermal stability, acid strength and the maintenance of the crystal structure, since -Si-O-Si- bond in the mordenite crystalline structure is changed to -Si-O-H-by the dealumination reaction. Further, if the dealumination reaction is carried out in such a manner that silica/alumina molar ratio is taken to above a certain level,the crystal structure is destroyed. Thus, in using mordenite as a catalyst, activity thereof has been limited in the prior art, though a higher activity has been required. BRIEF DESCRIPTION OF THE DRAWINGS Figs. 1 to 5 show X-ray diffractio patterns of the synthetic, crystalline aluminosilicate compositions obtained by the process of the present invention. Fig. 6 shows carbon number distribution of a liquid hydrocarbon product according to gas chromatography. After intensive investigations and experiments, a method has been found for producing a crystalline aluminosilicate (from substantially inorganic reaction materials) having an SiO2/A1203 molar ratio of at least 15 and having a mordenite framewor' structure which exhibits remarkable shape selectivity and catalyst performance. A main object of the present invention is to provide a crystalline aluminiosilicate composition of mordenite type having a high silica content, i.e. an SiO2/A1203 molar ratio of at least 15 and also having high thermal stability, acid resistance and catalytic activity. Another object of the present invention is to provide a process for directly producing a crystalline, aluminosilicate of mordenite type having a high silica content and an SiO2/Al2 0 molar ratio of above about 15 in the aqueous reaction mixture in the hydrothermal reaction without necessitating acid treatment. According to the present invention, the above objects can be attained effectively. The present invention relates to a synthetic, crystalline aluminosilicate composition having the following chemical composition (in terms of molar ratios of oxides): 0.5-3.0M2/nO.Al2O3.15-30SiO30-50H2O wherein M is at least one metallic cation and n is a valence of the metallic cation and also having an X-ray powder diffraction pattern having a d-spacing as shown in Table 1. Table 1 Interplanner Spacing, d (A) Relative Intensity 13.59 + 0.2 S. 9.15 + 0.15 T9.S. 6.55 + 0.07 So 4.51 9 0.03 S. 3.97 + 0.03 V.5. 3.46 + 0.02 S. 3.37 + 0.02 S. 3.22 t 0.02 S. S = Strong, V.S. = Very Strong The above values were determined by standard techniques. The radiation was the K-alpha doublet of copper, and a scintillation counter spectrometer with a strip chart pen recorder was used. The peak heights, I and the positions as a function of 2 times theta, where theta is the Bragg angle, were read from the spectrometer chart. The relative intensities, I/Io, where I is the intensity of the strongest line or peak, 0 and d, the interplanar spacing in Angstrom units, corresponding to the recorded lines, were calculated. The crystalline aluminosilicate of the present invention has the highest relative intensity at an interplanar spacing of 9.15 A. From the X-ray powder diffraction pattern, it is understood that the framework structure of the crystalline aluminosilicate of the present invention is the same as a framework structure of conventional mordenite. The present invention also relates to a method for producing the above crystalline aluninosilicate composition. More particularly, the present invention also provides a method for producing a crystalline aluminosilicate composition which comprises preparing an aqueous reaction mixture substantially comprising-in-- organic reaction materials of the following molar ratios of oxides: SiO2/A1203 16-50 Na2O/SiO2 0.05-1.5 (Na2O+M2/nO)/5i62 0-05-1.5 H2O/(Na2O+M2/nO) 100-1200 wherein M is at least one metallic cation and n is the valence of the metallic cation, and maintaining the mixture at a temperature in the range of about 150-200 C under an autogenous pressure for about 10-40 hours. A preferred composition of the aqueous reaction mixture is as follows (molar ratios of oxides): SiO2/A1203 16-35 Na2O/SiO2 0.05-0.50 (Na20+M2/nO)/SiO2 0.05-0.50 H2O/(Na2O+M2/nO) 100-1000 The most suitable range of the proportion of the components of the aqueous mixture is as follows (molar ratios of oxides): SiO2/Al2O3 16-30 (Na2O+M2/nO)/SiO2 0.08-0.25 H2O/(Na2O+M2/nO) 100-1000 wherein M is at least one metallic cation