SYNTHESIS OF A CRYSTALLINE MOLECULAR SIEVE

Abstract: A method for synthesizing a large pore crystalline molecular sieve having an X-ray diffraction pattern with the characteristic lines (IA) comprises (i) preparing a mixture comprising sources of oxides of aluminum, phosphorus, and optionally one or more elements (M) other than aluminum or phosphorus, water and a directing agent (DA), and having a composition, in terms of mole ratios, within the following ranges: M/Al2O3 0 to 0.5; P2O5/Al2O3 0.5 to 1.25; H2O/Al2O3 10 to 100; DA/Al2O3 0.5 to 1.5; wherein DA is a compound of formula (I), wherein R, R', R'' and R''' are the same or different and are selected from -CH2X, -CH2CH2X, and X is a cation, (ii) maintaining said mixture under conditions including a temperature of 100 DEG C to 145 DEG C for a period of time of up to 80 hours and (iii) recovering the crystalline product from step (ii).

Description: SYNTHESIS OF A CRYSTALLINE MOLECULAR SIEVE This invention relates to a method for synthesizing a crystalline molecular sieve having pore windows measuring greater than 10 Angstroms in diameter, such as, for example, greater than 12 Angstroms in diameter. Zeolitic materials, both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion. Certain zeolitic materials are ordered, porous crystalline aluminosilicates having a definite crystalline structure as determined by »ray diffraction, within which there are cavities which may be interconnected by channels or pores. These cavities and pores are uniform in size within a specific zeolitic material. Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as "molecular sieves" and are utilized in a variety of ways to take advantage of these properties. Such molecular sieves, both natural and synthetic, include a wide variety of positive ion--containing crystalline aluminosilicates. These aluminosilicates can be described as rigid three--dimensional frameworks of SiO. and A10, in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total aluminum and silicon atoms to oxygen atoms is 1:2. The electrovalence of the tetrahedra containing aluminum is balanced by the inclusion in the crystal of a cation, for example an alkali metal or an alkaline earth metal cation. This can be expressed wherein the ratio of aluminum to the number of various cations, such as Ca/2, Sr/2, Na, K or Li, is equal to unity. Che type of cation may be exchanged either entirely or partially with another type of cation utilizing ion exchange techniques in a conventional manner. By means of such cation exchange, it is possible to vary the properties of a given aluminosilicate by suitable selection of the cation. Prior art techniques have resulted in the formation of a great variety of synthetic zeolites. The zeolites have come to be designated by letter or other convenient symbols, as illustrated by zeolite A (U.S. Patent 2,882,243), zeolite X (U.S. Patent 2,882,244), zeolite Y (U.S. Patent 3,130,007), zeolite ZK-5 (U.S. Patent 3,247,195), zeolite ZK-4 (U.S. Patent 3,314,752), zeolite ZSM-5 (U.S. Patent 3,702,886), zeolite ZSM-11 (U.S. Patent 3,709,979), zeolite ZSM-12 (U.S. Patent 3,832,449), zeolite ZSM-20 (U.S. Patent 3,972,983), zeolite ZSM-35 (U.S. Patent 4,016,245), zeolite ZSM-38 (U.S. Patent 4,046,859), and zeolite ZSM-23 (U.S. Patent 4,076,842). Porous alu inophosphates and their synthesis with the aid of organic directing agents are disclosed in U.S. Patent Nos. 4,310,440 and 4,385,994, whereas the synthesis of silicophosphoaluminates of various structures are disclosed in U.S . Patents 4,440,871 and 4,673,559. Methods for synthesizing crystalline etalloalurπinophosphates are described in U.S. Patent No. 4,713,227. The present invention resides in a method for synthesizing a crystalline molecular sieve having an X-ray diffraction pattern with lines shown in Table 1A of the specification, which comprises (i) preparing a mixture comprising sources of oxides of aluminum, phosphorus, and optionally one or more elements (M) other than aluminum or phosphorus, water and a directing agent (DA), and having a composition, in terms of mole ratios, within the following ranges: M/A1 2 0 3 0 to 0.5 P2O5/AI2O3 0.5 to 1.25 H 2 0/A1 2 0 3 10 to 100 DA/A1 2 0 3 0.5 to 1.5 wherein DA is a compound of the formula: X- wherein P, R 1 ', R 1 ' are the same or different and are selected from -Q- X and «-CH2CH2X, and X is a cation, (ii) maintaining said mixture under conditions including a temperature of 100°C to 145°C for a period of time of up to 80 hours and (iii) recovering the crystalline product from step (ii). The crystalline molecular sieve produced according to the