LARGE-PORED MOLECULAR SIEVES CONTAINING AT LEAST ONE OCTAHEDRAL SITE AND TETRAHEDRAL SITES OF AT LEAST ONE TYPE

Abstract: A crystalline molecular sieve is disclosed having both at least one octahedrally coordinate metal and at least one tetrahedrally coordinated metal in its framework.

Description: LARGE-PORED MOLECULAR SIEVES CONTAINING rl LEAST ONE OCTAHEDRAL SITE AND TETRAHEDRAL 5ITES OF AT LEAST ONE TYPE BACKGROUND OF THE INVENTION 1. Field of th Invention This invention relates to new crystalline molecular sieve zeolite compositions, having a pore size of from about 6 to at least 10 Angstrom units, containing at least one metal capable of forming an octahedral site in the framework structure, methods for preparing the same; uses thereof such as organic compound conversions therewith, especially hydrocarbon conversions, ion exchange applications, removal of metal ions from solutions thereof, removal of gases in both a selective and non-selective mode, including storage of the same; and removal of hydrocarbons from a non-hydrocarbon media, e.g., water. The novel materials of this invention possess a framework which contains at least one metal in an octahedrally coordinated state and at least one other metal in the framework in a tetrahedrally coordinated state. 2. Background of the Invention and Prior Art Since the discovery by Milton and coworkers (U. Ξ. 2,882,243 and U. S. 2,882,244) in the late 1950's that aluminosilicate systems could be induced to form uniformly porous, internally charged crystals, analogous to molecular sieve zeolites found in nature, the properties of synthetic aluminosilicate zeolite molecular sieves have formed the basis cf numerous commercially important catalytic, ≥dscrpt ve and ion-exchange applications. This high degree of utility s the result of a unique combination of high surface area and uniform porosity dictated by the "framework" structure cf the zeolite crystals coupled with the electrosc-ticaliy cnarged sites induced by tetrahedrally coordinated Al~ . Thus, a large r.u oer of "active" cnarged sites are readily accessible to molecules cf tr.e proper size and geometry for adsorptive or catalytic interactions. Further, since charge compensating cations are electrostatically and not covalently bound to the aluminosilicate framework, they are generally exchangeable for other cations with different inherent properties. This offers wide latitude for modification of active sites whereby specific adsorbents and catalysts can be tailormade for a given utility. In the publication "Zeolite Molecular Sieves", Chapter 2 , 1974, D. . Breck hypothesized that perhaps 1,000 aluminosilicate zeolite framework structures are theoretically possible, but to date only approximately 150 have been identified. While compositional nuances have Deen described in puDlicatlons such as . S. 4,524,055, U. Ξ. 4,603,040 and ". ≤. 4,606,399, totally new aluminosilicate framework structures are Demg discovered at a negligible rate. of particular importance to fundamental progress in the catalysis. of relatively large nydrocarbon molecules, especially fluid cracking operations, is tne fact that t has been a generation since the discovery cf ar new large Dored aluminosilicate zeolite. With slow progress in the discovery cf new vide pored aluminosilicate based molecular sieves, researchers have taken various approaches to replace aluminum or silicon m zeolite synthesis in the hope of generating either new zeolite-like framework structures or inducing the formation of qualitatively different active sites than are available in analogous aluminosilicate based materials. While progress cf academic interest has been made from different approaches, little success has been achieved in discovering new wide pore molecular sieve zeolites. It has been believed for a generation that phosphorus could be incorporated, to varying degrees, in zeolite type aluminosilicate frameworks. In the more recent past (JACS 104 pp. 1146 (1982); Proceedings of the 7th International Zeolite Conference, pp. 103-112, 1986) Ξ. M. Flanigan and coworkers have demonstrated the preparation of pure aluminophosphate based molecular sieves of a wide variety of structures. However, the site inducing Al *3 is essentially neutralized by the P *5 , imparting a -1 charge to the framework. Thus, while a new class of "molecular sieves" was created, they are not zeolites in the fundamental sense since they lack "active" charged sites. Realizing this inherent utility limiting deficiency, for the past few years the molecular sieve research community ha empnasized the synthesis of mixed aluminosilicate-metal oxide an mixed alummophosphate-metal oxide framework systems. While thi aDcroach to overcommσ the slow croσress m aluminosilicate zeolite synthesis has generated approximately 200 new compositions, all of which suffer either from the site removing effect of incorporated P *5 or the site diluting effect of incorporating effectively neutral tetrahedral -4 metals into an aluminosilicate type framework. As a result, extensive research by the molecular sieve research community has failed to demonstrate significant utility for any of these materials. A series of zeolite-like "framework" silicates have been postulated, some of which have larger uniform pores than are observed for aluminosilicate zeolites. (W. M. Meier, Proceedings of the 7th International Zeolite Conference, pp. 13-22 (1986).) While this particular synthesis approach produces materials which, by definition, totally lack active, charged sites, back implementation after synthesis would not appear out of the question although little work appears in the open literature on this topic. Another and most straightforward means cf potentially generating new structures or qualitatively different sites than those induced by aluminum would be the direct substitution of some other charge inducing species for aluminum m zeolite-like structures. To date the most notably successful example of this approach appears to be boron in the case of ZSM-5 analogs, although iron has also been claimed in similar materials. (EPA 53,796 (1983), Taramasso et al; Proceedings cf the 5th International Zeolite Conference; pp. 40-48 '1980)); Z . W. 3all et al; Proceedings cf -he 7th International Zeolite Conference: pp. 137-144 (1986); U. 5. 