selected from the group consisting of Groups I and TI in the Periodic Table, particularly, sodium, lithium, barium, calcium and strontium, most preferably lithium and n represents the valence of the metallic cation. M2/nO and Na2 0 are both in the free form. They are generally in the form of hydroxide or an extremely weak acid salt effective in the zeolite synthesis such as aluminate or silicate. "Free Na2O" can be controlled by the addiction of aluminum sulfate, sulfuric acid or nitric acid. The oxides of the above composition used in the preparation of the aqueous reaction mixture are those generally used in the preparation of synthetic zeolites. For example, silica sources are sodium silicate, silica gel, silicic acid, dissolved silica, aqueous colloidal silica sol, powdery silica and amorpnous silica. As alumina sources, there may be used various aluminum salts such as activated alumina, alumina, alumina trihydrate, sodiumaluminate and. aluminum chloride, nitrate and sulfate. The metal oxide of the formula M2/nO is added to the reaction mixture in the form of a watersoluble salt or hydroxide thereof. Na2O used as sodium cation source is added in the form of sodium hydroxide, sodium aluminate or sodium silicate. Li2 0 used as lithium cation source is added in the form of its hydroxide, halide, sulfate, nitrate, chlorate (LiClO4) or the like. The aqueous reaction mixture is prepared by mixing the above silica source, alumina source, alkali source and water together Particularly preferred silica sources are sodium silicate, water glass and colloidal silica. Particularly preferred alumina sources are sodium aluminate and aluminum sulfate. In the production of the crystalline aluminosilicate having a high silica content of the present invention, water content of the aqueous reaction mixture is important. As described above1 the reaction mixture should contain at least 100 moles,. preferably at least 300-500 moles, of water per mole of Na2O+M2/nC By controlling the water content in the above-described range, the mixing and stirring of the gel reactants are facilitated. As described above, after mixing the reagents, the reaction mixture is maintained at a temperature in the range of about 150-2000C for about 10-40 hours under an autogenous pressure. The crystallinity of the crystallized product can be further improved and the formation of amorphous aluminosilicate can be prevented by adding a mineralizer to the aqueous reaction mixture in the crystallization. As the mineralizers, there may be used salts of alkali metals and alkaline earth metals such as NaCl, Na2CO3, Na2SO4, Na2SeO4, KC1, RBr, KF, Back2 and Babr2. The amount of the mineralizer is preferably such that molar ratio of X /SiO2 wherein X represents an anion of the salt used as the mineralizer (if the anion has a valence of n, one valence equivalent thereof is taken), is in the range of about 0.01-20. The resulting crystalline aluminosilicate is separated out of the solution by filtration, washed with water and dried. After drying, the product is calcined at a temperature of above 2000C in air or an inert gas atmosphere to remove intercrystalline water. Thus, the dehydrated product is useful as a catalyst for chemical reaction or catalyst carrier. Further, it is preferred to remove or to exchange at least a part of the cation in the product by thermal treatment and/or ion exchange. The cation-exchanged product is effective particularly as a catalyst for hydrocarbon conversion. A cation species used for the ion-exchange may be selected depending upon the intended reaction. Among them, at least one cation selected from the group consisting of metals of Groups IIa, IIIa, IVa, Ib, IIb, IIIb, IVb and VIII is preferred. In addition, the cation in the product can be exchanged with hydrogen ion by the treatment with an acid or by the combination of the ion exchange with NH4 with the thermal treatment. Exchanging cations preferred for the cracking, isomerization and alkylation of hydrocarbons are hydrogen ion and cations of metals of Group VIII in the Periodic Table. The cation exchange may be effected by con- tacting the crystallized product with salt(s) of desired exchanging cation(s). In this step, various salts may be used. Particularly, chlorides, nitrates, sulfates and acetates are preferred. Framework aluminum can be