method of the invention has a framework topology which exhibits, even after being heated at 110°C or higher, a characteristic X-ray diffraction pattern having the following lines: Table 1A Interplanar d-Spacings (A) Relative Intensity ■ 16.4 +_ 0.2 vs 8.2 _+ 0.1 w 4.74 + 0.05 w and more specifically the following characteristic values: Ta ble IB Interplanar d-Spacings (A) Pelative Intensity 16.4 + 0.2 s 8 .2 + 0.1 w 5 .48 + 0.05 w 4.74 + 0.05 w and even more specifically the following characteristic values: 5.48 + 0.05 w 4.74 + 0 .05 w 4.10 + 0.04 w 4.05 + 0 .04 w 3.76 + 0.03 w 0 3.28 + 0 .03 w The X-ray diffraction lines in Tables 1A, IB and 1C identify a crystal framework topology in the composition exhibiting large pore windows of 18-membered ring size. The pores are at least ^ 10 Angstroms in diameter, such as for example at least 12 gstroms, e.g. 12-13 Angstroms, in diameter. These lines distinguish this topology from other crystalline aluminosilicate, aluminophosphate and silicoalu inophosphate structures. It is noted that the X-ray pattern of the present composition is void of a d-spacing value at " u 13.6-13.3 Angstroms with any significant intensity relative the strongest d-spacing value. If a d-spacing value in this range appears in a sample of the present composition, it is due to impurity and will have a weak relative intensity. These X-ray diffraction data were collected with 25 conventional X-ray systems, using copper -alpha radiation. The positions of the peaks, expressed in degrees 2 theta, where theta is the Bragg angle, were determined by scanning 2 theta. The interplanar spacings, d, measured in Angstrom units (A), and the relative intensities of the lines, I/I Q , where I is 30 one-hundredth of the intensity of the strongest line, including subtraction of the background, were derived. The relative intensities are given in terms of the symbols vs = very strong (75-100%), s = strong (50-74%), m = medium (25-49%) and w = weak (0-24%). It should be understood that this X-ray diffraction pattern is characteristic of all the species of the present compositions . Ion exchange of cations with other ions results in a composition whi ch reveals substantially the same X-ray diffraction pattern with some minor shifts in interplanar spacing and variation in relative intensity. Relative intensity of individual lines may also vary relative the strongest line when the composition is chemically treated , such as by dilute acid treatment. Other variations can occur , depending on the composition component ratios of the particular sample , as well as i ts degree of thermal treatment . The relative intensities of the lines are also susceptible to changes by factors such as sorption of water , hydrocarbons or other components in the channel structure . Further , the optics of the X-ray diffraction equipment can have significant • effects on intensity, particularly in the low angle region . Intensities may also be affected by preferred crystallite orientation . More specifically, the molecular sieve produced by the method of the invention comprises a three-dimensional framework structure composed of tetrahedral units of A10 2 , P0 2 and optionally MO , where M is at least one element other than aluminum or phosphorus . Where the element M is absent , the molecular sieve has the following composition , in terms of mole ratios of oxides : Al 2 0 3 : xP 2 0 s :nH 2 0 where x is 0 .5 to 1 .5 , and n is 0-100 and preferably 0-10 . Where present , M is preferably silicon alone , in which case the molecular sieve has the following composition in terms of mole ratios of oxides: Al 2 0 3 : xP 2 0 5 :ySi0 2 :nF 2 0 where x is 0 .5 to 1 .5 , y is 0 .01 to 0.5 and n is 0- 100 and preferably * 0-10. Alternatively M includes an element other than' silicon , such that the sum of the aluminum and phosphorus exceeds the number of M atoms and the molecular sieve has the following composition, in the anhydrous state and in terms of mole ratios of oxides: A10-) 1,χ : R) 1 . y :CMθ5" , ) χ+y together with anions and/or cations necessary for electrical neutrality and where m is the valence (or weighted average valence) of M, x and y satisfy the following relationship: z = y - x +(4 + m) . (x + y) and z is greater than -1 and less than +1. ien z is greater than 0, the molecular sieve will behave as a cation exchange material with potential use an an acidic catalyst. When z is less than 0, the molecular sieve will behave as an anion exchange material with potential use as a basic catalyst. In some cases silicon may also be present such that the ratio of silico :non-silicon atoms is less than 1, preferably less than 0.5. The element M in this alternative embodiment has an oxidation number of from +2 to +6, and an ionic "Radius Patio" of 0.15 to 0.73, except that when the oxidation number of M is +2, the Radius Ratio of the element M is 0.52 to 0.62. The term "Radius Patio" is defined as the ratio of the crystal ionic radius of the element M to the crystal ionic radius of -2 the oxygen anion, 0 . Radius Ratio = crystal ionic radius of the element M crystal ionic radius of 0" 2 The crystal ionic radii of elements are listed in the CRC Handbook of Chemistry and Physics, 61st edition, CRC Press, Inc., . 