Novel crystalline aluminophosphates and related compounds

Abstract: Crystalline aluminophosphates and related compounds having in the as-synthesized anhydrous form the chemical composition: mR(X n Al q P x )O₂, wherein R represents ethylenediamine, X represents one or more elements which can be substituted for Al and/or P, wherein m = 0.01-0.33 n = 0-0.40 q = 0.30-0.60 x = 0.30-0.60 and wherein n + q + x = 1 and which have a distinct X-ray diffraction pattern. The compounds can be prepared from a forming solution or gel comprising a source of aluminium, a source of phosphorus, a source of ethylenediamine and optionally a source of at least one component X, wherein the appropriate forming components are initially present in specific molar ratios and which mixture is kept at elevated temperature for a period of time sufficient to produce a crystalline aluminophosphate or related compound followed by separating off the crystalline product obtained and drying, and which may subsequently be calcined.

Description: The present invention relates to novel crystalline aluminophosphate compositions and a process for preparing such aluminophosphate compositions. Crystalline aluminophosphate compositions are well known materials which find a promising reception in industry as new generations of molecular sieves, catalyst carriers as well as catalysts. For instance, in United States patent specification No. 4,310,440, the preparation of various crystalline aluminophosphates is described from reaction mixtures containing inter alia organic structure directing or templating agents including tetrapropylammonium hydroxide, quinuclidine, t-butylamine and ethylenediamine. Classes of these materials comprise compositions crystallized in the AlPO₄, SAPO₄ (siliconaluminophosphate), MeAPO₄ (metalloaluminophosphate) and ElAPO₄ (non-metal substituted aluminophosphate) families. It has now been found that novel crystalline aluminophosphates, e.g. of the AlPO₄-, SAPO₄- and MeAPO₄-type can be prepared from reaction gels or solutions when use is made of the appropriate forming components and a certain organic diamine compound in specific molar ratios. The present invention thus relates to crystalline aluminophosphates having in the as-synthesized anhydrous form the chemical composition: mR(X n Al q P x )O₂ , wherein R represents ethylenediamine as defined hereinbelow, X represents one or more elements which can be substituted for Al and/or P, wherein m = 0.01-0.33 n = 0-0.40 q = 0.30-0.60 x = 0.30-0.60 and wherein n + q + x = 1 , and having an X-ray diffraction pattern containing at least the following lines: d(A) Intensity 11.3 ± 0.2 s 4.19 ± 0.1 vs 3.97 ± 0.1 w-m 3.77 ± 0.05 w-m 3.65 ± 0.05 m 3.56 ± 0.05 m-vs 3.17 ± 0.03 w-m 3.12 ± 0.03 m-s 2.99 ± 0.03 m-s 2.81 ± 0.03 w In particular, the present invention relates to aluminophosphates having the chemical composition as described hereinabove, wherein m = 0.05 - 0.20 n = 0-0.30 q = 0.35-0.60 and x = 0.35-0.60. As element X which can be substituted for aluminium and/or phosphorus in the crystalline aluminophosphates according to the present invention can suitably be used one or more of beryllium, magnesium, titanium, manganese, iron, cobalt, zinc, vanadium, nickel, chromium, silicon, lithium, boron, gallium, germanium and arsenic. Typically, said element will be one or more of magnesium, titanium, manganese, iron, cobalt, zinc, nickel, silicon, gallium or germanium, and preferably one or more of magnesium, titanium, manganese, iron, cobalt and silicon. It should be noted that the expression ethylenediamine as used throughout this specification also includes lower alkyl substituted ethylenediamines as well as protonic forms of ethylenediamine and its lower alkyl derivatives. In the event that n > 0 it will be appreciated that the as-synthesized anhydrous form of the crystalline aluminophosphates according to the present invention also contains an appropriate charge-balancing cation such as a proton or a protonic form of R as described hereinbefore. An example of a novel crystalline aluminophosphate according to the present invention and belonging to the AlPO₄-class has in the as-synthesized anhydrous form the following chemical composition: 0.11 R (Al 0.5 P 0.5 )O₂ having an X-ray diffraction pattern as given in Table I. The present invention also relates to a process for preparing novel crystalline aluminophosphates as defined hereinbefore from a forming solution or gel comprising a source of aluminium, a source of phosphorus, a source of ethylenediamine and optionally a source of at least one component X, which mixture is kept at