4,280,305 to Kouenhowen et al. Unfortunately, the low levels of incorporation cf the species substituting for aluminum usually leaves doubt f the species are occluded or framework incorporated. In 1967, Young in U. S. 3,329,481 reported that the synthesis of charge bearing (exchangeable) titanium silicates under conditions similar to aluminosilicate zeolite formation was possible if the titanium was present as a "critical reagent" -III peroxo species. While these materials were called "titanium zeolites" no evidence was presented beyond some questionable X-ray diffraction (XRD) patterns and his claim has generally been dismissed by the zeolite research community. (D. W. Breck, Zeolite Molecular Sieves, p. 322 (1974); R. M. Barrer, Hydrothermal Chemistry of Zeolites, p. 293 (1982); G. Perego et al, Proceedings of 7th International Zeolite Conference, p. 129 .'1986).) For all but one end member of this series of materials (denoted TS materials) , the presented XRD patterns indicate phases too dense to be molecular sieves. in the case of the one questionable end member (denoted TS-26) , the XRD pattern might possibly be interpreted as a small pored zeolite, although without additional supporting evidence, this appears extremely questionable. A naturally occurring alkaline titanosilicate identified as "Zorite" was discovered in trace quantities on the Kola Peninsula in 1972 (A. N. Mer'kov et al; Zapiski Vses Miπeralog. Obshch. , pages 54-62 (1973)). The puci sned XRD pattern was challenged and a proposed structure reported in a later article entitled "The OD Structure cf Zoπte" , candomirrkii et al, Sov. Phys. Crystallogr. 24 (6), Nov-Dec 1S79, pages 686-693. No further reports on "titanium zeolites" appeared m tne open literature until 1983 when trace levels cf tetrahedrai Ti(I7) were reported in a ZSM-5 analog. (M. Taramasso et al; T . 3. Patent 4,410,501 (1983); G. Perego et al; Proceedings of the 7th International Zeolite Conference; p. 129 (1986).; A similar claim appeared from researchers in mid-1985 (EPA 122,550 (1985)., More recently, the research community reported mixed aluminosilicate-titanium(IV) (EPA 179,876 (1985); EPA 131,884 (1985) structures which, along with TAPO (EPA 121,232 (1985) systems, appear to have no possibility of active titanium sites because of the titanium coordination. As such, their utility s highly questionable. That charge bearing, exchangeable titanium silicates are possible is inferred not only from the existence cf excnangeable alkali titanates and the early work discicsed in ' . 5. 2,329,481 on ill defined titanium silicates but also from the ooservation (S. . Kuznicki et al; Z . Phys. Chem. ; 1 . ; pp. 525-537 (1980)) cf TiO..- units in some modified zeolites. David . Chapman, in a speech before 11th North American Meeting cf the Catalysis Society m Dearsorn, Michigan '13891 gave a presentation wnerem a titanium aluminosilicate g was crystallized with Chapman claiming all the aluminum was seσregated into analcime (an ultra-small pored aluminosilicate) and not incorporated into any titanium-bearing pnase sucn as .-. s observed analog of the mineral vmogradovite whicn was a pure titanium silicate. It is noted that vinogradov te, as found in nature, has been reported to contain aluminum. However, neither the synthetic analog of vinogradovite nor the mineral vmogradovite is a molecular sieve. A ma^or breakthrough in the field cf large pored titanium silicate molecular sieves is disclosed and claimed r. U.S. Patent 4,853,202. The crystalline titanium silicate large pored molecular sieve of said patent, hereafter designated ETS-10, contains no deliberately added alumina but may contain very minor amounts of alumina due to the presence of impurities. Thus, ETS-10 typically has a molar ratio of Si0,/Al,c, greater than 100 or more. A second breakthrough is disclosed and claimed in copending application Ser. No. 07/373,855, filed on June 29, 1989, the entire disclosure of which is herein incorporated by reference. Said application relates to large-pored sieves with cnarged octahedral titanium and charged tetranedral aluminum sites identified as ETAS-10. SUMMARY OF THE INVENTION The present invention relates to a new family of stable molecular sieves which result from: (1) replacement cf at least a portion cf the εctar.eαra- titanium r. either ITS- 1 cr ΞTΛΞ-11 v tr. i least :r.e otr.er cctanedrai metal atom; (2) replacement of at least a portion cf -.-.e tetranedral silicon n ETS-10 or the tetranedrai silicon ana aluminum in ΞTAS-10 with at least one ther tetranecral metal atom; (3) a combination of (l) and (2) . DETAILED DESCRIPTION OF THE INVENTION These novel materials can be identified m terms of mole ratios of oxides as follows: a (1.0 - 0.25) M 2/n O : X0 3 : dZO, : 0-100 H.C wnerein X is at least one octahedral framework atom; I s at least one tetrahedral framework atom; M is at least one cation cf valence n; a is 1/2 the valence of X; β is 1/2 the valence of Z; d is 2-200; a is equal to 1/2 the charge provided by the total of X and Z; with the proviso that when X is only titanium then Z cannot be only silicon or any mixtures of silicon with aluminum. In the above formula, X is selected from the group consisting of titanium, aluminum, arsenic, cobalt, cnromium, copper, iron, germanium, magnesium, manganese, molybdenum, niobium, nickel, antimony, tin, uranium, vanadium, yttrium the actinides such as uranium, the lanthanides such as cerium, sine, zirconium, hafnium, and mixtures tnereof; Z is selected from the group consisting cf silicon, aluminum, arsenic, oismuth, boron, oeryilium, coDalt, cnromium, copper, iron, gallium, germanium, indium, lead, magnesium, manganese, olvDdenum, nioDium, r.