1980, pages F-216 and F-217. In determining the Padius Patio, it is necessary to use crystal ionic radii of the M atom and oxygen anion _2 (0 ' ) which have been measured by the same method. Examples of element M useful herein include: M Valence Padius Ratio As +3 0.44 B +3 0.17 Bi +3 0.73 Co +2 0.55 Cu +2 0.54 Fe +2 0.56 Fe +3 0.48 Re +2 0.55 Ge +4 0.40 In +3 0.61 Mh +2 0.61 Sb +3 0.57 Sn +4 0.54 Ti +3 0.58 Ti +4 0.52 V +3 0.56 V +4 0.48 V +5 0.45 Zn +2 0.56 Examples of elements not included as M of the present invention include Element Valence Radius Patio B +1 0.26 Ba +1 1.16 Fa +2 1.02 Ce +3 0.78 Cd +1 0.86 Cd +2 0.73 Cr +1 0.61 Cr +2 0.67 Cu +1 0.73 La +1 1.05 Mg +1 0.62 Mg +2 0.50 Mo +1 0.70 Sn +2 0.70 Sr +2 0.85 Th +4 0.77 Ti +1 0.73 Ti +2 0.71 Zn +1 0.67 As synthesized, the crystalline composition will generally comprise structural aluminum, phosphorus and element M, and will exhibit an M/(aluminum plus phosphorus) atomic ratio of less than unity and greater than zero, and usually within the range of from 0.001 to 0.99. The phosphorus/aluminum atomic ratio of such materials may be found to vary from 0.01 to 100.0, as synthesized. It is well recognized that aluminum phosphates exhibit a phosphorus/aluminum atomic ratio of about unity, and essentially no element M. Also, the phosphorus-substituted zeolite compositions, sometimes referred to as "aluminosilicophosphate" zeolites, have a silicon/aluminum atomic ratio of usually greater than unity, and generally from 0.66 to 8.0, and a phosphorus/aluminum atomic ratio of less than unity, and usually from 0 to 1. According to the invention, the molecular sieve described above is synthesized from a reaction mixture hydrogel containing sources of aluminum, phosphorus and optionally the non-aluminum, non- hosphorus element M, an organic directing agent, and water and having a composition, in terms of mole ratios, within the following ranges: Broad Preferrred Most Preferred P 2 0ς/Al 2 0 3 0.5 to 1.25 0.9 to 1.1 0.9 to 1.1 H 2 0/A1 0 3 10 to 100 20 to 80 30 to 60 DA/A1 2 0 3 0.2 to 0.8 0.3 to 0.7 0.4 to 0.6 and when the element M is present: M/A1 2 0 3 0.01 to 0.5 0.01 to 0.2 0.01 to 0.1 The directing agent DA is a compound represented by the formula: -..α, . wherein R, R', R'' and R''' are the same as different and are selected from -CH^X and -CH^CH^X, and X is a cation such as hydroxide or halide (e.g. chloride or bromide). Preferred examples of these compounds include tetrakis (2-hydroxyethyl) ammonium hydroxide, tetrakis (2-chloroethyl)ammonium chloride and tetrakis(hydroxymethyl)ammonium bromide. Reaction conditions involve heating the foregoing reaction mixture to a temperature of 100°C to 145°C for 1 hour to 80 hours. A more preferred temperature range is from 130°C to 145°C with the amount of time at temperature being from 10 hours to 30 hours. If the temperature is higher than 145°C and/or the time exceeds 80 hours, the product composition will contain less of the des ' ired large pore crystals characterized by the X-ray diffraction patterns of Tables 1A, IB and 1C. Also important in the synthesis procedure is the ratio of P 2 0-./Al 2 C- in the reaction mixture. When the ratio P 2 0 5 /A1 2 0 3 is greater than about 1.25, especially if the temperature is higher than 145°C, product composition will contain decreased amounts of the desired crystalline material. The solid product composition comprising the desired molecular sieve is recovered from the reaction medium, such as by cooling the whole to room temperature, filtering and water washing. The organic directing agent can then be removed from the product by conventional calcination procedures. The synthesis method of the present invention is facilitated by the presence of seed crystals, such as those having the structure of the product crystals, in the reaction mixture. The use of at least 0.01%, preferably 0.10%, and even more preferably 1% seed crystals (based on total weight) of crystalline material in the reaction mixture will facilitate crystallization