Aluminophosphates containing cobalt and/or silicon and process for preparing the same

Abstract: An aluminophosphate containing cobalt and/or silicon, having in the as-synthesized anhydrous form the structure type 21 and having in the calcined form the structure type 25 and having in the anhydrous form the chemical composition mR(Co c Si s Al q P x )O₂, wherein R represents an organic template and wherein m = 0.03 - 0.3, c = 0 - 0.4, s = 0 - 0.4, q = 0.3 - 0.6, and x = 0.3 - 0.6 and wherein c + s + q + x = 1 and c + s > 0, is prepared at a temperature below 150⁰C using a source of pyrrolidine. Its use as catalyst, catalyst carrier or molecular sieve.

Description: The present invention relates to aluminophosphates containing silicon and optionally cobalt in their crystalline structure, hereinafter referred to as (cobalt) silicoaluminophosphates. The present invention further relates to a process for preparing the (cobalt) silicoaluminophosphates and to their use as catalyst, catalyst carrier or molecular sieve. Crystalline aluminophosphates and related compounds 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 (US 4,310,440) a new class of aluminophosphates has been described having a crystalline microporous structure comparable with zeolitic aluminosilicates. A disadvantage of these crystalline aluminophosphates is that the aluminophosphate structures are substantially neutral, that is, no charge-balancing cations are present in the structure and the structure lacks acid and/or basic sites. Hence, the aluminophosphates have limited applicability as catalyst. In order to create acid sites in the crystalline aluminophosphate structure, related compounds have been synthesised in which Al and/or P is partly replaced by other elements. United States patent specification No. 4,440,871 describes siliconaluminophosphates (SAPO), substantially having the same crystalline structures as described in US 4,310,440, but containing silicon next to Al and P in the crystalline structure. United States patent specification No. 4,567,029 describes metal aluminophosphates (MeAPO), wherein the metal is chosen from the group of magnesium, cobalt (CoAPO = cobalt aluminophosphates), manganese and zinc. United States patent specification No. 4,793,984 describes 'ELAPSO' compositions, that is 'element silicoaluminophosphates', wherein one of the elements described is cobalt (CoAPSO = cobalt silicoaluminophosphates). In the ten years following the publication of US 4,310,440, most aluminophosphate structures described in the said publication have been synthesised in the SAPO, CoAPO or CoAPSO form. However, sofar attempts have failed to prepare (cobalt) silicoaluminophospates analogues of a potentially very interesting aluminophosphate, described in US 4,310,440, having in the as-synthesised anhydrous form the structure type 21 and in the calcined form the structure type 25. Cheetham et al. (Acta Cryst. (1991) C47, 1361-1364) describe the synthesis of a cobalt-doped aluminophosphate of structure type 21 (CoAPO-21). The synthesis described herein was carried out under static conditions at 468 K over 4 days, using ethylene diamine as organic template. This publication is silent on how to prepare other element-substituted aluminophosphates of structure types 21 and 25, like silicon-substituted aluminophosphates of structure types 21 and 25. British patent application publication No. 2 155 916 describes iron-modified aluminophosphates of structure types 21 and 25 and vanadium-modified aluminophosphates of structure types 21 and 25. The reaction conditions applied were similar to the reaction conditions described in US 4,310,440 for the preparation of the aluminophosphates of structure types 21 and 25. A disadvantage associated with iron or vanadium-modified aluminophosphates is that the stable valencies (in air) of iron and vanadium are +3 and +5 respectively. Therefore, even when lower valencies of iron or vanadium are used to substitute for Al³⁺ and V⁵⁺ in the aluminophosphate crystal lattice, such iron or vanadium aluminophosphate still will lack acidic sites. Stable valencies (in air) of cobalt and silicon are, however, +2 and +4 respectively. Thus it would be highly desirable to be able to prepare (cobalt) silicoaluminophosphates of structure types 21 and 25. However, it has been found that silicon and optionally cobalt modified aluminophosphates of structure types 21 and 25 cannot be prepared by reaction conditions described and exemplified in US 4,310,440. Instead, by applying these reaction conditions, a silicon and optionally cobalt modified aluminophosphate of structure type 20 is produced. Surprisingly, it has now been found that novel crystalline (cobalt) silicoaluminophosphates of the structure types 21 and 25 can be provided. The present invention thus relates to a (cobalt) silicoaluminophosphate, having in the as-synthesized anhydrous form an X-ray diffraction pattern containing at least the lines given in Table A, d (A) Intensity (I/I₀) 8.8 ± 0.2 m/s 5.58 ± 0.2 w/m 3.88 ± 0.1 vs 3.53 ± 0.1 m/s 2.72 ± 0.05 m (v)w = (very) weak, m = moderate, (v)s = (very) strong d (A) = d hkl spacing in Angstrom (10⁻¹⁰ m) Intensity (I/I₀) = intensity of peaks in X-ray diffraction pattern