ιcκel, pnospnorus, antimony, tin, titanium, vanadium, tungsten, zinc, ana mixtures tr.erecf . In order to account for charge balance, the total cations in the above equation is multiplied by a factor designated as "a" which is 1/2 the sum of the charges provided by the octahedral sites and the tetrahedral sites. Since both the octahedral atoms X and the tetrahedral atoms Z can be a plurality of atoms, it is necessary to take into consideration both the moles and the valance cf a particular metal atom in order to obtain proper charge valence. For the octahedral sites X, this is accomplished by calculating the moles of each X having a particular valence and proceeding as follows: (6 - the valence of each X) multiplied by its moles. Thus, if X was 0.5 moles of titanium * " and 0.5 moles of chromium *3 , then the total charge contributed by both of the above octahedrally coordinated atoms would be: For titanium (6 - 4) X .5 = 1 For chromium (6 - 3) x .5 = 1.5 Total charge from X = l - l.5 = 2.5. Thus, its contribution to a is 1/2 of 2.5 or 1.25. For the tetrahedral sites Z, this is accomplished by calculating the moles of each Z having a particular valence and proceeding as follows: d multiplied by ( 4 - the valence cf each 2) multiplied cv ts moles. Similarly, if d was 0.5 moles of aluminum" ** and 2.5 moles of silicon *2 , then the total charge contributed by both cf the above tetrahedrally coordinated atoms would be For aluminum d (4 - 3) = d For silicon d ( 4 - 4 ) = o Total charge from Z = 0 + d = d. Thus , the contribution to "a" is i/ 2 d. DESCRIPTION OF THE MOST PREFERRED EMBODIMENTS It is preferred that d is from 2-20 with 2-10 being particularly preferred. It is also preferred that M is a mixture of alkali metal cations in the as-synthesized materials, particularly sodium and potassium. A particularly preferred embodiment of this invention is wnen at least some atoms of X are titanium and at least some atoms of Z are silicon. It is also preferred that X does not equal Z. The following table will illustrate specific molecular sieves of this invention: -12- The original cations M can be replaced at least in part wi t h other cations by well known excnange tecnniques. Preferred replacing cations include hydrogen, ammonium, transition metals, rare earth, and mixtures thereof. The novel molecular sieve zeolites have a high degree of thermal stability of at least 250 β C or higher, thus rendering them effective for use in high temperature processes. Members of the novel family of molecular sieve zeolites have a crystalline structure and an X-ray powder diffraction pattern substantially the same as ETAS-10 or ETS-10 and contain •rhe following significant lines: TABLE - XRD POWDER PATTERN OF NOVEL MOLECULAR SIEVES (0 - 40° 2 theta) SIGNIFICANT d-SPACING (ANGS.) I/I, 15.5 - 2.0 W-M 7.20 - l.G (optional) w-M 4.41 - .05 - 0.25 W-M 3.60 - .10 - 0.40 VS 2.28 - .05 - .25 M-Ξ In the above table, S = 100 5 = 40-60 M = 20-40 * .v = ~ - - ~ The above values and values later mentioned were collected using standard techniques on a Phillips APD3720 diffractomater equipped with a theta compensator. The theta compensator maintains a constant area of illumination en the sample, so X-ray intensities obtained from a theta compensated unit are not directly comparable to those of a non-compensated unit. Thus, all values mentioned in the specification and claims were determined by said theta compensated X-ray equipment. The radiation was the K-a^pha doublet of copper, and a scintillation counter spectrometer was used. The peak heights, ' !, and the positions as a function of 2 times theta, where theta is the Bragg angle, were read from the spectrometer chart. From these, the relative intensities, 100 I/I 0 , where l a is the intensity of the strongest line or peak, and d (obs.), the interplanar spacin in A, corresponding to the recorded lines, were calculated. It should be understood that this X-ray diffraction pattern is characteristic of all the compositions. Ion exchange of the sodium ion and potassium ions with cations reveais substantially the same pattern with some minor shifts in interplanar spacing and variation in relative intensity. Other minor variations can occur depending on the ratio of the X to Z cf a particular sample, the various metals in the framework, as well as f t ha been subjected to thermal treatment. The novel molecular sieves can be prepared from a reaction mixture containing a source of at least one metal capable cf being octahedrally coordinated and also containing a source o f a t leas t one metal capable cf being t e t ranedraliy coordina t e d in the framework structure, a source cf aikaiin i tv such as an alkali metal hydroxide, water an d , op t ionally, an alkali metal fluori d e mmeralizer having a composition m terms of mole ratios falxing within the following ranges. TAB E 2 B road Preferred Most Preferr e Z/X 1-200 2-100 2 - 20 H,0/Z 2-100 5-50 - - M n /Z 0.1-20 0.5-1 0 ϊ- 5 - wherein M indicates the cations of valence n d erived from the alkali metal hydroxide and fluoride and/or alkali me t al salts. The reaction mixture is heated to a temperature of from about 100 - C to 25 0 ' C for a period of time ranging from a b ou t 2 hours t 4 0 days, or more. The hydrothermal reaction is carried out unti crys t als are formed and the resulting crys t alline pro d uc t is t h ereafter separa t ed from the reaction mix t ure , coole d to room tempera t ure, filtered and water washed. The reac t ion mixture ca b e stirred although it is not necessary. it has oeen found tha t when using gels, stirring is unnecessary but can b e employed. The preferre d temperature range is 150°C t o Z25° C for a per i od c ti me rang i ng from 4 hours to 7 days. Crys t alliza ti on i s per f orme d in a continuous or batcnwise manner un d er au t ogenous pressure m an au t oclave or static bomb reac t or. Follow i ng the wa t er washing s t ep, the crystalline molecular sieve i s d rie d a t t emperatures of ιoo to 600°F for periods up t o 20 nours. It s to be understood that trier to crystallizatio . the gel resulting from the reaction mixture can ce suc ected tc one cr more thermal treatments at temperatures c;. from aπout l50 β C to 800°C for 1-48 hours. The thermally treated gel is mixed with water and crystallized. Quite obviously, it is possible to use less caustic cr ther reactants in the gel than set forth in Table 2 and supply these during the crystallization step after the gel has been thermally treated. The source of metal which is either is octahedrally coordinated or tetrahedrally coordinated can be the appropriate metal salts such as