removed and silica/ alumina ratio can be increased to above 30 by contacting the hydrogen ion-exchanged crystalline aluminosilicate of the invention with an acid extraction. As a result, the acid strength and catalytic activity can be improved further. In the case of mordenite zeolite used in the prior art, it is difficult to attain a high silica/ alumina ratio by a conventional extraction treatment with an acid. Under the circumstances as above, specific processes such as a process wherein the combination of an acid extraction with steaming is employed or a process wherein multi-stage extraction treatment with an acid have been proposed. However, when the crystalline aluminosilicate of mordenite type having a high silica content according to the present invention is used, the silica/alumina ratio can be increased remarkably without destroying the crystalline structure as will be described below. As preferred acids used in the extraction treatment, there may be mentioned various mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid and nitric acid as well as organic acids such as acetic acid and formic acid. Among them, hydrochloric acid is particularly preferred. The concentration of the acid used is in the range of 1 to 12 N. The temperature in the process of the extraction with an acid ranges from room temperature to about 950C. The higher'the temperature, the better. For example, by effecting the acid treatment with 3N hydrochloric acid at 900C for 4 hours, silica/alumina molar ratio of the starting crystalline aluminosilicate (mordenite type) can be converted from 20 to 35. It has been found that after this treatment, crystallinity of the product was substantially unchanged as compared with that of the starting material. By the above-described process, crystalline aluminosilicate having a silica/alumina molar ratio of at least about 600-700 can be obtained. Thus, the present invention relates to a synthetic crystalline aluminosilicate composition having the following chemical composition (in terms of molar ratios of oxides): 0.5-3M2/n0.Al2O3.15-30SiO2.0-50H2O wherein M represents a metallic cation and n is the valence of the metallic cation and also having an X-ray powder diffraction pattern having d-spacing as shown in Table 1, and a process for the production of said composition. According to the present invention, crystalline aluminosilicate (mordenite type) having a high silica content and a high commercial value can be provided. The following examples further illustrate the crystalline aluminosilicate of the present invention. Example 1 9.lg of aluminum sulfate, l.lg of concentrated sulfuric acid and 14g of sodium chloride were dissolved in 150g of pure water. 49g of water-glass (No. 3 waterglass: Japanese Industrial Standard) was added to the solution to obtain an aqueous reaction mixture having a composition of 1.5Na2O A1203 17.0SiO2 641H2O. The mixture was aged at room temperature for about one hour and then charged in an autoclave. The temperature was elevated rapidly and the mixture was maintained to 1800C for 20 hours. The resulting product was cooled at room temperature, filtered, washed thoroughly with water and dried at 110 C. A part of the solid product was calcined at 700 C in air. After allowing the same to adsorb water, it was subjected to chemical analysis to obtain the following results: Chemical Composition Wt. % SiO2 74.4 Al2O3 7.26 Na2O 5.04 Ignition loss (600 C, 3 hrs.) 11.0 The chemical composition was as follows (in terms of molar ratios of oxides): 1.14NazOA1203 17.SSiO2 8.6H2O A part of the product was subjected to X-ray analysis to obtain the results shown in Table 2 and Fig. 1. From the results, it was proved that the product having a crystal structure of mordenite was a new synthetic, crystalline aluminosilicate (HSM). TABLE 2 Interclannar Spacing a ( ) Relative Intensity 13.59 + 0.2 S. 10.16 + 0.2 S. t.15 + 0.1 V.S. 6.55 + 0.05 S. 6.36 + 0.05 S. 6.03 + 0.05 S. 5.80 + 0.05 S. 5.08 + 0.05 S. 4.51 + 0.02 S. 3.97 + 0.02 V.S. 3.81 + .0.02 S. 3.75 + 0.02 S. 3.46 + 0.01 S. 3.37 + 0:01 S. 3.22 + 0.01 S. 2.89 + 0.01 S. 2.51 + 0.01 S. 2.03 + 0.01 S. 2.01 + 0.01 S. 1.87 + 0.01 S. -S. = Strong, V.S. = Very Strong Example 2 6.7g of aluminum sulfate, 1.97g of concentrated sulfuric acid and 14g of sodium chloride were dissolved in 150g of pure water. 