in the present method. The reaction mixture composition for the present method is prepared utilizing materials which supply the appropriate oxide. Useful sources of aluminum oxide include, as non-limiting examples, any known form of aluminum oxide or hydroxide, organic or inorganic salt or compound, e.g. alumina and aluminates. Such sources of aluminum oxide include pseudo-boehmite and aluminum tetraalkoxide. Useful sources of phosphorus oxide include, as non-limiting examples, any known form of phosphorus acids or phosphorus oxides, phosphates and phosphites, and organic derivatives of phosphorus. Useful sources of element M include, as non-limiting examples, any known form of non-aluminum, non-phosphorus element, e.g. metal, its oxide or hydride or salt, alkoxy or other organic compound containing M. It will be understood that each oxide component utilized in the reaction mixture can be supplied by one or more essential reactants and they can be mixed together in any order. For example, any oxide can be supplied by an aqueous solution. The reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time for the product composition comprising the desired metalloaluminophosphate will vary with the exact nature of the reaction mixture employed within the above-described limitations. While the molecular sieve of the present invention may be used as an absorbent or as a catalyst component in a wide variety of organic compound, e.g. hydrocarbon compound, conversion reactions, it is notably useful as a catalyst in the processes of cracking, hydrocracking, isomerization and reforming. Other conversion processes for which the present composition may be utilized as a catalyst component include, for example, dewaxing. The crystalline molecular sieve prepared in accordance herewith can be used either in the as-synthesized form, the hydrogen form or another univalent or multivalent cationic form/ It can also be used in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium where a hydrogenation-dehydrogenation function is to be performed. Such components can be exchanged into the composition, impregnated therein or physically intimately admixed therewith. Such components can be impregnated in or on to the crystalline composition such as, for example, by, in the case of platinum, treating the material with a platinum metal-containing ion. Suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing the platinum amine complex. Combinations of metals and methods for their introduction can also be used. The present composition, when employed either as an adsorbent or as a catalyst in a hydrocarbon conversion process, should be dehydrated at least partially. This can be done by heating to a temperature in the range of from 65°C to 315°C in an inert atmosphere, such as air and nitrogen, and at atmospheric or subatmospheric pressures for between 1 and 48 hours. Dehydration can be performed at lower temperature merely by placing the zeolite in a vacuum, but a longer time is required to obtain a particular degree of dehydration. The thermal decomposition product of the newly synthesized composition can be prepared by heating same at a temperature of from 200°C to 550°C for from 1 hour to 48 hours. As above mentioned, synthetic metalloaluminophosphate prepared in accordance herewith can have the original cations associated therewith replaced by a wide variety of other cations according to techniques well known in the art. Typical replacing cations include hydrogen, ammonium and metal cations including mixtures thereof. Of the replacing metallic cations, particular preference is given to cations of metals such as rare earths and metals from Groups IIA, IIIA, IVA, IB, IIB, IIIB, IVB, VIB AND VTII of the Periodic Table of Elements, especially Mh, Ca, Mg, Zn, Cd, Pd, Ni, Cu, Ti, Al, Sn, Fe and Co. A typical ion exchange technique would be to contact the synthetic material with a salt of the desired replacing cation or cations. Although a wide variety of salts can be employed, particular preference is given to chlorides, nitrates and sulfates. When used as a catalyst, it may be desirable to incorporate the molecular sieve of the invention with another material resistant to the temperatures and other conditions employed in organic conversion processes. Such matrix materials include active and inactive materials and synthetic or naturally occurring zeolites as well as incorganic materials such as clays, silica and/or metal oxides, e.g. alumina. The latter maybe either naturally occurring or in the form of gelatinous precipitates, sols or gels including mixtures of silica and metal oxides. Use