nitrates, sulfates, chlorides, carbonates, etc., as well as solid sources of soluble metals. The source of alkalinity is preferably an aqueous solution of an alkali metal hydroxide, such as sodium hydroxide, which provides a source of alkali metal ions for maintaining electrovalent neutrality and controlling the pH cf the reaction mixture within the range of about 10.0 to 12.3 using the tecnnique elaborated in U.S. 4,853,202. The aikaii metal hydroxide serves as a source of sodium oxide which can aiso be supplied by an aqueous solution of sodium silicate for siiiccn containing molecular sieves. The crystalline molecular sieve as synthesized can hav the original components thereof replaced by a wide variety of ctners according to techniques well known in the art. Typical replacing components would include nydrogen, ammonium, aiky ammonium ana ary ammonium ana meta_≤, including mixtures :r tr.e same. The nydrogen form may oe prepared, for example, cy substitution of original sodium with ammonium cr zγ the use of a weak acid. The composition is then calcined at a temperature cf, say, iπoo°F causing evolution of ammonia and retention of hydrogen in the composition, i.e., hydrogen and/cr decationized form. Of the replacing metals, preference is accorded to metals of Groups II, IV and VIII of the Periodic Table, preferably the rare earth metals. The crystalline molecular sieves are then preferably wasned with water and dried at a temperature ranging from about 10θ β F to about 600 β F and thereafter calcined in air or other inert gas at temperatures ranging from 500°F to 1500°F for periods of time ranging from 1/2 to 48 hours or more. Regardless of the synthesized form of the molecular sieves, the spatial arrangement of atoms which form the basic crystal lattices remain essentially unchanged by the replacemen cf sodium or other alkali or alkaline earth metal cr by the presence in the initial reaction mixture of metals in addition sodium, as determined by an X-ray powder diffraction pattern of the resulting molecular sieves. The X-ray diffraction patterns cf such products are essentially the same as those set forth in Table 2 above (with the exception that the 7.20 - .15 A line is sometimes not observed) . The crystalline molecular sieves prepared in accorda with the invention are formed in a wide variety cf particular sizes. Generally, the particles can be in the form of powder, cranuie, cr a molded product such as an extrudate navmσ a par t icle size sufficient to pass through a 2 mesn Tyler ) screen an d b e main t aine d on a 400 mesh (Tyler) screen ir. cases where t he catalys t is molded such as by extrusion. The composition can be extruded b efore drying or dried or partially dried and then extruded. Sometimes, it is desired to incorpora t e t he new crys t alline molecular sieves with another ma t eria l resis t an t t o the temperatures and other conditions employed during use. Such ma t erials include active and inactive materials and synthetic and naturally occurring zeolites as well as inorganic ' materials such as clays, silica and/or metal oxides. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Use of a material in conjunction with the new molecular sieves, i.e., com b ine d therewith which is active, ten d s t o improve t he conversion and/or selectivity of the catalys t in cer t ain organ i c conversion processes. Inactive materials suita b ly serve as diluents to control the amount of conversion m a g i ven process so that pro d uc t s can be obtained economically and in an orderly manner withou t employing other means for con t rolling t he ra t e cf reaction. N ormally, crystalline materials have oeen incorpora t e d in t o na t ural l y occurring clays, e.g., ben t cni t e an d k aolin t o i mprove the crush strength when employed as a ca t alys t under commercial operating conditions such as hydrocar b on conversion. These e—tc., runc t ion as b inders for the ca t alys t . :t is desirable o prcv d e a ca t aivs t hav i r.σ good crush strength Decause in a petroleum refinery tne catalyst s often subjected to rough handling which tends to creak the catalyst down into powder-like materials wh;ch cause problems m processing. These clay binders have been employed for the purpose of improving the crusn scrength cf the catalyst. Naturally occurring clays that can be composited with the crystalline molecular sieves described herein include the smectite and kaolin families, which families include the ontmorillonites such as sub-bentonites and the aolinr in which the main constituent is kaolinite, halloysite, dickitε, nacrite or anauxite. Such clays can be used in the raw state after conventional gritting or they can be subjected to additional processing such as calcination, acid treatment or chemical modification. In addition to the foregoing materials, the crystallin molecular sieves may be composited with matrix materials such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-berylia, silica-titania as well as ternary compositions such as silica-alu ina-thoria, silica-alumma-zirconia, silica-alumina-magnesia and silica-magnesia-zirconia. The matri can be in the form of a cogel. The relative proportions of finally divided crystalline metal organosilicate and inorganic oxide gel matrix can vary widely with the crystalline organosilicate content ranging from about 1 to 90 percent by weight and more usually m the range cf aoout 2 to acout ΞO πercent bv weight cf the comDosite. In addition to the above, the crystalline molecular sieves can be incorporated with a matrix employing in-situ tecr.niques. Thus, for example, when preparing ε.n aluminum- containing material, a forming solution can be prepared as previously described, or the forming solution can contain no aluminum or less aluminum than set forth in Table 2. Quite obviously, it can also contain less caustic or other reactants. A mixture is formed, as previously described, and to it is added a reactive clay such as metakaolin. The mixture is blended, seeds such as ETAS-10 or ETS-10 may be added and sufficient water introduced in order to be able to spray dry the mixture into microspheres. The microspheres are converted to molecular sieves by adding an aqueous solution