SYNTHETIC, CRYSTALLINE, POROUS MATERIAL CONTAINING OXIDES OF SILICON AND BORON

Abstract: A synthetic, crystalline, porous material containing oxides of silicon and boron is disclosed, which, in the non-calcined state, has the following empyrical formula: mM 2/n O,pR,xM I ₂O₃,(1-x)B₂O₃,yM II O₂,qH₂O and, in the calcined and anhydrous state, has the following empyrical formula: mM 2/n O,xM I ₂O₃,(1-x)B₂O₃,yM II O₂, wherein : M is an H⁺, NH or a metal cation with valence n, M I is a trivalent metal selected from Al, Cr, Fe, Ga, V or Mn, M II is either Si or mixtures thereof with such tetravalent metals as Ge, Ti or Zr, R is piperidine or hexamethyleneimine, m has a value comprised within the range of from 0.1 to 1.5, x has a value comprised within the range of from 0 to 0.9, y has a value greater than 2 and preferably comprised within the range of from 5 to 300, p has a value greater than zero and smaller than 3, and q has a value greater than zero and smaller than 5, and having a volume of the pores larger than 0.3 cm³/g.

Description: The present invention relates to synthetic, crystalline and porous materials containing Si oxide and B oxide, and to the method of their preparation. Several synthetic materials based on Si and B oxides are known, such as the zeolite called AMS-lB, prepared in the presence of the tetrapropylammonium cation, and disclosed in BE-A-859,656. BE-A-877,205 discloses several synthetic materials of that kind, having a crystalline porous structure: these are synthesized in the presence of cations capable of addressing the synthesis towards the desired structure, and are called BOR-A (tetramethylammonium), BOR-B (tetraethylammonium), BOR-C (tetraethylammonium or tetrapropylammonium or a cation derived from ethylenediamine) and BOR-D (tetrabutylammonium). BE-A-896,686 discloses boralites BOR-E, having a structure intermediate between BOR-C and BOR-D (mixture of tetraethylammonium and tetrapropylammonium, or methylbutylammonium). FR-A-2 573 326 discloses a zeolite consisting of Si- and B-oxides, which is prepared in the presence of an optically active enantiomer of the N,N-dimethyl-3-methyl-piperidinium cation. The present Applicants have now found a synthetic zeolite containing oxides of silicon and boron, the synthesis of which is realized in the presence of piperidine or hexamethyleneimine, which can be used either as a molecular sieve, or as an ion-exchanger, or as a catalyst in several reactions among which, for exemplifying purposes, hydrocarbon cracking, oligomerization of olefins and skeleton isomerization can be mentioned. The object of the present invention is a crystalline, porous material containing oxides of silicon and boron and having, in the non-calcined state, the following empirical formula: mM 2/n O,pR,xM I ₂O₃,(1-x)B₂O₃,yM II O₂,qH₂O and having, in the calcined and anhydrous state, the following general formula: mM 2/n O,xM I ₂O₃,(1-x)B₂O₃,yM II O₂, wherein : M is an H⁺, NH + / 4 or a metal cation with valence n, M I is a trivalent metal selected from Al, Cr, Fe, Ga, V or Mn, capable of replacing a portion of boron in the crystal lattice, M II is either Si or mixtures thereof with such tetravalent metals as Ge, Ti or Zr, capable of replacing a portion of silicon in the crystal lattice, R is piperidine or hexamethyleneimine, m has a value comprised within the range of from 0.1 to 1.5, x has a value comprised within the range of from 0 to 0.9, preferably equal to zero or smaller than 0.5, y has a value greater than 2 and preferably comprised within the range of from 5 to 300, p has a value greater than zero and smaller than 3, and q has a value greater than zero and smaller than 5, and having a volume of the pores larger than 0.3 cm³/g, preferably equal to, or larger than, 