of an active material in conjunction with the present molecular sieve, i.e. combined therewith, may enhance the conversion and/or selectivity of the catalyst in certain organic conversion processes. Inactive materials suitably serve as diluents to control the amount of conversion in a given process so that products can be obtained economically and orderly without employing other means for controlling the rate or reaction. Frequently, crystalline catalytic materials have been incorporated into naturally occurring clays, e.g. bentonite and kaolin. These materials, i.e. clays, oxides, etc., function, in part, as binders for the catalyst. It is desirable to provide a catalyst having good crush strength, because in a petroleum refinery the catalyst is often subjected to rough handling, which tends to break the catalyst down into powder-like materials which cause problems in processing. Naturally occurring clays which can be composited with the present molecular sieve include the montmorillonite and kaolin families which' include the subbentonites, and the kaolins commonly known as Dixie, McNamee, Georgia and Florida clays, or others in which the main mineral constituent is halloysite, kaolinite, dickite , nacrite or anauxite . Such clays can be used in the raw state as originally mined or initially subjected to calcination , acid treatment or chemical modifi cation. In addition to the foregoing materials , the crystals hereby synthes ized can be composited wi th a porous matrix material such as silica-alumina , silica -magnesia , silica-zirconia , silica -thoria , silica-beryllia , silica-ti tania , as well as ternary compos itions such as silica -alumina -thoria , s ilica-alumina-zirconia , silica -alumina -magnesia and silica-magnesia-z irconia. The matrix can be in the form of a cogel . A mixture of these components could also be used . The relative proportions of finely divided crystalline material and matrix vary widely wi th the crystall ine material content ranging from 1 to 90 percent by weight, and more usually in the range of 2 to 50 percent by weight of the composite . Employing a catalyst comprising the molecular sieve of this invention containing a hydrogenation component , reforming stocks can be reformed employing a temperature between 450 °C and 550 °C . The pressure can be between 445 and 3550 kPa (50 and 500 psig) , but is preferably between 890 and 2170 kPa (100 and 300 psig) . The liquid hourly space velocity is generally between 0.1 and 10 hr , preferably between 1 and 4 hr and the hydrogen to hydrocarbon mole ratio is generally between 1 and 10 , preferably between 3 and 5 . A catalyst comprising the present composition can also be used for hydroisomerization of normal paraffins , when provided with a hydrogenation component , e .g . platinum. Hydroisomerization is carried out at a temperature between 250 °C to 450 °C, preferably 300°C to 425°C , with a liquid hourly space velocity between 0 .1 and 10 hr~ , preferably between 0.5 and 4 hr~ , employing hydrogen such that the hydrogen to hydrocarbon mole ratio is between 1 and 10. Additionally, the catalyst can be used for olefin or aroma tics isomerization employing temperatures between 0 °C and 556 °C. A catalyst comprising the molecular seive of this invention can also be used for reducing the pour point of gas oils . This process is carried out at a liquid hourly space velocity between 0.1 and 5 hr" and a temperature between 300°C and 425°C. This invention will now be more particularly described with reference to the Examples and the accompanying drawings in which Figures 1-8 are X-ray diffraction patterns of the calcined product of Examples 1 to 8 respectively. Example 1 A mixture containing 103.5 g of 85% orthophosphoric acid (H,P0.) in 155 g water was mixed with 50.8 g aluminum oxide source (pseudo-boehmite). The mixture was heated to 8 °C with stirring for 1 hour. To this mixture was added 105.5 g tetrakis(2-hydroxyethyl)ammoniuπ_ hydroxide (DA) in 150 g water, giving a final reaction mixture composed as follows: P 0 5 /A1 2 0 3 = 1.26 H 2 0/A1 2 0 3 = 52 DA/A1 2 0 3 = 0.7 The reaction mixture was placed in a 1000 cc autoclave. Crystallization in the autoclave was at 140°C under 2170 kPa (300 psig) nitrogen for 16 hours. The solid product was filtered, washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus. The product was calcined at 538°C in air for 10 hours. The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 2 and Figure 1. Table 2 Interplanar Observed Relative d-Spacings (A) 2xTheta Intensities (I/Ip) 19.62633 4.502 2.0 16.50637 5.354 100 .0 11.95308 7.396 7 .1 8.24634 10.728 27.2 6.20381 14.277 12.9 4.74095 18.717 12.7 4.33935 20.467 1 .4 4.19087 21.200 4.5 4.08690 21.746 57 .1 4.06799 21.848 67 .2 3.96914 22.399 42.0 3.95098 22.504 46.0 3.79405 23.447 13.3 3.77009 23.598 24. 