Crystalline aluminophosphates

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 is derived from a 2,2′-bipyridyl moiety, 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. The compounds can be prepared from a forming solution or gel comprising a source of aluminium, a source of phosphorus, optionally a source of at least one component X, and a template source based on a 2,2′-bipyridyl moiety, 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 aluminophosphates. 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 (silicoaluminophosphate), MeAPO₄ (metalloaluminophosphace) 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 2,2'-bipyridyl compound. 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 is derived from a 2,2'-bipyridyl moiety, 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 8.3-8.7 m 7.2-7.4 w 7.0-7.2 m/s 5.1-5.3 w 5.0-5.2 vw/w 4.16-4.26 w/m 4.13-4.23 m/s 4.08-4.18 w/m 3.97-4.07 w/m 3.92-4.02 m 3.60-3.70 vs 3.24-3.30 m 2.90-2.96 w 2.73-2.79 vw/w In particular the present invention relates to crystalline aluminophosphates having the chemical composition as described above, wherein m = 0.10 - 0.20 n = 0 - 0.30 q = 0.44 - 0.60 and x = 0.44 - 0.60 and wherein n + q + x = 1 . Particularly preferred to be present in a crystalline compound according to the invention, are compounds derived from a 2,2'-bipyridyl moiety containing one or more alkyl-groups, specifically alkyl-groups comprising not more than 6 carbon atoms, more specifically alkyl-groups representing methyl, ethyl and/or propyl. Especially preferred are compounds which are derived from a 2,2'-bipyridyl moiety made up of two similarly substituted pyridyl-groups, more specifically compounds which are derived from 4,4'-dimethyl 2,2'-bipyridyl or 2,2'-bipyridyl. 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, manganese, titanium, iron, cobalt and silicon. In the event that n > 0 it will be appreciated that the as-synthesized anhydrous form also contains an appropriate charge-balancing cation such as a proton, or a protonated form of a compound based on R. An example of a novel crystalline aluminophosphate according to the present invention and belonging to the AlPO₄-class has in the as synthesized form the following chemical composition, wherein R represents a compound derived from 2,2'-bipyridyl: 0.13 R(Al 0.5 P 0.5 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2. A further example of a novel crystalline aluminophosphate according to the present invention and belonging to the SAPO₄-class has in the as-synthesized form the following chemical composition: 0.12 R(Si 0.07 Al 0.49 P 0.44 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2. A further example of a novel crystalline aluminophosphate according to the present invention and belonging to the CoAlPO₄-class has in the as-synthesized form the following chemical composition: 0.12 R(Co 0.04 Al 0.47 P 0.49 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2. It should be understood that the anhydrous form referred to in this specification may also contain chemically bound water as the case may be. The present invention also relates to novel crystalline aluminophosphates which are substantially in the calcined, R-free form having the general chemical composition: (X n Al q P x )O₂, wherein X, n, q and x have the meaning as described hereinabove and wherein n + q + x = 1 . 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, optionally a source of at least one component X, and a template source based on a 2,2'-bipyridyl moiety, which mixture is kept at elevated temperature 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: R : Al₂O₃ = 0.1 - 3 X : Al₂O₃ = 0 - 2 P : Al₂O₃ = 0.3 - 1.3 H₂O : Al₂O₃ = 40 - 500 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: R : Al₂O₃ = 0.15 - 2 X : Al₂O₃ = 0 - 2 P : Al₂O₃ = 0.4 - 1.25 H₂O : Al₂O₃ = 45 - 320 Crystalline aluminophosphates having in the as-synthesized anhydrous form an X-ray diffraction pattern containing at least the lines as given in Table 1 are suitably prepared whilst keeping the temperature between 80 and 220 °C, in particular at a temperature in the range of from 100 to 200 °C. The use of aqueous forming solutions or gels is preferred. For preparing the forming solution or gel, any source or promoter form based on a 2,2'-bipyridyl moiety can be used as template source, such as a quaternary compound of such a 2,2'-bipyridyl moiety, which source or promoter form should be such that it can be converted into a 2,2'-bipyridyl moiety. The process according to the present invention can be