of caustic, caustic silicate (if silicon is desired) or water (if sufficient caustic is present) and crystallizing the same in an autoclave under autogeneous pressure. It is obvious that a portion of the metakaolin can supply a source of aluminum and/or silica. As is known in the art, it is often desirable to limit the alkali metal content of materials used for acid catalyzed reactions. This is usually accomplished by ion exchange with hydrogen ions or precursors thereof such as ammonium and/or meta cations such as rare earth. Employing the catalyst of this invention, containing a hy rogenation component, heavy petroleum residual stocks, cycle stocKs, and other hydrocrackable cnarge stocks can be vdrccracked at temperatures between 400°F and S25°F sinσ molar ratios of hydrogen to hydrocarbon cnarge ir. tne range cetween 2 and 80. The pressure employed will vary between 10 and 2,500 psig and the liquid hourly space velocity between 2.1 and 10. Employing the catalyst of this invention for catalytic cracking, hydrocarbon cracking stocks can be cracked at a liquid hourly space velocity between about 0.5 and 50, a temperature between about 550°F and 1100 β F, a pressure between aoout subat ospheric and several hundred atmospheres. Employing a catalytically active form of a member cf the family of molecular sieves of this invention containing a hydrogenation component, reforming stocks can be reformed employing a temperature between 700°F and 1000°F. The pressure can be between 100 and 1,000 psig, but is preferably between 200 to 700 psig. The liquid hourly space velocity is generally between 0.1 and 10, preferably between 0.5 and 4 and the hydrogen to hydrocarbon mole ratio is generally between 1 and 20, preferably between 4 and 12. The catalyst can also be used for hydroisomerization c normal paraffins when provided with a hydrogenation component, e.g. , platinum. Hydroisomerization is carried cut at a temperature between 200° and 700 β F, preferably 200°F to 550°F, with a liquid hourly space velocity between 0.01 and 2, preferably between 0.25 and 0.50 employing hydrogen sucn that th nydrogen to hydrocarbon mole ratio is between 1:1 and 5:1. Additionally, the catalyst can De used for clefin isomerization employing temperatures cetween 20°F and Ξ00°F. In order to more fully illustrate the nature cf the invention and a manner cf practicing the same, the following examples illustrate the best mode now contemplated. EXAMPLE 1 In octahedral coordination, Zr(IV) is somewhat larger than Ti(IV). A solution of TiCl 3 and ZrCi j was prepared such that Zr/Ti = 1 and Zr - Ti = 1.06 molar in 20% by HC1. An alkaline silicate solution was prepared by blending ,758.4g of "n"-brand sodium silicate with 252g of NaOH and 112. g of KF. 163.2g of the mixed metal solution was thoroughly blended with 212.8g of the silicate solution. This mixture was analogous to a "standard" ETS-10 gel with Zr replacing 1/2 of Ti. A portion of the mixture was autoclaved under autogenous pressure for 48 hours at 200°C. A crystalline product was obtained with an XRD pattern greatly resembling ETS-10 although somewhat upεhifted. -- ~- ΞTS ~ 10 ETS-12 MTYT'--P.F -.—'-' -, r ? £5 ENT Largest d-spacmg 14.6 - 14.7 -.-... o.. ** ; Strongest 3.60 c - W hile no t profound, these shiftr are ou t si d e normal analy t ical error and indicate some degree of zircon i um incorporation. EXAMPT.F r In tetrahedral coordination, Ga( is larger than S i ( I V) or Al ( III ) . A solution of TiCi, an d Gael, was prepare d sucn that G a/Ti = 0.5 and Ga - Ti --1.45 molar m 2 0 % HCi. An alkaline silicate solution was prepared by b lending 10 0. 5 g of " N» -Brand sodium silicate section with 2 1 . 0 g N a O H and 9.5 g anhydrous F. The Ti „ Ga solution was mixed and " thoroughly blende d with the alkaline silicate solution and t he "?H" was found to be 10.2. To the mixture a solution contain i ng 3 . 0 g of N a O H in 4 . 9 g D.I. water was added and thoroughly b lended in or d er to elevate the "pH" which was then found to oe about 1 0 . 6 . To t he mixture was added 0.93 g of calcine d ΞT S - 10 -_ype see d . A 1 5 gram port i on of the mixture was autoclave d un d er au t ogenous pressure at 200 - for 24 hours, A crys t aliine pro d uc t was ob t a i ned w i th an XRD pattern greatly resem b ling ET S - 22, althoug h somewhat upshifted. ^ TS"10 ETS-10 MIXTURE WTTH Ga PRESENT Largest d -spacmg 14.6 - 14.7 -S5 Strongest 2.6 0 - -- d-spacmg " ~ - A s w ith t ne cc t aneαrai suostiruticn c f a t oms larger th an tit an i um , the su b stitution cf tetrane d ral a t oms larger t han silicon is seen to "expand" the lattice parameters cf ΞTS-10-type structures. EXAMPLE 2 Ce(IV) is larger than Zr(IV) in octahedral coordination and significantly larger than Ti(IV). Framework incorporation would be expected to yield more pronounced upshifts than zirconium. Example 1 was repeated with the exception that CeCl 3 was directly substituted for ZrC on a mole per mole basis in the mixed metal solution. A crystalline product was obtained which contained multiple phases, one of which greatly resembled ETS-10, but with a pronounced upshift in XRD peak positions. ETS-10 ETS-10 MIXTURE WITH Ce PRESENT Largest d-spacing 14.6 - 14.7 15.2 Strongest 3.60 2.69 These upshifts are pronounced. It is unmistakable tha sucstantial cerium incorporation has occurred in an ΞTS-10-iike crvstalline lattice. EXAMPLE 4 While examples 1 and 3 demonstrate that atoms which essentially always occur in octahedral coordination oxides and therefore presumably substitute for octahedral titanium, can be incorporated into ETS-lύ-like materials, it was decided t o test the hypothesis that the noted expansion of lattice planes was occurring by a totally different mechanism than the expansion observed during aluminum incorporation in ETAS-10. If these two expansions were independent, then their effect might well be additive. To a portion of the remaining gel of Example 1 was added NaA10 2 such that Al/(Ti + Zr) = 0.5. This is empirically equivalent to Example 5 of Ser. No. 07/373,855 (ETAS-10) with Zr substituting for 1/2 of the Ti. Eight gram samples were fortified with varying additions of caustic to accelerate growth. With the addition of