0.35 cm³/g. The passage from a cationic form to a different cationic form can be carried out by means of the usual exchange processes known from the prior art. The synthetic material in accordance with the present invention results crystalline on X-ray analysis. Such an analysis was carried out by means of a powder diffractometer equipped with an electronic impulse counting system, using Cukα radiation. For computing the values of the intensities, the heights of the peaks were measured and the relevant percentages relatively to the height of the most intense peak were computed. The main reflections for the product dried at 120°C are characterized by the following d values (wherein d is the interplanar distance): d (Å=10⁻ ¹ nm) 100 I/I o 27.1 ± 0.4 70-95 13.5 ± 0.3 80-100 12.3 ± 0.2 100 11.1 ± 0.2 40-50 9.2 ± 0.1 30-40 9.0 ± 0.1 30-40 4.45 ± 0.05 25-35 3.98 ± 0.05 25-35 3.53 ± 0.05 15-30 3.39 ± 0.05 45-55 3.30 ± 0.05 25-35 The main reflections for the product calcined at 550°C are characterized by the following d values: d (Å=10⁻¹nm) 100 I/I o 12.3 ± 0.2 100 11.05 ± 0.2 65-75 8.80 ± 0.1 55-70 6.82 ± 0.05 10-20 6.22 ± 0.05 20-35 6.15 ± 0.05 20-35 5.52 ± 0.05 10-20 4.36 ± 0.05 10-20 4.08 ± 0.05 15-25 4.03 ± 0.05 15-25 3.88 ± 0.05 30-40 3.72 ± 0.05 15-25 3.40 ± 0.05 35-50 In Figure 1, the I.R. spectrum of non-calcined product, and in Figure 2 the spectrum of calcined product is shown (on the abscissa, the wave number as cm⁻¹, and on the ordinate the transmittance % is reported). Another aspect of the present invention is a process for hydrothermally preparing a synthetic, crystalline and porous material as defined hereinabove, comprising the step of reacting, at a temperature of from 130°C to 250°C, at a pH of from 8 to 13, and for a time of from 1 day to 30 days, a silicon derivative, a boron derivative and an organic nitrogenous base selected from piperidine and hexamethyleneimine, with the facultative addition of a derivative of a trivalent metal selected from Al, Cr, Fe, Ga, V and Mn and/or a derivative of a tetravalent metal selected from Ge, Ti , and Zr, and/or a sodium salt or a sodium hydroxide to which other alkali metal or alkaline earth metal salts and/or hydroxides may be added, under the conditions that: the molar ratio SiO₂ to B₂O₃ in the reactants is from 0,5 to 10; the molar ratio R to SiO₂ in the reactants is from 0,75 to 1,4; the molar ratio M I ₂O₃ to SiO₂ in the reactants is from nil to 0,02; the molar ratio M II O₂ to SiO₂ in the reactants is from 1 to 3, and the molar ratio Na to SiO₂ in the reactants is from nil to 0,5. The molar ratio of H₂O/SiO₂ of the reactants is preferably comprised within the range of from 5 to 50. The silicon derivative is selected from silica gel, silica sol, aerosil, colloidal silica, sodium silicate or an alkyl-silicate. The boron derivative can be selected from trialkylborates, alkaline borates, ammonium borate and boric acid. The derivative of the trivalent metal and/or of the tetravalent metal used can be selected from the corresponding salts. Some examples are given now for the purpose of better illustrating the invention, which however should not be construed as being in any way limited by them, or to them. Examples The synthesis examples which follow were carried out according to the hereunder reported procedure. To a pyrex glass vessel equipped with a stirrer, the required amount of demineralized water is charged. In this water, firstly sodium hydroxide, when envisaged, and then the amine are dissolved with stirring. The alkaline solution is heated, with stirring, to 30-50°C, and to it boric acid is then added; the temperature is then adjusted at a value comprised within the range of from 50 to 80°C, until the acid is completely dissolved. To the