carried out at autogeneous pressure as well as at elevated pressure. Normally, the novel crystalline aluminophosphates 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 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. An especially preferred aluminium source is 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 various 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 calcined substantially R-free aluminophosphates. It has been found that agitation can be applied advantageously 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 according to the present invention. They can be incorporated by well-known techniques such as, for instance, impregnation and ion-exchange. The invention will now be illustrated by means of the following Examples. Example 1 A crystalline AlPO₄, referred to as SCS-14, was prepared by mixing 13.75 grammes of boehmite, 23.1 grammes of 85 % H₃PO₄, 15.6 grammes of 2,2'-bipyridyl (bipy) and 68.6 grammes of water giving a reaction gel mixture on a molar basis of 1 Al₂O₃ : 1 P₂O₅ : 1 bipy : 45 H₂O. This mixture was kept at 160 °C for a period of 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, wherein R represents a compound derived from 2,2'-bipyridyl: 0.13 R(Al 0.5 P 0.5 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2, below. d (A) Intensity 8.5 m 7.3 (sh) w 7.1 m/s 5.2 w 5.1 vw/w 4.21 (sh) w/m 4.18 m/s 4.13 (sh) w/m 4.02 w/m 3.97 m 3.65 vs 3.27 m 2.93 w 2.76 vw/w Example 2 A crystalline SAPO₄ was prepared by mixing 3.4 grammes of boehmite, 5.2 grammes of 85 % H₃PO₄, 3.9 grammes of 2,2'-bipyridyl (bipy), 1.2 grammes of silicasol (Ludox, s.a.) and 21.4 grammes of water, giving a reaction gel mixture on a molar basis of 0.3 SiO₂ : 1 Al₂O₃ : 0.9 P₂O₅ : 1 bipy : 56 H₂O. This mixture was kept at 160 °C for a period of 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 has in the anhydrous form the following chemical composition, wherein R represents a compound derived from 2,2'-bipyridyl: 0.12 R(Si 0.07 Al 0.49 P 0.44 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2. Example 3 A crystalline CoAlPO₄ was prepared by mixing 3.1 grammes of boehmite, 5.8 grammes of 85 % H₃PO₄, 3.9 grammes of 2,2'-bipyridyl (bipy), 2.2 grammes of Co(CH₃COO)₂.4H₂O and 19.2 grammes of water, giving a reaction gel mixture on a molar basis of 0.3 CoO : 0.9 Al₂O₃ : 1 P₂O₅ : 1 bipy : 50.5 H₂O. This mixture was kept at 160 °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 has in the anhydrous form the following chemical composition, wherein R represents a compound derived from 2,2'-bipyridyl: 0.12 R(Co 0.04 Al 0.47 P 0.49 )O₂ having an X-ray diffraction pattern containing at least the lines as given in Table 2.

Claims: Claims for the following Contracting States : BE, CH, DE, DK, FR, GB, IT, LI, NL, SE Crystalline aluminophosphates having in the as-synthesized anhydrous form the chemical composition: mR(X n Al q P x )O₂, wherein R is derived from a 2,2'-bipyridyl moiety, 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 8.3-8.7 m 7.2-7.4 w 7.0-7.2 m/s 5.1-5.3 w 5.0-5.2 vw/w 4.16-4.26 w/m 4.13-4.23 m/s 4.08-4.18 w/m 3.97-4.07 w/m 3.92-4.02 m 3.60-3.70 vs 3.24-3.30 m 2.90-2.96 w 2.73-2.79 vw/w Crystalline aluminophosphates according to claim 1, wherein m = 0.10 - 0.20 n = 0 - 0.30 q = 0.44 - 0.60 and x = 0.44 - 0.60 Crystalline aluminophosphates according to claim 1 or 2, wherein R is derived from a 2,2'-bipyridyl moiety containing one or more alkyl-groups, preferably alkyl-groups comprising not more than 6 carbon atoms, in particular methyl, ethyl and/or propyl groups. Crystalline aluminophosphates according to any one of claims 1-3, wherein R is derived from a 2,2'-bipyridyl moiety made up of two similarly substituted pyridyl-groups. Crystalline aluminophosphates according to claim 4, wherein R is derived from 4,4'-dimethyl 2,2'-bipyridyl. Crystalline aluminophosphates according to claim 1, wherein R is derived from 2,2'-bipyridyl. Crystalline aluminophosphates according to any one of claims 1-6, wherein element 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 1-7, 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, optionally a source of at least one component X, and a template source based on a 2,2'-bipyridyl moiety, which mixture is kept at elevated temperature 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: R:Al₂O₃ = 0.1 - 3 X:Al₂O₃ = 0 - 2 P:Al₂O₃ = 0.3 - 1.3 H₂O:Al₂O₃ = 40 - 500 A process according to claim 9, wherein the various components in the forming solution or gel are initially present in the following molar ratios: R:Al₂O₃ = 0.15 - 2 