approximately 0.25 grams of NaOH an eight gram charge, a crystalline product resulted which resembled ETAS-10 but with clearly upshifted XRD d-spacings. ETS-10 EXAMPLE 1 ETAS-10 EXAMPLE 4 (Al/Tι=.5) Largest d-spacing 14.6 - 14.7 14.85 14.9 - 15.0 15.3 Strongest 3.60 3.62 2.63 - 3.64 2.70 d-spacmg N ot only are the lattice expansions addi t ive, it appears t ha t the t wo mechanisms act synp.rgisricaily. This can b ra t ionalize d b y aluminum "relaxing" mixed Ti/Zr chain t o a higher d egree than less constricted pure Ti(l V) chains. EXAMPT.K - To a portion of the remaining gel cf Example 2 was added N a A l O , such that Al/ (Ti - Ce, = 0.5. This is emp i rically equivalent to Example 5 of Ser. No. 07/ 3 7 3 , 855 wi t h C e substituting ■ a for 1 ~/t2 *. of. ttnhee T11i. iiirgrnwtt- «g ^ ra=«m „sa-.mp l es were fortifie d with varying additions of caustic to accelera t e growth. W ith the addition of approximately 0 .25 grams of NaOH t an eight gram charge, a mixed phase crystalline product resulted, a su b stantial portion of which resembled ETA S - 10 but with XRD d-spacings upshifted still further beyond the previous examples. ΞTS -**r 0 EXAMPLE - ETAS-10 EXAMPLE ( Al/Tl=.5) Largest d-sDacing ^ 1 1 4 4, A b - 1 1Λ 4 --' 115c-- 14.9 - 15.0 15.45 Strongest 3>60 d -spacing 2 ' 69 ^-63 - 2.64 3./8 A gain , t he effects of both cerium an d a l uminum su b s t itution are apparent in lattice expansion. m t he case cf the strongest peak, an apparent synergy is no t e d as in t he previous example. EXAMPLE 6 Cr(III) is insignificantly larger than Ti(lV) . A preparation similar to Example 5 of Serial No. 373,855 was prepared with CrCl 3 replacing the aluminum source on an equivalent molar basis. An alkaline silicate solution was prepared from the following reactants: 502.4 g n-brand sodium-silicate 105.0 g NaOH 46.4 g KF (anhydrous) A mixed Cr/Ti solution was prepared from the following reactants: 326.4 g Fisher TiCl 3 solution (20% in Acid) 46.4 g CrCl j .6H 2 0 The alkaline silicate and the mixed Cr/Ti solution were thoroughly blended using an overhead stirrer and to the resultant gel was added 4g calcined ETS-10 seed crystals. The seeded chromium-titanium-aluminum-silicate reactant mixture was autoclaved under autogeneous pressure for 24 hours at 200°C. In this example, the Cr/Ti ratio in the reactant mixture was prepared to be 1:2. A highly crystalline product was obtained whose air-equilibrated d-spacings corresponding to those of ETS-10. ETS 10 ETS-10 MIXTURE WITH Cr PRESENT Largest d-spacmg 14.6 - 14.7 14.6 - 14.7 Strongest 3.60 3.60 The . highly crystalline product of this Example was analyze d by standard wet chemical procedures. The elemental composition and that of ETS-10 re presented below: ETS-10 ETS-10-LIKE PHASE WITH OCTAHEDRAL CR(III) SUBSTANTIALLY SUBSTITUTING FOR TI(IV) In ETS-10 the ratio Na+K/2Ti is 1. For the chromium su b stituted material (Na+K) / (2Ti+3Cr) = 0.97. Charge balance is only possible if chromium induces a triply charged site. If chromium(III) was simply the cation in standard ETS-10 ( Na+K=3Cr) /2Ti to equal unity. The suppression of the titanium content in this highly pure phase as well as the equivalence of S i/(Cr+Ti) in comparison to Si/Ti in ETS-10 leave essentially no doubt that direct substitution of octahedral chromium for titanium has occurred and a triply charged octahedral Cr(III) site generated. EXAMPLE 7 In some cases, the substitution of species other than octahedral titanium or tetrahedral silicon or aluminum in ETS-10 and ETAS-10 structures can be hard to pinpoint from a coordination perspective, although some substitution has clearly ccurred. A case in point is niobium wnere tetranedrai "bf l " , cr cc t anedral Nb(V) cr mixtures thereof would appear identical from a cnarσe balance perspective. An alkaline silicate solution was prepared from the following reactants: 124.00 g sodium disilicate solution (SDS) 42.60 g NaOH 10 . 45 g KF (anhydrous) 8 .44 g DI H 2 0 A mixed Nb/Ti/Al solution with a Ti:Nb:Al ratio of 1:1:1 was prepared from the following reactants: 10.65 g TiCl 4 15.20 g NbCl 5 13.56 g A1C1 3 -6H 2 0 46.40 g cone. HC1 0.63 g Di H 2 0 The alkaline silicate and the mixed Nb/Ti/Al solution were thoroughly blended using an overhead stirrer and to the resultant gel was added 4 g calcined ETS-10 seed crystals. The pH of the resultant gel was 11.6 by our standard dilution method Eight grams of the niobium-titanium-aluminum-silicate reactant mixture was mixed with 0.21 g sodium aluminate and 1.79 g DI H,0 and autoclaved under autogeneous pressure for 7 days at 200°C. A highly crystalline product was obtained whose air-equilibrated d-spacings are the following: ETS 10 ETS-10 MIXTURE WITH Nb and Al PRESE Largest d-spacmg 14.6 - 14.7 15.8 Strongest 3.60 3.62 d-sDacinσ gAMPLE 8 Other synthesis techniques may also be employed that result *n larger lattice expansions and presumable higher levels of metal incorporation. One such technique was employed as fol l ows for the incorporation of niobium. An alkaline silicate solution was prepared from the following reactants: 1116.0 g sodium disilicate solution (SDS) 318.8 g NaOH 83.6 g KF (anhydrous) A mixed Nb/Ti/Al solution with a Ti:Nb:Al ratio of 1:1:1 was prepared from the following reactants: 85.2 g TiCl 4 121.4 g NbCl 5 108.5 g A1C1 3 - 6H 2 0 371. 1 g cone. HC1 5. 0 g Di 1^0 The alkaline silicate and the mixed Nb/Ti/Al solution were thoroughly blended using an overhead stirrer and to the resultant gel was added 10.0 g calcined ETS-10 seed crystals. The pH of the resultant gel was 11.6 by our standard dilution method. The niobium-titanium-aluminum-silicate reactant mixtu was placed in a steel tray and dried at 200°C. The dried produ was ground to a fine powder and calcined at 500°C for 2 hours. Four grams of the calcined gel was mixed with 6 grams of Di H.O and autoclaved for 4 days at 200-C. A highly crystalline produ was obtained whose air-equilibrated d-spacings are the followin ETS 10 ETS-10 MIXTURE WITH Nb and A. PRESENT Largest d-spacmg 14.6 - 14." 16.3 Strongest 3.60 3.62 d-spacing The reason for the profound shift cf the lead d-spacmg while the strongest peak is only mildly upshifted is not yet known. EXAMPLE 9 The niobium-titanium-aluminum-silicate gel similar to that of Example 7 was prepared and crystallized for 6 days at 200 β C. The crystalline product was boiled in a 1.0 wt.