49g of water-glass (No. 3 waterglass) was added to the solution to obtain an aqueous reaction mixture having a composition of 2.53Na2O:Al2O3: 23.SiO2:990H2O. The mixture was aged at room temperature for about one hour and then charged in an autoclave. The temperature was elevated rapidly and the mixture was maintained at 1800C for 20 hours. The resulting product was cooled to room temperature, filtered, washed thoroughly with water and dried at 110 C. A part of the solid product was calcined at 7000C in air. After allowing the same to adsorb water, it was subjected to chemical analysis to obtain the following results. Chemical Composition wt. % SiO2 79.1 Awl203 5.96 Na20 3.51 Ignition loss (6000C, 3 hrs.) 10.0 The chemical composition was as follows (in terms of molar ratios of oxides). 0.98Na20'A1203 22.6SiO2 9.5H20 A part of the product was subjected to X-ray analysis to obtain the results shown in Table 2 and Fig. 2. From the results, it was proved that the product had crystal structure of mordenite. Example 3 26.2g of aluminum sulfate, 10.4g of concentrated sulfuric acid and 60.g of sodium chloride were dissolved in 542g of pure water. 207g of water glass (No. 3 waterglass) was added to the solution to obtain an aqueous reaction mixture having a composition of 2.54Na20 A1203 25.3SiO2955R2O. The mixture was aged at room temperature for about one hour and then charged in an autoclave. The temperature was elevated rapidly and the mixture was maintained at 1800C for 20 hours. The resulting prod uct was cooled to room temperature, filtered, washed thoroughly with water and dried at 110owe for about 16 hours. A part of the solid product was subjected to the X-ray analysis to obtain the results shown in Table 2 and Fig. 3. From the results, it was proved that the product had a crystal structure of mordenite. A part of the product was calcined at 7000C in air, then allowed to adsorb water and subjected to chemical analysis to obtain the following results. Chemical Composition t. % SiO2 82.3 Al2O3 5.43 Na2O 3.31 Ignition loss (6600C, 3 hrs.) 8.9 The chemical composition was as follows (in terms of molar ratios of oxides). 1.00Na2OAl2O3.25.8SiO2.9.3H2O Example 4 48.2g of aluminum sulfate, 4.0g of concentrated sulfuric acid and 70g of sodium chloride were dissolved in 750g of pure water. 245g of water-glass (No. 3 waterglass) was added to the solution to obtain a mixture having a composition of 1.5Na20-A1203 16.0SiO2 535H20. The mixture was aged at room temperature for about one hour and then charged in an autocalve. The temperature was elevated rapidly and the mixture was kept at 1800C for 20 hours. The resulting product was cooled to room temperature, filtered, washed thoroughly with water and dried at 1100C. After the drying, a part of the solid product was calcined at 7000C in air, allowed to adsorb water and subjected to chemical analysis to obtain the following results. Chemical Composition wt. % SiO2 8.54 Al2O3 75.4 Na2O 5.79 Ignition loss (6000C, 3 hrs.) 10.3 From the above analytical results, the synthetic, crystalline aluminosilicate in this example can be represented in terms of molar ratios of oxides as follows: l.lla2OA1 203 l3OSiO2 6. 8H2 0 From the results of X-ray diffraction (Fig. 4), it was proved that the product had a crystal structure of mordenite type. Example 5 77g of aluminum sulfate, 14.7g of concentrated sulfuric acid and 140g of sodium chloride were dissolved in 1500g of pure water. 490g of water-glass (No. 3 water-glass) was added to the solution to obtain an aqueous reaction mixture having a composition of 2.2Na20° A12O3.20SiO2.718H2O. The mixture was aged at room temperature for about one hour and then charged in an autoclave. The temperature was elevated rapidly and the mixture was maintained at 1800C for 20 hours. The resulting product was cooled to room temperature, filtered. washed thoroughly with water and dried at 1100C. After the-drying, a part of the solid product was calcined at 700 C in air, allowed to adsorb water and subjected to chemical analysis to obtain the following results: Chemical Comcosition wt. % SiO2 80.7 A12O3 6.64 Na2O 4.52 Ignition loss (6000C, 3 hrs.) 8.2 From the above analytical results, the synthetic, crystalline aluminosilicate in this example can be represented in terms of molar ratios of oxides as follows: 1.12Na2O.Al2O3. 