3 3.58563 24.831 5 .7 3.50222 25.433 0.4 3.47553 25.631 1.4 3.43484 25.940 2. 2 3.41076 26.126 1 .0 3 28214 27.169 32. 2 3.17008 28.149 4.9 3.15501 28.287 4.4 3.08670 28.926 14.2 3.08117 28.979 11 .1 3.03351 29.445 2.3 2.95461 30.249 9.2 2.95086 30.289 10.4 2.91456 30.675 1.4 2.81518 31.786 0 .9 2.73786 32.709 12.7 2.73145 32.788 7.4 Chemical analysis of the extracted Example 1 product indicated the following composition: Al 19.63 wt.% P 21.04 wt.% Si 0.026 wt.% Na 0.029 wt.% Example 2 A mixture containing 115 g of 85% orthophosphoric acid (H,P0.) in 155 g water was mixed with 71 g aluminum oxide source (pseudo-boehmite). The mixture was heated to 80°C with stirring for 3 hours. To this mixture was added 105.5 g tetrakis(2-hydroxyethyl)a_πmonium hydroxide (DA) in 150 g water, giving a final reaction mixture composed as follows: P 2 0 5 /A1 2 0 3 = 1 H 2 0/A1 2 0 3 = 40 DA/A1 2 0 3 = 0.5 The reaction mixture was placed in a 1000 cc autoclave. Crystallization in the autoclave was at 142°C under 2170 kPa (300 psig) nitrogen for 17 hours. The solid product was filtered, washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus. The product was calcined at 530°C in air for 10 hours. The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 3 and Figure 2. The reaction mixture was placed in an autoclave. Crystallization in the autoclave was at 138°C under 2170 kPa (300 psig) nitrogen for 14 hours. The solid product was filtered, washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus. The product was calcined at 530°C in air for 10 hours. The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 4 and Figure 3. Table 3 Interplanar Observed Pelative d-Spacings (A) 2xTheta Intensities (I/I 0 ) 3.28000 27.188 30.3 3.19718 27.906 1.1 3.16223 28.221 5.3 3.07912 28.999 12.3 2.95194 30.277 10.7 2.94785 30.320 12.1 2.89369 30.902 3.2 2.73464 32.748 13.5 2.58822 34.658 0.6 Chemical analys is of the extracted Example 2 product indicated the following composition : Al 19.46 wt . %- P 16.63 wt.% Si 0.046 wt . % Na 0.033 wt. % Example 3 A mixture containing 57.5 g of 85% orthophosphoric acid in 77.5 g water was mixed with 35.5 g aluminum oxide source (pseudo-boehmite). The mixture was heated to 80°C with stirring for 1 hour. To this mixture was added 52.75 g tetrakis(2-hydroxyethyl)ammonium hydroxide (DA) in 75 g water, giving a final reaction mixture composed as follows: P 2 0 5 /A1 2 0 3 = 1 H 2 0/A1 2 0 3 = 41 DA/A1 ? 0 3 = 0.5 The reaction mixture was placed in an autoclave. Crystallization in the autoclave was at 138°C under 2170 kPa (300 psig) nitrogen for 14 hours. The solid product was filtered, washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus. The product was calcined at 530°C in air for 10 hours. The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 4 and Figure 3. Table 4 Interplanar Cbserved Relative d-Spacings (A) 2xTheta Intensities ( i/ι 0 ) 16.33147 5.411 100.0 8.19161 10.800 24.4 6.15847 14.382 13.7 4.73260 18.750 13.5 4.46994 19.863 1.1 4.07984 21.784 54.7 4.05933 21.895 61.4 3.95056 22.506 38.3 3.93839 22.576 39.4 3.77224 23.585 16.9 3.76217 23.649 23.5 L0 3.62809 24.536 8.9 3.58473 24.838 8.0 3.27475 27.232 34.8 3.16219 28.221 8.4 3.07736 29.016 14.9 3.02653 29.514 8.7 2.94680 30.331 16.9 15 2.89666 30.869 8.4 2.88632 30.983 9.2 2.74261 32.650 11.0 2.73319 32.766 12.4 2.72987 32.807 9.7 Chemical analysis of the extracted Example 3 product 20 indicated the following composition: Al 21.33 wt.% P 20.13 wt.% Si 0.028 wt.% Na 0.021 wt.% 25 Example 4 (Comparative ) A mixture containing 61.5 g of 85 % orthophosphoric acid (H 3 P0 4 ) in 92.1 g water was mixed wi th 30.2 g aluminum oxide source (pseudo-boehmite ) . The mixture was heated to 80?C with 30 stirring for 1 hour. To this mixture was added 62.7 g tetrakis ( 2-hydroxyethyl )ammonium hydroxide (DA) in 89.2 g water , giving a final reaction mixture composed as follows: P 2 0 5 /A1 2 0 3 = 1.28 H 2 0/A1 2 0 3 = 52 DA/A1 2 0 3 = 0.71 The reaction mixture was placed in an autoclave. Crystallization in the autoclave was at 160°C under 2170 kPa (300 psig) nitrogen for 5 hours. The solid product was filtered, washed with water and dried. The product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 5 and Figure 4. Table 5 Interplanar Observed Relative d-Spacings (A) 2xTheta Intensities (I/I n ) 1 111..8833994477 7 7..446677 56.4 6.83277 12.957 9.2 5 .91531 14.977 23.9 4.46975 19.863 57.5 4.23470 20.978 47.9 3.94108) 22.561 56.7 3.95335J 22.490 100.0 3.59716 24.750 5.1 3.41379 26.103 36.8 3. 