so-obtained, generally clear, solution, the source of silica is added in such a way that the addition is complete within 1-2 hours. The mixture is then maintained stirred at 70°C for a further hour, and is then cooled down to room temperature; after recording its pH, the mixture is charged to a stainless-steel autoclave which is fastened on a swinging basket installed inside an oven, so that the autoclave can be kept at the desired temperature, while being always kept stirred. The autoclave is maintained under its autogenous pressure at 150-210°C over a time ranging from 1 day to 7 days, and is then cooled and discharged. The obtained product is washed with demineralized water, firstly by decantation and then over a filter on which the solid is separated. This latter is dried for one hour at 120°C and is then calcined for 5 hours at 550°C in air. The exchange into the acidic form is carried out as follows: 10 g of zeolite is suspended in 100 g of a 1% solution of ammonium acetate. The suspension is heated to 50-70°C and is maintained stirred for one hour, then is filtered and the solid is thoroughly washed with demineralized water on the filter. The operation is repeated three times, and at the end the solid is dried for one hour at 120°C and is then calcined for 5 hours at 550°C in air. Examples 1-9 By means of the above reported procedure, 9 preparations were carried out according to the invention. The composition of the reaction mixture, the operating conditions and the characteristics of the obtained products are reported in Table I. In Figure 3 and Table II, the X-ray diffraction spectrum of the product dried at 120°C, relevant to Example 1, is reported. In Figure 4 and Table III, the X-ray diffraction spectrum of the same product calcined at 550°C is reported. The products of Examples 2 to 9 are characterized by the same X-ray diffraction spectrum as of Example 1. Examples 10-15 Still according to the same procedure as above reported, other products were prepared, which do not have the same characteristics as of those as claimed by the present Applicant. From Table 1, the following can be observed: when boron is totally absent, a completely different zeolite, i.e. ZSM-39, is obtained (Example 10); when as the nitrogenous base heptamethyleneimine (Example 11), or 1-methyl-piperidine (Example 12) is selected, amorphous products are obtained; by starting from a molar ratio of SiO₂/B₂O₃ of the reactants equal to 10 (Examples 13), or larger (Example 14), non-zeolitic crystalline products are obtained; when the components are reacted in the presence of potassium (Example 15), a different crystalline product is obtained. Some applications of the herein disclosed material are now given. Example 16 Four grams of the material produced according to Example 1 and exchanged into the acidic form according to the processes known from the prior art, is suspended in 120 g of a N/10 solution of CsCl and is kept stirred at room temperature for approximately 10 minutes, after which pH value is measured. To 120 g of a fresh CsCl N/10 solution, a (N/10 and N/100) solution of HCl is added, until the same pH as read in the previous case is obtained. The dropwise added volume of HCl solution is equivalent to an exchange of 1.5x10⁻¹ meq/g of Cs. Example 17 0.8 g of zeolite in H⁺ form prepared as in Example 5 and granulated by pressing into particles having a particle size comprised within the range of from 20 to 40 mesh is charged to a quartz tube and is left in an air stream at 550°C for approximately 15 minutes. Air is then replaced by He and the temperature is reduced down to 450°C. An equimolar mixture of n-hexane and 3-methylpentane diluted in He is then fed, in such a way that the space velocity, expressed as LHSV, is equal to 1. The