20.6Si02 7H20 From the results of X-ray diffraction (Fig. 5), it was proved that the solid product had a crystalline structure of mordenite type. Example 6 9.lg of aluminum sulfate, l.lg of concentrated sulfuric acid and 14g of sodium chloride were dissolved in 150g of pure water, 49g of water-glass (No. 3 waterglass) and 7.6g of LiOHH2O were added to the solution. The mixture had a composition of 0.5 Li200 98Na2OAl2O3. 17.0SiO2641H2O. The mixture was aged at room temperature for about one hour and then charged in an autoclave. The mixture was maintained at 1800C for 20 hours. The resulting product was cooled to room temperature, filtered, washed thoroughly with water and dried at 1100C for about 16 hours. A part of the product was calcined at 7000C in air, allowed to adsorb water and subjected to chemical analysis to obtain te following results: Chemical Composition wt. % SiO2 75.1 Al2O3 7.47 Na2O 3.86 Li2O 0.40 Ignition loss (6000C, 3 hrs.) 11.1 From the above analytical results, the following composition.in terms of molar ratios of oxides was obtained: 0.18Li20 0.85Na20 A1203 17.1SiO2 8.4H20 A part of the product was subjected to the X-ray analysis to obtain the same results as in Example 1. From the results, it was proved that the product had a crystalline structure of mordenite. Example 7 9.lg of aluminum sulfate, I.lg of concentrated sulfuric acid and 14g of sodium chloride were dissolved in 150g of pure water. 49g of water-glass, (No. 3 waterglass) 20g of CaCl2 and 14g of Na0H were added to the solution to obtain an aqueous reaction mixture having a composition of 0.51CaO-0.98Na20-A1203 17.0SiO2-641H20. The mixture was aged at room temperature for about one hour, charged in an autoclave and maintained at 1800C for 20 hours. The resulting product was cooled to room temperature, filtered, washed thoroughly with water and dried at 1100C for about 16 hours. A part of the solid product was calcined at 7000C in air, allowed to adsorb water and subjected to the chemical analysis to obtain the following results: Chemical ComDosition wt. % SiO2 75.8 -A1203 7.81 Na2O 4.51 CaO 7.81 Ignition loss (6000C-, 3 hrs.) 10.75 From the above analytical results, the following composition in terms of molar ratios of oxides was obtained: : 0.17CaO.0.95Na2O.Al2O3.16.5SiO2.7.8H2O Example 8 Thermal stability of the new crystalline aluminosilicate (HSM) obtained in EXample 1 was compared with that of a commercially available, synthetic mordenite. An X-ray sample-heating device capable of scanning a specific angle of diffraction while heating is effected at a rate of 5 C/min. in air was used. The operation was effected by a standard technique of X-ray powder diffraction. Radiation was the K-a doublet of copper and the intensity of diffraction line at 25.7028 was measured. The measurement was continued while the tem- perature was elevated, taking an intensity of diffraction line at 2# = 25.7 @ at 3000C as 100. Thus, a point at which the relative intensity of the line is lowered to below 100 was defined as thermal resisting temperature and a point at which the relative value is lowered to was defined as limiting thermal resisting temperature. The results of the measurement are shown in Table 3. Table 3 Limiting Thermal Resist- Thermal Resist ance Temp. ( C) ance Temp. ( C) Conmercially Available Zeolon lOCH 740 880 Mordenite of a high silica content (HSM) 810 970 It is apparent from the above results that mordenite having a high silica content after the synthesis has an improved thermal stability due to the large number of bands -Si-O-Si-. Example 9 Activity of the new crystalline aluminosilicate obtained in Example 1 (HSM) was compared with that of a co=mercially available synthetic mordenite. The cracking reaction of n-hexane was effected in a glass reactor. The new crystalline aluminosilicate (HSM) was ion-exchanged with 5% NH4Cl solution at 800C for 1.5 hours. The ion-exchange was repeated four times. Then1 the L;H4-type HSM was calcined at 600 CC for 3 hours to obtain H-type zeolite. (Preparation of alumina binder) A solution of 202g of sodium aluminate (NaA102) in 264g of water (H20) was added to an ion-exchanged water (4800g) kept at 700C. Then, a solution of 288g of aluminum sulfate [A12(S04)3 17.8E20] in 507g of water (H20) was added thereto and the whole was aged for one hour. Thereafter, the