a temperature between 80 °C and 175 °C for a period of time sufficient to produce a crystalline aluminophosphate followed by separating off the crystalline product obtained and drying, in which solution or gel the various components are initially present in the following molar ratios: 0.10 < R : Al₂O₃ < 0.65 X : Al₂O₃ = 0-2 P : Al₂O₃ = 0.3-1.3 H₂O: Al₂O₃ = 30-500, wherein X and R have the meanings as defined hereinbefore. The crystalline aluminophosphates according to the present invention are preferably prepared from a forming solution or gel in which the various components are initially present in the following molar ratios: 0.15 < R : Al₂O₃ < 0.60 X : Al₂O₃ = 0-2 P : Al₂O₃ = 0.4-1.25 H₂O: Al₂O₃ = 35-320. Crystalline aluminophosphates according to the present invention are normally prepared from forming solutions or gels at a temperature between 80 °C and 175 °C, in particular between 100 °C and 165 °C. The use of aqueous forming solutions or gels is preferred. The process according to the present invention can be carried out at autogenous pressure as well as at an elevated pressure. Normally, the novel crystalline aluminophosphates and related compounds will be produced when the forming solution or gel has been kept under the appropriate conditions for a period of time allowing the proper structure to be formed. Preferably, the process according to the present invention is carried out for a period of time ranging between 18 hours and 144 hours, in particular between 24 and 96 hours. Examples of suitable aluminium sources comprise aluminium oxide, such as gibbsite, boehmite, pseudo-boehmite and aluminium alkoxides, such as aluminium isopropoxide. Also mixtures of various aluminium sources can be suitably applied. Preference is given to the use of boehmite and, in particular, pseudo-boehmite. Suitable phosphorus sources comprise phosphorus acids and derivatives thereof such as esters, phosphorus oxides, phosphates and phosphites, preferably ortho-phosphoric acid. Also mixtures of phosphorus sources can be applied. Examples of suitable sources of X comprise the appropriate chlorides, iodides, bromides, nitrates, sulphates and acetates, preferably acetates, as well as oxides. If desired, the crystalline aluminophosphates produced can be calcined after drying to produce the desired calcined substantially R-free aluminophosphates. It has been found that agitation can advantageously be applied to produce the desired crystalline aluminophosphates from the forming solution or gel. The novel crystalline aluminophosphates according to the present invention can suitably be used as molecular sieves, catalysts or as catalyst carriers in the operation of various catalytic processes. If desired, one or more (catalytically) active species, in particular protons and/or precursors thereof and/or one or more metal(s) (compounds) of Group III and/or the transition metals and/or rare earth metals and/or precursors thereof, can be incorporated into the crystalline aluminophosphates and related compounds according to the present invention. They can be incorporated by well-known techniques such as, for example, impregnation and ion-exchange. The invention will now be illustrated by the following Examples. Example I A crystalline AlPO₄ was prepared by mixing 9.8 grammes of pseudo-boehmite, 15.4 grammes of 85% H₃PO₄, 2 grammes of ethylenediamine and 45.1 grammes of water to form a mixture having a pH between 2 and 3. This mixture was consequently maintained at 120 °C for 72 hours until a crystalline compound was obtained. After synthesis the crystalline compound produced was separated from the reaction mixture by filtration, water washed, and dried at 120 °C. The crystalline compound obtained had in the anhydrous form the following chemical composition: 0.11 R (Al 0.5 )P 0.5 O₂ (R = ethylenediamine) and an X-ray diffraction pattern containing at least the lines as given in Table I below. d(A) Intensity 11.4 s 8.0 w-m 7.5 w-m 6.0 w-m 4.19 vs 3.97 m 3.77 w-m 3.65 m 3.56 vs 3.18 w-m 3.12 m-s 2.99 m-s 2.96 w-m 2.81 w-m Example II A crystalline AlPO₄ was prepared in an experiment which was carried out in a substantially analogous manner as described in Example 1, except that the reaction was carried out at 160 °C for 72 hours and using 39.1 grammes of water. The crystalline AlPO₄ obtained had in the anhydrous form the following chemical composition: 0.09 R (Al 0.5 P 0.5 )O₂ (R = ethylenediamine) and an X-ray diffraction pattern containing at least the lines as given in Table II hereinbelow. d(A) Intensity 11.2 s 7.9 w-m 7.4 w 6.0 w-m 4.18 vs 3.96 w-m 3.76 w-m 3.65 w-m 3.55 vs 