products leaving the reactor are analysed online by means of a gas-chromatograph. The conversion is of 30%, and the ratio Such a ratio is generally referred to as the Constraint Index. Example 18 100 cc of octene-1 was charged to an autoclave together with 7 g of zeolite powder in the acidic form, prepared as disclosed in Example No. 5. The suspension was heated to 195°C for 5 hours, with strong stirring. After being cooled, and the catalyst being filtered off, the mixture was analysed by means of gas-chromatography and the chromatographic peaks were identified by mass-spectrometry. The dimers, trimers and tetramers of octene-1 are present: - octene-1 4% - dimers C₁₆H₃₂ 50% - trimers C₂₄H₄₈ 32% - tetramers C₃₂H₆₄ 16% 2 d (Å=10⁻¹nm) 100 I/I o 2 d (Å=10⁻¹nm 100 I/I o 3.28 26.94 72 23.96 3.714 14 6.60 13.39 87 25.37 3.511 18 7.23 12.22 100 26.41 3.374 46 8.00 11.05 43 26.85 3.321 28 9.63 9.18 36 29.07 3.072 7 9.88 8.96 31 29.68 3.009 8 12.93 6.85 11 30.13 2.966 7 13.31 6.65 15 32.06 2.791 6 14.60 6.07 7 32.85 2.727 5 14.99 5.91 8 33.15 2.703 6 15.86 5.59 6 34.16 2.625 7 16.23 5.46 6 35.65 2.518 4 16.59 5.34 6 37.02 2.428 5 17.99 4.93 5 37.98 2.369 5 19.34 4.59 12 38.47 2.340 6 20.09 4.42 31 41.30 2.186 4 21.30 4.17 11 45.42 1.997 5 21.92 4.05 17 46.92 1.936 5 22.41 3.967 29 49.18 1.852 5 23.14 3.843 19 2 d (Å=10⁻¹nm) 100 I/I o 2 d (Å=10⁻¹nm) 100 I/I o 7.21 12.26 100 28.11 3.174 19 8.05 10.98 71 28.99 3.080 12 10.12 8.74 69 29.53 3.025 8 13.04 6.79 12 30.03 2.976 8 14.29 6.20 25 30.67 2.915 6 14.48 6.12 28 31.97 2.799 6 14.93 5.93 17 32.68 2.740 7 16.15 5.49 17 33.80 2.652 8 17.90 4.95 6 34.77 2.580 6 19.26 4.61 10 35.69 2.515 5 19.56 4.54 8 36.86 2.439 5 20.44 4.34 17 37.57 2.394 5 21.44 4.14 12 38.32 2.349 6 21.85 4.07 18 41.17 2.192 4 22.13 4.02 21 41.99 2.152 4 22.69 3.919 18 43.28 2.090 4 22.98 3.869 37 43.85 2.065 4 23.99 3.709 24 45.32 2.001 4 25.27 3.524 14 46.66 1.946 4 25.49 3.494 13 47.00 1.933 5 26.30 3.389 46 48.96 1.861 4 27.28 3.269 18

Claims: Claims for the following Contracting States : AT, BE, CH, DE, FR, GB, GR, LI, LU, NL, SE Synthetic, crystalline, porous material of zeolitic nature containing oxides of silicon and boron, characterized in that in the non-calcined state, it complies with the following empirical formula: mM 2/n O,pR,xM I ₂O₃,(1-x)B₂O₃,yM II O₂,qH₂O and in the calcined and anhydrous state, it complies with the following empirical formula: mM 2/n O,xM I ₂O₃,(1-x)B₂O₃,yM II O₂, wherein : M is an H⁺, NH + / 4 or a metal cation with valence n, M I is a trivalent metal selected from Al, Cr, Fe, Ga, V or Mn, M II is either Si or mixtures thereof with such tetravalent metals as Ge, Ti or Zr, R is piperidine or hexamethyleneimine, m has a value comprised within the range of from 0.1 to 1.5, x has a value comprised within the range of from 0 to 0.9, y has a value greater than 2 and preferably comprised within the range of from 5 to 300, p has a value greater than zero and smaller than 3, and q has a value greater than zero and smaller than 5, and that it has a volume of the pores larger than 0.3 cm³/g. Synthetic, crystalline, porous material according to claim 1, wherein the volume of the pores is equal to, or larger than, 0.35 cm³/g. Synthetic, crystalline, porous material according to Claim 1, wherein: m is from 0,5 to 1,2; x is from nil to 0,2; y is from 10 to 100, p is from 1 to 3, and q is from 1 to 4. Process for hydrothermally preparing a synthetic, crystalline and porous material as defined in Claim 1, comprising the step of reacting, at a temperature of from 130°C to 250°C, at a pH of from 8 to 13, and for a time of from 1 day to 30 days, a silicon derivative, a boron derivative and an organic nitrogenous base selected from piperidine and hexamethyleneimine, with the facultative