30072 27.014 P .O 3.07036) 29.083 13.3 3.065153 29.134 11.7 2.95580 30.237 21.4 2.65608 33.746 5.0 2.58051 34.765 17.1 The product of Example 4, crystallized from the indicated reaction mixture at 160°C was found to be primarily A1P0.-5, void of any significant amount of the large pore aluminophosphate crystals of the present synthesis invention. Example 5 A mixture containing 56.4 g of 85% orthophosphoric acid (H j PO^) in 77.5 g water was mixed with 35.5 g aluminum oxide source (e .g. pseudo-boehmite) and 0.6 g silicon oxide source (e .g. HiSil). The mixture was heated to 80°C with stirring for 1 hour. To this mixture was added 52.75 g tetrakis(2-hydroxyethyl)ammonium hydroxide (DA) in 75 g water, giving a final reaction mixture composed as follows: Si0 2 /Al 2 0 3 = 0.04 P 2 0 5 /A1 2 0 3 = 1 H 2 0/A1 2 0 3 = 41 DA/A1 2 0 3 = 0.5 The reaction mixture was placed in a 300 cc autoclave. Crystallization in the autoclave was at 142°C under 2170 kPa (300 psig) nitrogen for 17 hours. The solid product was filtered, washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus. The product was calcined at 530°C in air for 10 hours. The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 6 and Figure 5. Table 6 Interplanar Observed Relative d-Spacings (A) 2xTheta Intensities ( ι/ι 0 ) 16.68787) 5.296 58.5 16.26226) 5.434 100.0 8.89212 9.947 7.3 8.17058 10.828 20.6 6.13784 14.431 11.1 5.46353 16.223 1.8 4.73902 " ) 18.724 9.0 4.70722) 18.852 8.4 4.07994) 21.783 67.3 4.07134) 21.830 61.1 4.05055 21.943 53.7 3.96029) 22.450 32.3 3.94729! 22.525 38.9 3.92603J 22.649 46.9 3.75873 23.671 16.2 3.62657 24.547 3.4 3.33667 26.717 2.3 3.31352 26.907 2.4 3.27994 27.188 21.1 3.26921 27.279 23.0 3.15504 28.286 3.8 3.07718 29.018 8.4 3.02872 29.492 2.4 3.01346 29.645 1.2 2.98113 29.974 0.4 2.95165 30.280 6.5 2.94100 30.393 9.0 2.82514 31.671 0.0 2.75903 32.451 2.0 Chemical analysis of the extracted Example 5 product indicated the following composition: Al 22.09 wt.% P 18.84 wt.% Si 0.29 wt.% Na 0.04 wt.% Example 6 (Comparative) A mixture containing 55 .8 g of 85% orthophosphoric acid (H,P0 4 ) in 77.5 g water was mixed with 35 .5 g aluminum oxide source (e .g . pseudo-boehmite ) and 1 .0 g silicon oxide source (e .g . HiSil ) . The mixture was heated to 80 °C with stirring for 1 hour . To this mixture was added 52.75 g tetrakis (2-hydroxyethyl )ammonium hydroxide (DA) in 75 g water , giving a final reaction mixture composed as follows : Si0 2 /Al 7 0 3 = 0.068 P 7 0 5 /Al 7 θ3 = 1 H 2 0/A1 2 0 3 = 41 DA/A1 2 0 3 = 0.5 The reaction mixture was placed in a 300 cc autoclave. Crystallization in the autoclave was at 151°C under 2170 kPa (300 psig) nitrogen for 20 hours. The solid product was filtered, wa nitrogen for 16 hours. The solid product was filtered, washed and dried at 110°C for 17 hours. The product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 7 and Figure 6. Table 7 Interplanar Observed Pelative d-Spacings (A) 2xTheta Intensities (I/Ip) 11.87357 7.445 56 .6 6.84887 12.926 9.5 5.92402 14.955 26 .1 4.47513 19.839 60.8 4.22879 21.008 57 .8 3.95662 22.471 100 .0 3.59569 24.761 4.9 3.41744 26.074 . 35 .1 33..2255886655 2277..336699 0 .5 3.07050 29.082 15 .8 2.95952 30.198 19.3 2.65784 33.722 5 .0 2.58301 34.730 15 .4 The product of Example 6 , crystallized from the indicated reaction mixture at 151°C for 20 hours was primarily SAP0-5 and was void of any significant amount of the large pore silicoaluminophosphate crystals of the present synthesis invention . Example 7 A mixture containing 56.6 g of 85% orthopbosphoric acid (H,P0, ) in 77.5 g water was mixed with 0.46 g of vanadium pentoxide (V-Or ) . The mixture was heated to 50°C with stirring for 30 minutes until complete dissolution of the vanadium pentoxide. Then, 35.5 g of aluminum oxide source (e.g . pseudo-boehmite) was added and the mixture was heated to 80 °C for 1 hour. To this mixture was added 52.75 g tetrakis ( 2- hydroxyethyDammoniu hydroxide (DA) in 75 g water, giving a final reaction mixture composed as follows: The reaction mixture was placed in a 300 cc autoclave. Crystallization in the autoclave was at 142°C at autogenous pressure for 17 hours . The solid product was filtered , washed and dried. Washing was accomplished by extraction with water in a Soxhlet apparatus . The product was calcined at 530 °C in air for 10 hours . The calcined product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 8 and Figure 7. Table 8 Interplanar Observed Relative d-Spacings (A) 2xTheta Intensities σ/ι 0 ) 8.24762 10.727 9.0 6.16987 