3.16 w-m 3.13 m-s 2.99 m-s 2.95 w-m 2.81 w-m Example III A crystalline AlPO₄ was prepared in an experiment which was carried out in a substantially analogous manner as described in Example 1, except that the reaction mixture contained 9.2 grammes of boehmite, 15.4 grammes of 85% H₃PO₄ and 45.7 grammes of water and was carried out at 120 °C for 72 hours. The crystalline AlPO₄ obtained had in the anhydrous form the following chemical composition: 0.15 R (Al 0.5 P 0.5 )O₂ (R = ethylenediamine) and an X-ray diffraction pattern containing at least the lines as given in Table III hereinbelow. d(A) Intensity 11.4 vs 6.0 w 4.19 m 3.97 w 3.76 w 3.65 w 3.56 w-m 3.17 w 3.12 w-m 2.99 w-m 2.95 w 2.81 w

Claims: Crystalline aluminophosphates having in the as-synthesized anhydrous form the chemical composition: mR(X n Al q P x )O₂, wherein R represents ethylenediamine, lower alkyl substituted ethylenediamines as well as protonic forms of ethylenediamine and its lower alkyl derivatives, X represents one or more elements which can be substituted for Al and/or P, wherein m = 0.01-0.33 n = 0-0.40 q = 0.30-0.60 x = 0.30-0.60 and wherein n + q + x = 1 , and having an X-ray diffraction pattern containing at least the following lines: d(A) Intensity 11.3 ± 0.2 s 4.19 ± 0.1 vs 3.97 ± 0.1 w-m 3.65 ± 0.05 m 3.56 ± 0.05 m-vs 3.17 ± 0.03 w-m 3.12 ± 0.03 m-s 2.99 ± 0.03 m-s 2.81 ± 0.03 w Crystalline aluminophosphates according to claim 1, wherein m = 0.05-0.20 n = 0-0.30 q = 0.35-0.60 and x = 0.35-0.60. Crystalline aluminophosphates according to claim 1 or 2, wherein X represents one or more of beryllium, magnesium, titanium, manganese, iron, cobalt, zinc, vanadium, nickel, chromium, silicon, lithium, boron, gallium, germanium and arsenic, preferably one or more of magnesium, manganese, titanium, iron, cobalt and silicon. Crystalline aluminophosphates according to any one of claims 1-3 having in the calcined substantially R-free form the formula: (X n Al q P x )O₂ wherein X, n, q and x have the meanings as described hereinabove and wherein n + q + x = 1 . Crystalline aluminophosphates according to any one of claims 1-4, wherein one or more (catalytically) active species have been incorporated, preferably protons and/or precursors thereof and/or one or more metal(s) compounds of Group III and/or the Transition Metals and/or Rare Earth Metals and/or precursors thereof. A process for preparing crystalline aluminophosphates as claimed in claim 1 from a forming solution or gel comprising a source of aluminium, a source of phosphorus, a source of ethylenediamine as defined in claim 1 and optionally a source of at least one component X, which mixture is kept at a temperature between 80 °C and 175 °C for a period of time sufficient to produce a crystalline aluminophosphate followed by separating off the crystalline product obtained and drying, in which solution or gel the various components are initially present in the following molar ratios: 0.10 < R : Al₂O₃ < 0.65 X : Al₂O₃ = 0-2 P : Al₂O₃ = 0.3-1.3 H₂O: Al₂O₃ = 30-500. A process according to claim 6, wherein the various components in the forming solution or gel are initially present in the following molar ratios: 0.15 < R : Al₂O₃ < 0.60 X : Al₂O₃ = 0-2 P : Al₂O₃ = 0.4-1.25 H₂O: Al₂O₃ = 35-320. A process according to claim 6 or 7, wherein the forming solution or gel is kept for a period of time ranging between 18 and 144 hours, in particular between 24 and 96 hours under crystal-forming conditions. A process according to any one of claims 6-8, wherein use is made of gibbsite, boehmite, pseudo-boehmite or aluminium alkoxides as source of aluminium, preferably pseudo-boehmite. A process according to any one of claims 6-9, wherein use is made of phosphorus acids and/or esters thereof, phosphorus oxides, phosphates or phosphites as source of phosphorus, preferably of phosphoric acid. A process according to any one of claims 6-10, wherein use is made of components X in the form of the appropriate chlorides, iodides, bromides, sulphates, nitrates, acetates or oxides, preferably of the acetates. A process according to any one of claims 6-11, wherein the crystalline product obtained is calcined. A process for carrying out catalytic reactions, wherein use is made of a crystalline aluminophosphate as claimed in any one of claims 1-5, as a catalyst, a catalyst carrier or a molecular sieve in the operation of the process.

Inventors: CLARK DAVID MICHAEL, DOGTEROM RONALD JAN, CLARK, DAVID MICHAEL, DOGTEROM, RONALD JAN
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1990
Main classification: C01B25
IPC codes: C01B39, C01B33, B01J29, C01B25, C01B37