% NaOH solution for 30 minutes to dissolve amorphous contaminants and subjected to elemental analysis by XRF. Analysis revealed. ETS-10 ETS-10-LIKE PHASE WITH NIOBIUM AND ALUMINUM INCORPORATION In ETS-10 the ratio Na+K/2Ti is -l. For the niobium/aluminum substituted material (Na+K) / (2Ti*--Nb+Al) = 1.04. It is clear that each niobium induces one framework cnarge although it is unclear whether this represents octahedral Nb(V) cr tetrahedral Nb(III) cr a comDination thereof. Irrespective the aDOve, the composition still falls within the formula set forth on Daσe 3 for mole raz o of xiάes. CONCLUSIONS We have demonstrated that octahedral atoms other than titanium may be incorporated into ETS-10-like structures. If the substituted atoms are larger than Ti(IV), a lattice expansion results. The lattice defines the crystalline pores of the sieve and with lattice expansion, pore expansion is intuitively obvious. We have demonstrated that this expansion may act additively with lattice expansions induced by appropriate tetrahedral substitutions. In fact, there is reason to believe that a synergistic effect may exist between certain pairs of octahedral and tetrahedral substitutions in ETS-10-like structures as larger octahedral atoms expand octahedral chains and larger tetrahedral "binding" atoms allow the constrained chains to "relax" to a higher degree. The lattice expansions of Examples 3, 4, 5, 7 and 8 are of significant magnitude. There is little doubt that the pores of these materials are substantially larger than the 8-9 Angstroms of ETS-10. Other molecular sieves can be prepared in a similar manner by replacing all or a portion of the titanium with at least one octahedrally coordinated metal and/or replacing a portion of the silicon and/or aluminum with at least one other tetrahedrally coordinated metal. GLOSSARY OF TERMS DEFINITIONS, PROCEDURES AND REACTANTS EMPLOYED N R Brand Sodium Silicate is a commercial solution obtained from PQ Corporation. Typical lot analysis would include approximately 29 wt.% SiO, and 9 wt.% caustic as Na,0, the balance being water. SDS (sodium di-silicate) is a commercially used sodium silicate solution in Engelhard FCC operations and was obtained internally. Typically lot analysis would include approximately 27 wt.% Si0 2 and 14 wt.% caustic as Na 2 0, the balance being water. Potassium fluoride (KF) was obtained on an anhydrous basis from Pfaltz and Bauer, Inc. Solubility of fluorides in the silicate solutions employed is such that they are only partially dissolved upon mixing, the balance appearing suspended in the silicate mixtures. Caustic (NaOH) was obtained as an essentially anhydrous material from Fisher Scientific. Titanous Chloride solution (TiCl 3 ) was obtained from Fisher Scientific as 20 wt.% TiCl 3 in 20 wt.% HC1, the balance being water yielding a net molality of 1.25 - 1.30 TiCI T . Titanium tetrachloride (TiCl., was obtained as a -99 wt.ϊ liquid from Al a-Ventron. Aluminu trichloride as the hexa-aquated salt (A1C1 3 *6H ? 0) was obtained from Fisher Scientific. The aluminum trichloride is completely dissolved in the titanous chloride solution before the mixed metal solution is blended into alkaline silicate mixtures. Sodium aluminate (NaA10 2 ) was obtained en an essentially anhydrous basis from Pfaltz and Bauer, Inc. Where this m.actant is employed as the aluminum source, sodium aluminate is added as a solid to freshly prepared titanium silicate gels and blended until it apparently dissolves. Sodium Chloride (NaCl) was obtained as an essentially anhydrous salt from Fisher Scientific. Sodium chloride was added to mixtures of low aluminum content to increase the ion content to a level approaching that of the higher aluminum content mixtures. Thoroughly blended refers to gels which have been stirred by overhead stirrers to the point where they visually appear homogeneous. All blending is done at ambient temperature although acid base reactions and base dissolution may temporarily elevate the temperature of the gel. All products of the examples are vacuum filtered, washed with an excess of deionized water (at least 10 cc/g) and dried at 200 B C for at least 30 minutes prior to any further treatment or testing. Air-equilibration is carried out by exposure of dried samples to ambient air for a period of at least one hour. Elemental analyses are presented on a volatile free basis as determined by x-ray fluorescence. The x-ray fluorescence sample preparation technique used involves exposure to elevated temperature - typically H00 β C. Thus, the samples presented as ammonium exchanged are in reality the hydrogen form since the said exposure at elevated temperatures converts the samples to some hydrogen form. Octahedral coordination - A condition occurring when the metal shares 6 oxygen atoms which impart a charge of -12/2 = -6. Ti (IV) , for example, imparts a charge of +4 such that the charge is -2. Tetrahedral coordination - A condition occurring when the metal shares 4 oxygen atoms which impart a charge of -8/2 = 4. Al (III), for example, imparts a charge of ->-3 such that the coordinated aluminum center bears a net charge of -i. On the other hand, a metal with a valence of -4 such as silicon incurred a result m a net cnarπe cf -4 - cf zero. rcre Size - is cerineα as tr.e n elie ciameter cr the l a rgest tiolecuie substantially (5 wt. τ . or greater at 1/2 sa t uration pressure and a temperature of 25°C - 5°C) sorbed from the gas phase by the particular pure molecular sieve. Prior to sorption capacity measure¬ ments said molecular sieve is activated by heating ιo 350°C under vacuum or flow of inert gas for a perio *** of a t least one hour. For example, toluene is known to have a molecular dimension of about 6 angstrom units, triethyla ine about 8 angstrom units and 1,3,5-triiso- propylbenzene about 10 angstrom units. Thus, the novel molecular sieves of this invention are all capable of sorbing toluene according to the above procedure. Elemental analysis - The elemental analysis for Examples 6 and 9 are given on a volatile-free weight basis.