14.356 6.1 5.70737 15.526 4.1 5.49256 16.137 1.8 5.13743 17.261 1.5 4.83746 18.340 1.8 4.63375 19.154 0.5 4.48486 19.796 7.2 4.44217 19.988 3.4 4.38940 20.231 0.2 4.09681 21.693 100.0 3.95979 22.453 44.6 3.93834 22.577 56.9 3.92046 22.681 38.3 3.55416 25.055 8.4 3.52731 25.249 4.2 3.45606 25.778 0.9 3.43090 25.970 0.6 3.40681 26.157 1.7 3.32695 26.797 6.0 3.28900 27.112 15.8 3.26948 27.277 18.3 3.15962 28.244 0.8 3.09672 28.830 4.9 3.08958 28.898 6.3 3.08135 28.977 7.0 3.02691 29.510 9.7 2.98840 29.899 5.1 2.95680 30.226 1.5 2.94644 30.335 0.4 2.90223 30.809 2.4 2.82792 31.639 2.4 2.77318 32.281 2.2 2.73918 32.692 5.5 2.72426 32.877 2.3 2.67483 33.502 0.7 2.60065 34.487 1.1 2.57558 34.833 0.3 Chemical analysis of the extracted Example 7 product indicated the following composition: Al 18.75 wt. % P 17.39 wt.% V 0.19 wt. % Si 0.17 wt.% Example 8 (Comparative) A mixture containing 56 .6 g of 85% orthophosphoric acid (H,P0, ) in 77.5 g water was mixed with 0 .46 g of vanadium pentoxide (V o O,- ) . The mixture was heated to 50 °C with stirring for 30 minutes until complete dissolution of the vanadium pentoxide. Then, 35 .5 g of aluminum oxide source (e.g . pseudo-boehmite) was added and the mixture was heated to 80 °C for 1 hour. To this mixture was added 52.75 g tetrakis (2-hydroxyethyl )ammonium hydroxide (DA) in 75 g water, giving a final reaction mixture composed as follows: The reaction mixture was placed in a 300 cc autoclave. Crystallization in the autoclave was at 147°C at autogenous pressure for 17 hours. The solid product was filtered, washed with water and dried at 110°C for 17 hours. The product was analyzed by X-ray powder diffraction and found to be crystalline and to show the pattern of Table 9 and Figure 8. Table 9 Interplanar Observed Pelative d-Spacings (A) 2xTheta Intensities (I/I 0 ) 11.86314 7.452 56.5 6.84404 12.935 10.0 5.92515 14.952 24.7 4.47602 19.835 57.1 4.20617 21.122 51.4 3.95363 22.488 100.0 3.58446 24.840 3.1 3.41877 26.064 34.6 3.19075 27.963 0.4 3.06316 29.153 14.7 2.96016 30.191 17.9 2.65390 33.774 4.4 2.58432 34.712 13.7 The product of Example 8 was composed primarily of crystals having the structure of AlP0 4 -5, with only a small amount of the large pore metalloaluminophosphate crystals of the present invention.

Claims: CLAIMS: 1. A method for synthesizing a crystalline molecular sieve having an X-ray diffraction pattern with lines shown in Table 1A of the specification, which comprises (i) preparing a mixture comprising sources of oxides of aluminum, phosphorus, and optionally one or more elements (M) other than aluminum or phosphorus, water and a directing agent (DA), and having a composition, in terms of mole ratios, within the following ranges: M/A1 2 0 3 0 to 0.5 P 2 0 5 /A1 2 0 3 0.5 to 1.25 H 2 0/A1 2 0 3 10 to 100 DA/A1 2 0 3 0.5 to 1.5 wherein DA is a compound of the formula: wherein R, R' , R 1 ' and P" 1 are the same or different and are selected from -CH 3 X, -CH 2 CH 2 , and X is a cation, (ii) maintaining said mixture under conditions including a temperature of 10 °C to 145°C for a period of time of up to 80 hours and (iii) recovering the crystalline product from step (ii). 2. The method of claim 1 wherein M is present in the reaction mixture and M/Al O,- is 0.01 to 0.5. 3. The method of claim 1 wherein the mixture has the following composition ranges: P 2 0 5 /A1 2 0 3 0.9 to 1.1 H 2 0/A1 2 0 3 20 to 80 DA/A1 2 0 3 ' 0.3 to 0.7 4. The method of claim 3 wherein M is present in the reaction mixture and M/A1 2 0 3 is 0.01 to 0.2 5. The method of Claim 1 wherein said mixture has the following composition ranges: P 2 0 5 /A1 2 0 3 0.9 to 1.1 H 2 0/A1 2 0 3 30 to 60 DA/A1 2 0 3 " 0.4 to 0.6 6. The method of claim 5 wherein M is present in the reaction mixture and M/Al.,0, is 0.01 to 0.1 _. ._> 7. The method of claim 2 wherein M includes an element other than silicon having an oxidation number +2 and an ionic radius ratio of 0.52 to 0.62 or an oxidation number of +3 to +6 and an ionic radius ratio of 0 .15 to 0 .73. 8. The method of claim 2 wherein M includes In , Sb 4+ , Sn 4+ , Ti 3+ or Ti 4+ . 9 . The method of claim 2 , wherein M also includes silicon such that the ratio of silicon on-silicon atoms in the M0 7 component is less than 1. 10. The method of claim 1 wherein the directing agent DA is tetrakis( 2-(hydroxyethyl )ammonium hydroxide.

Inventors: CHANG CLARENCE DAYTON, LUTNER JOHN DENNIS, CHANG, CLARENCE, DAYTON, LUTNER, JOHN, DENNIS
Applicants: MOBIL OIL CORP, MOBIL OIL CORPORATION
Application year: 1989
Main classification: C01B25
IPC codes: B01J20, B01J29, C01B25, C01B33, C01B37, C01B39, C10G45, C10G47, C10G49