mixture was filtered and washed to obtain an aluminum hydrogel. (reparation of pellets) The new crystalline aluminosilicate (HSM) of H-type obtained as above was mixed with the alumina binder in such as ratio that weight ratio of them after the calcination would be 7:3. The mixture was kneaded well together with water and then extrusion-molded to obtain pellets of a diameter of l.5mm. The pellets were dried and then calcined at 6000C for 3 hours to obtain a catalyst. (Evaluation of activity) n-Hexane cracking reaction was carried out as follows: 3.2my. of the catalyst ground into 16/30 mesh was charged in a glass reactor. Then, 3.2my, of silica chips also ground into 16/30 mesh was placed over the catalyst bed to facilitate the diffusion and heating of the reactants. The catalyst bed was kept at 3000C. n-Hexane was charged in a saturator kept at 100C. Nitrogen gas was introduced therein as a carrier gas so that n-hexane concentration in the nitrogen gas would be 10%. After a certain period of time has passed after the introduction of the n-hexane/nitrogen mixture in the reactor, a residual amount of n-hexane was measured by gas chromatograph. From the residual amount and the amount of n-hexane in the feed, conversion was calculated. Thereafter, air was introduced in the reactor, and carbonaceous substances deposited on the catalyst were burnt at 500 C to recover the fresh condition of the catalyst. Space velocity was altered and the experiment was effected again. Conversions of n-hexane at 300"C and 2750C were thus determined to obtain the results shown in Table 4. From the results, it is understood that the new crystalline aluminosilicate obtained in Example 1 had a high n-hexane cracking activity. TABLE 4 n-Hexane-Cracking Activities k 1 (1n7) Reaction temp. (OC) 300 - 300 275 Contact time (HR-1)/1/S.V x 102 1.67 0.83 1.67 Time after initiation of the reaction (Min.) 5 (*1) 3.22 (*1) 10 (*1) 0.94 1.51 20 0.94 0.36 0.40 30 0.41 0.33 45 0.26 60 0.1.6 (*1) 1008 cracking of n-hexane S.V. in explanation of contact time means volume hourly space velocity. Example 10 Activity of the new crystalline aluminosilicate (lISM) obtained in Example 1 was compared with that of a commercially available synthetic mordenite. Alcohol conversion reaction was effected in a glass reactor. 3.0ml. of the aluminosilicate zeolite of 16/30 mesh obtained in Example 9 was mixed thoroughly with 3.0ml. of silica chips also ground into 16/30 mesh. The mixture was charged in a glass reactor. The catalyst bed was kept in nitrogen stream at 5000C for 2 hours. Then, the temperature was lowered to 3700C in the nitrogen stream and the whole was kept at that temperature. Then, the supply of nitrogen stream was stopped and methanol was introduced rapidly at a rate of 4.5m1./hr. in the reactor. After one hour, the methanol injection was stopped and nitrogen was introduced again therein to purge the reaction product and unreacted reactants from the reactor. The product discharge from the reactor was cooled with water at 200C to separate the same into a gaseous product and a liquid product (mixture of water and hydrocarbons). The resulting liquid product had the following composition: Hydrocarbons 0.5g Water 1.93g The theoretical quantity of water to be formed was 1.99g. Yield of water was thus 97, Carbon number distribution of the liquid hydro- carbons according to gas chromatography is shown in Fig. 6. The composition of the gaseous product was as shown in Table 5. Table 5 Gas Composition C1 24.5% C2 23.0% C3 - 19.3% C3 10.5% iC4 6.3% nC4 4.6% 4 7.18 iC5 2 3% nC5 0.4% c5= 1.9% Comparative Example The commercially available, synthetic mordenite (molded product of Zeolon 10 OH) used in Example 8 was ground into 16/30 mesh and subjected to the reaction in the same manner as in Example 9. The liquid product comprised substantially methanol and contained only a trace of hydrocarbons. From the above results, it is apparent that the synthetic, crystalline aluminosilicate (HSM) of the present invention has a high catalytic activity. The Periodic Table of the elements for the purpose of this patent specification is the Periodic Table published by the Fisher Scientific Company, Catalogue No. 5-702-10. Mesh sizes referred to herein are those of the American Society for Testing Materials (ASTM), Standard E-ll-70.