addition of a derivative of a trivalent metal selected from Al, Cr, Fe, Ga, V and Mn and/or a derivative of a tetravalent metal selected from Ge, Ti, and Zr, and/or a sodium salt or a sodium hydroxide to which other alkali metal or alkaline earth metal salts and/or hydroxides may be added, under the conditions that: the molar ratio SiO₂ to B₂O₃ in the reactants is from 0,5 to 10; the molar ratio R to SiO₂ in the reactants is from 0,75 to 1,4; the molar ratio M I ₂O₃ to SiO₂ in the reactants is from nil to 0,02; the molar ratio M II O₂ to SiO₂ in the reactants is from 1 to 3, and the molar ratio Na to SiO₂ in the reactants is from nil to 0,5. Process according to claim 4, wherein the molar ratio of H₂O/SiO₂ of the reactants is comprised within the range of from 5 to 50. Process according to claim 4, wherein the derivative of silicon is selected from silica gel, silica sol, aerosil, colloidal silica, sodium silicate or alkyl silicate. Process according to claim 4, wherein the derivative of boron is selected from trialkyl borates, alkali metal borates and ammonium borate, boric acid. Claims for the following Contracting State : ES Process for hydrothermally preparing a synthetic, crystalline and porous material, having in the non calcined state the empirical formula: mM 2/n O,pR,xM I ₂O₃,(1-x)B₂O₃,yM II O₂,qH₂O and, in the calcined and anhydrous state, the following empirical formula: mM 2/n O,xM I ₂O₃,(1-x)B₂O₃,yM II O₂, wherein : M is an H⁺, NH + / 4 or a metal cation with valence n, M I is a trivalent metal selected from Al, Cr, Fe, Ga, V or Mn, M II is either Si or mixtures thereof with such tetravalent metals as Ge, Ti or Zr, R is piperidine or hexamethyleneimine, m has a value comprised within the range of from 0.1 to 1.5, x has a value comprised within the range of from 0 to 0.9, y has a value greater than 2 and preferably comprised within the range of from 5 to 300, p has a value greater than zero and smaller than 3, and q has a value greater than zero and smaller than 5, and that it has a volume of the pores larger than 0.3 cm³/g. characterized by comprising the step of reacting, at a temperature of from 130°C to 250°C, at a pH of from 8 to 13, and for a time of from 1 day to 30 days, a silicon derivative, a boron derivative and an organic nitrogenous base selected from piperidine and hexamethyleneimine, with the facultative addition of a derivative of a trivalent metal selected from Al, Cr, Fe, Ga, V and Mn and/or a derivative of a tetravalent metal selected from Ge, Ti , and Zr, and/or a sodium salt or a sodium hydroxide to which other alkali metal or alkaline earth metal salts and/or hydroxides may be added, under the conditions that: the molar ratio SiO₂ to B₂O₃ in the reactants is from 0,5 to 10; the molar ratio R to SiO₂ in the reactants is from 0,75 to 1,4; the molar ratio M I ₂O₃ to SiO₂ in the reactants is from nil to 0,02; the molar ratio M II O₂ to SiO₂ in the reactants is from 1 to 3, and the molar ratio Na to SiO₂ in the reactants is from nil to 0,5. Process according to Claim 1 , characterized in that the molar ratio H₂O to SiO₂ in the reactants is from 5 to 50. Process according to Claim 1 , characterized in that the derivative of silicon is selected from silica gel,, silica sol, colloidal silica, sodium silicate and alkyl silicate. Process according to Claim 1, characterized in that the derivative of boron is selected from trialkyl borates, alkali metal borates, ammonium borate and boric acid.

Inventors: BELLUSSI, GIUSEPPE, CLERICI, MARIO GABRIELE, GIUSTI, ALDO, PEREGO, GIOVANNI
Applicants: ENICHEM SYNTHESIS S.P.A., ENIRICERCHE S.P.A., SNAMPROGETTI S.P.A.
Application year: 1988
Main classification: C01B35
IPC codes: C01B39, C07C9, C01B35, C07C2, C07C5, C07C11, C07B61, B01J29, C01B33