Claims: WHAT IS CLAIMED IS: 1. A crystalline molecular sieve having a pore size of at least 6 Angstrom units and having a composition in terms of mole ratios of oxide as follows: a (1.0 + 0.25)M 2/n O : X0 β : dZO g : 0-100 H 2 0 wherein X is at least one octahedral framework atom; Z is at least one tetrahedral framework atom; M is at least one cation of valence T\ a is 1/2 the valence of X; β is 1/2 the valence of Z; d is 2-100; a is equal to 1/2 the charge provided by the total of X and Z, said molecular sieve characterized by the fact that when X is solely titanium then Z cannot be solely silicon or solely mixtures of silicon and aluminum. 2. A crystalline molecular sieve according to claim 1 wherein d is 2-20. 3. A crystalline molecular sieve according to claim 1 wherein d is 2-10. 4. A crystalline molecular sieve according to claim l wherein X is selected from the group consisting of titanium, aluminum, arsenic, cobalt, chromium, copper, iron, germanium, hafnium, magnesium, manganese, molybdenum, niobium, nickel, antimony, tin, uranium, vanadium, yttrium, zinc, zirconium, the actinides such as uranium, lanthanum and the lanthanides such as cerium and mixtures thereof. 5. A crystalline molecular sieve according to claim 4 wherein Z is selected from the group consisting of silicon, aluminum, arsenic, bismuth, boron, beryllium, cobalt, chromium, copper, iron, gallium, germanium, indium, lead, magnesium, manganese, molybdenum, niobium, nickel, phosphorus, antimony, tin, titanium, vanadium, tungsten, zinc, and mixtures thereof. 6. A crystalline molecular sieve according to claim 1 wherein X comprises titanium and Z comprises silicon. 7. A crystalline molecular sieve according to claim 6 wherein X comprises zirconium. 8 . A crystalline molecular sieve according to claim 6 wherein X comprises chromium. 9 . A crystalline molecular sieve according to claim 6 wherein Z comprises aluminum and cerium. 1 0. The composition of claim 1 wherein M is a mixture of sodium and potassium. 11. The composition of claim 1 wherein M comprises hydrogen. 12. The composition of claim 1 wherein M comprises rare earth. 1 3 . A crystalline molecular sieve according to claim 6 wherein X comprises gallium. 1 4. A crystalline molecualr sieve according to claim 6 wherein X or Z comprise niobium. 15. A crystalline molecular sieve according to claim 1 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 1 6. A crystalline molecular sieve according to claim 2 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 1 7. A crystalline molecular sieve according to claim 2 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 18. A crystalline molecular sieve according t o claim 4 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 19. A crystalline molecular sieve according to claim 5 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 20. A crystalline molecular sieve according t o claim 6 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 21. A crystalline molecular sieve according to claim 7 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 22. A crystalline molecular sieve according to claim 8 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 23. A crystalline molecular sieve according t o claim 9 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 24. A crystalline molecular sieve according to claim 10 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 25. A crystalline molecular sieve according t o claim 11 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 26. A crystalline molecular sieve according t o claim 1 2 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the SDecification. 27. A crystalline molecular sieve according to claim 13 characterized by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 28. A crystalline molecular sieve according to claim 14 characterised by having an X-ray diffraction pattern as set forth in Table 2 of the specification. 29. A process for conversion of an organic compound which comprises contacting the same at conversion conditions with the composition of claim 1. 30. A process for catalytic cracking of hydrocarbon which comprises contacting the same with the composition of claim 1 at elevated temperatures. 31. A process for reforming a naphtha which comprises contacting the same in the presence of added hydrogen and a hydrogenation/dehydrogenation component with the composition of claim 11. 32. A process for reforming a naphtha which comprises contacting the same in the presence of added hydrogen and a hydrogenation/dehydrogenation component with the composition of claim 12. 33. A process for the removal of divalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 1. 34. A process for the removal of polyvalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 2. 35. A process for the removal cf polyvalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 2. 36. A process for the removal of polyvalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 4. 37. The process of claim 34 wherein the polyvalent ion is Pb *2 . 38. The process of claim 35 wherein the polyvalent ion is Pb *2 . 39. The process of claim 36 wherein the polyvalent ion is Pb *2 . 40. A process for conversion of an organic compound which comprises contacting the same at conversion conditions with the composition of claim 15. 41. A process for catalytic cracking of hydrocarbon which comprises contacting the same with the composition of claim 15 at elevated temperatures. 42. A process for reforming a naphtha which comprises contacting the same in the presence of added hydrogen and a hydrogenation/dehydrogenation component with the composition of claim 25. 43. A process for reforming a naphtha which comprises contacting the same in the presence of added hydrogen and a hydrogenation/dehydrogenation component with the composition of claim 26. 44. A process for the removal of divalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 15. 45. A process for the removal of polyvalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 16. 46. A process for the removal of polyvalent ions from a solution containing the same which comprises contacting said solution with the composition of claim 17. 47. A process for the removal of polyvalent ions from a solution containing the seune which comprises contacting said solution with the composition of claim 18. 48. The process of claim 45 wherein the polyvalent ion is Pb *2 . 49. The process of claim 46 wherein the polyvalent ion is Pb* 2 . 50. The process of claim 47 wherein the polyvalent ion ss Pb* 2 .

Inventors: KUZNICKI STEVEN M, THRUSH KATHLEEN A, KUZNICKI, STEVEN, M., THRUSH, KATHLEEN, A.
Applicants: ENGELHARD CORP, ENGELHARD CORPORATION
Application year: 1991
Main classification: C02F1
IPC codes: B01J29, B01J39, C01B25, C01B33, C01B39, C02F1, C10G11, C10G35, C10G47