Claims: CLAIMS 1. A synthetic, crystalline aluminosilicate composition having the following chemical composition (in terms of molar ratios of oxides): 0.5-3.0M2/nO;A1203:15-30Si02:0-50H20 wherein M is at least one metallic cation and n is the valence of the metallic cation and also having an X-ray powder diffraction pattern having a d-spacing as shown in Table 1. 2. A synthetic, crystalline aluminosilicate composition according to claim 1 wherein M is or comprises at least one member selected from the alkali metal cations and alkaline earth metal cations. 3. A synthetic, crystalline aluminosilicate composition according to claim 1 or claim 2 wherein M is or comprises at least one member selected from sodium cation, lithium cation and calcium cation. 4. A synthetic, crystalline aluminosilicate composition according to any of claims 1 to 3 wherein M is or comprises a mixture comprising sodium cation and lithium cation. 5. A synthetic crystalline aluminosilicate composition according to any one of claims 1 to 4 which has one of the following chemical composition (in terms of molar ratios of oxides): (a) 1.14Na20.A1203:17.5SiO2 & .6H20; or (b) 0.98Na2O:Al2O3:22.6SiO2:9.5H2O; or (c) l.OONa2O:A1203:25. 8Si02:9 .3H20. 6. A catalyst for use in hydrocarbon conversion processes comprising a synthetic, crystalline aluminosilicate composition according to any one of or W claims 1 to 5,1the method of claim 12 or claim 13, which has been cation exchanged and contains at least one cation selected from the metals of Groups IIa, IIIa, IVa, Ib, IIb, IIIb, Ivb, and VIII. 7. A method for producing a crystalline aluminosilicate which comprises preparing an aqueous reaction mixture substantially comprising inorganic reaction materials of the following molar ratios of oxides: SiO2/A1203 16-50 Wa20/SiO2 0.05-1.5 (Na2O+M2jnO) /SiO2 0.05-1.5 H20/ (Na20+M2 in0 100-1200 wherein M is at least one metallic cation and n is the valence of the metallic cation, and maintaining the mixture at a temperature in the range of about 150-2000C under an autogenous pressure for about 10-40 hours. 8. A method for producing a crystalline aluminosilicate composition according to claim 7 wherein the aqueous reaction mixture has the¯following composition (in terms of molar ratios of oxides): SiO2/12e3 16-30 Na2O/SiO2 0.08-0.25 (Na2O+M2/nO/SiO2 0.08-0.25 H20/(Na2O+M2 in0 100-1000 wherein M is at least one metallic cation and n is the valence of the metallic cation. 9. A method for producing a crystalline aluminosilicate composition according to claim 7 or claim 8 wherein M in the aqueous reaction mixture is at least one member selected from alkali metal cations and alkaline earth metal cations. 10. A method for producing a crystalline aluminosilicate composition according to claim 9 wherein M in the aqueous reaction mixture is a mixture comprising sodium cation and lithium cation. 11. A method for producing a crystalline aluminosilicate composition according to any one of claims 7, 8, 9 or 10 wherein the composition of the aqueous reaction mixture, expressed in terms of molar ratios of oxides, is one of the (a) 1: 5Na20:A1203: 17.0SiO2:641H20; or or (b) 2.53Na20:A1203:23,1:SiO2:990H20; or (c) 2.54Na20:A1203:25.3SiO2:955H20 and the crystallization is effected at about 1800C for about 20 hours. 12. A method for producing a hydrogen ion-exchanged crystalline aluminosilicate composition which comprises contacting a synthetic, crystalline aluminosilicate composition according to any one of claims 1 to 5 with an acid. 13. A method according to claim 12 in which the contacting with an acid yields a hydrogen-ion exchanged material, and wherein the method comprises further contacting the resulting crystalline aluminosilicate composition of hydrogen ion-exchanged type with an acid to increase silica/alumint ratio of the crystalline aluminosilicate composition of hydrogen ion-exchanged type.

Inventors: HASIMOTO, TAKAO, MAESHIMA, TSUGIO, NUMURA, TOMIO, SAKURADA, SATOSHI, TAGAYA, NOBUAKI, TOYOIZUMI, TAKEO
Applicants: TOA NENRYO KOGYO KABUSHIKI KAISHA
Application year: 1981
Main classification: C01B33
IPC codes: B01J29, C01B39, C07C1