X:Al₂O₃ = 0 - 2 P:Al₂O₃ = 0.4 - 1.25 H₂O:Al₂O₃ = 45 - 320 A process according to claim 9 or 10, wherein use is made of aluminiumoxide and/or derivates thereof as source of aluminium, preferably of boehmite. A process according to any one of claims 9-11, wherein use is made of phosphorus acids, phosphorus oxides, phosphates or phosphites as source of phosphorus. A process according to any one of claims 9-12, wherein use is made of a template source which is based on a 2,2'-bipyridyl moiety containing one or more alkyl-groups, preferably alkyl-groups comprising more than 6 carbon atoms, in particular methyl, ethyl and/or propyl groups. A process according to claim 13, wherein use is made of a template source which is based on a 2,2'-bipyridyl moiety made up of two similarly substituted pyridyl-groups. A process according to claim 14, wherein use is made of a 4,4'-dimethyl 2,2'-bipyridyl as template source. A process according to claim 9, wherein use is made of 2,2'-bipyridyl as template source. A process according to any one of claims 9-16, wherein use is made of components X in the form of the appropriate chlorides, iodides, bromides, sulphates, nitrates, acetates or oxides. A process according to any one of claims 9-17, wherein the temperature is kept between 80 and 220 °C, in particular between 100 and 200 °C. A process according to any one of claims 9-18, wherein the forming solution or gel is kept for a period of time ranging between 18 and 144 hours under crystal-forming conditions. A process according to any one of claims 9-19, wherein the crystalline product obtained is calcined. Use of a crystalline aluminophosphate as claimed in any one of claims 1-8, as a molecular sieve, catalyst or catalyst carrier. Claims for the following Contracting State : ES A process for preparing crystalline aluminophosphates having in the as-synthesized anhydrous form the chemical composition: mR(X n Al q P x )O₂, wherein R is derived from a 2,2'-bipyridyl moiety, 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 8.3-8.7 m 7.2-7.4 w 7.0-7.2 m/s 5.1-5.3 w 5.0-5.2 vw/w 4.16-4.26 w/m 4.13-4.23 m/s 4.08-4.18 w/m 3.97-4.07 w/m 3.92-4.02 m 3.60-3.70 vs 3.24-3.30 m 2.90-2.96 w 2.73-2.79 vw/w from a forming solution or gel comprising a source of aluminium, a source of phosphorus, optionally a source of at least one component X, and a template source based on a 2,2'-bipyridyl moiety, which mixture is kept at elevated temperature 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: R:Al₂O₃ = 0.1 - 3 X:Al₂O₃ = 0 - 2 P:Al₂O₃ = 0.3 - 1.3 H₂O:Al₂O₃ = 40 - 500 A process according to claim 1, wherein the various components in the forming solution or gel are initially present in the following molar ratios: R:Al₂O₃ = 0.15 - 2 X:Al₂O₃ = 0 - 2 P:Al₂O₃ = 0.4 - 1.25 H₂O:Al₂O₃ = 45 - 320 A process according to claim 1 or 2, wherein use is made of aluminiumoxide and/or derivates thereof as source of aluminium, preferably of boehmite. A process according to any one of claims 1-3, wherein use is made of phosphorus acids, phosphorus oxides, phosphates or phosphites as source of phosphorus. A process according to any one of claims 1-4, wherein use is made of a template source which is based on a 2,2'-bipyridyl moiety containing one or more alkyl-groups, preferably alkyl-groups comprising more than 6 carbon atoms, in particular methyl, ethyl and/or propyl groups. A process according to claim 5, wherein use is made of a template source which is based on a 2,2'-bipyridyl moiety made up of two similarly substituted pyridyl-groups. A process according to claim 6, wherein use is made of a 4,4'-dimethyl 2,2'-bipyridyl as template source. A process according to claim 1, wherein use is made of 2,2'-bipyridyl as template source. A process according to any one of claims 1-8, wherein use is made of components X in the form of the appropriate chlorides, iodides, bromides, sulphates, nitrates, acetates or oxides. A process according to any one of claims 1-9, wherein the temperature is kept between 80 and 220 °C, in particular between 100 and 200 °C. A process according to any one of claims 1-10, wherein the forming solution or gel is kept for a period of time ranging between 18 and 144 hours under crystal-forming conditions. A process according to any one of claims 1-11, wherein the crystalline product obtained is calcined. Use of a crystalline aluminophosphate prepared by a process as claimed in any one of claims 1-12, as a molecular sieve, catalyst or catalyst carrier.

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: C01B37, B01J29, C01B25