relative to the strongest peak. and having the chemical composition mR(Co c Si s Al q P x )O₂, wherein R represents an organic template and wherein m = 0.03 - 0.3 c = 0 - 0.4 0 < s ≦ 0.4 q = 0.3 - 0.6 x = 0.3 - 0.6 and wherein c + s + q + x = 1 . As s(+c) > 0 , it will be appreciated that the as-synthesised anhydrous form also contains an appropriate charge-balancing cation, such as a proton or a protonated form of the organic template R. It should be understood that the as-synthesised anhydrous form as referred to in this specification may also contain chemically bound water or hydroxyl groups. Preferably, the (cobalt) silicoaluminophosphate has, in the as-synthesised anhydrous from, a chemical composition mR(Co c Si s Al q P x )O₂, wherein m = 0.05 - 0.2, c = 0 - 0.2, 0 < s ≦ 0.4, q = 0.4 - 0.6, and x = 0.4 - 0.6. In particular, the present invention relates to a (cobalt) silicoaluminophosphate having in the as-synthesized anhydrous form an X-ray diffraction pattern containing at least the lines given in Table I. d (A) Intensity (I/I₀) 8.8 ± 0.2 m/s 6.0 ± 0.2 w/m 5.58 ± 0.2 w/m 4.16 ± 0.1 w/m 3.88 ± 0.1 vs 3.76 ± 0.1 w/m 3.53 ± 0.1 m/s 2.72 ± 0.05 m The organic template R is typically chosen from the group of amines, imines, amides, imides, diamines, piperazines, pyrrolidines, pyrroles, pyrrolidones and pyrrolines. Preferably, the organic template R, chosen from said group, contains not more than a total of 12 carbon and nitrogen atoms. More preferably, R is chosen from the group comprising trimethylamine, pyrrolidine, 1,4-dimethyl piperazine, 3-(di-n-butylamino)-propylamine, N,N,N',N'-tetramethyl-1,3-propanediamine, N,N-dimethyl-ethanolamine, n-propylamine, N,N,N',N'-tetramethyl-ethylenediamine, ethylenediamine and N-methyl-ethanolamine. In a most preferred embodiment of the invention, pyrrolidine is used. The present invention further relates to a (cobalt) silicoaluminophosphate, having in the calcined form an X-ray diffraction pattern containing at least the lines given in Table B, d (A) Intensity (I/I₀) 9.4 ± 0.2 w/s 5.89 ± 0.2 m/s 4.68 ± 0.2 m/vs 4.18 ± 0.1 s/vs 3.51 ± 0.1 w/m 2.88 ± 0.05 m and having the chemical composition (Co c Si s Al q P x )O₂, wherein c = 0 - 0.4, 0 < s ≦ 0.4, q = 0.3 - 0.6, x = 0.3 - 0.6 and wherein c + s + q + x = 1 . As s(+c) > 0 , it will be appreciated that the calcined form also contains an appropriate charge-balancing cation, such as a proton. In particular, the present invention further relates to a (cobalt) silicoaluminophosphate having in the calcined form an X-ray diffraction pattern containing at least the lines given in Table II. d (A) Intensity (I/I₀) 9.4 ± 0.2 w/s 5.89 ± 0.2 m/s 4.68 ± 0.2 m/vs 4.18 ± 0.1 s/vs 3.51 ± 0.1 w/m 3.41 ± 0.05 w 3.12 ± 0.05 w 2.88 ± 0.05 m Preferably, the (cobalt) silicoaluminophosphate has, in the calcined form, the chemical composition (Co c Si s Al q P x )O₂, wherein c = 0 - 0.2, 0 < s ≦ 0.4, q = 0.4 - 0.6, and x = 0.4 - 0.6. The invention further relates to a process for preparing a (cobalt) silicoaluminophosphate in the as-synthesised anhydrous form, from a starting mixture comprising a source of phosphorus, a source of aluminium, a source of pyrrolidine and a source of silicon and/or a source of cobalt, keeping the starting mixture at a temperature below 150 °C and a synthesis time of at most 90 hours, separating the (cobalt) silicoaluminophosphate product from the starting mixture and drying. Preferably, the starting mixture is kept at a temperature of from 100 °C to 145 °C, more preferably of from 120 °C to 145 °C. The as-synthesised products of the present invention are preferably synthesised according to the process of the present invention by keeping the starting mixture within the selected temperature range for 10 to 90 hours, more preferably for 20 to 80 hours. Typically, the various components of the starting mixture are initially present in the following molar ratios, wherein R stands for pyrrolidine: R:Al 2 O 3 = 0.1 - 3 P 2 O 5 :Al 2 O 3 = 0.5 - 1.5 0 < SiO 2 :Al 2 O 3 ≦ 1 CoO:Al 2 O 3 = 0 - 1 H 2 O:Al 2 O 3 = 25 - 500. Preferably, the various components of the starting mixture are initially present in the following molar ratios: R:Al 2 O 3 = 0.1 - 2 P 2 O 5 :Al 2 O 3 = 0.8 - 1.5 0 < SiO 2 :Al 2 O 3 ≦ 0.8 CoO:Al 2 O 3 = 0 - 0.6 H 2 O:Al 2 O 3 = 30 - 350. It has been found that the synthesis of the products according to the present invention is facilitated and products of constant quality and composition are obtained when the starting mixture is kept in motion, continuously or intermittently, for example by stirring. The synthesis of the products according to the present invention can be further facilitated by adding seeds to the starting mixture. In principle, any source of phosphorus can be used in the starting mixture. Examples of suitable phosphorus sources comprise phosphorus acids and derivates thereof such as esters, phosphorus oxides, phosphates and phosphites and mixtures of various phosphorus sources. Particular good results have been obtained with phosphoric acid as phosphorus source. Examples of suitable aluminium sources comprise aluminium salts, aluminium (hydr)oxides, such as gamma and theta alumina, gibbsite, boehmite, pseudo-boehmite and aluminium alkoxides, such as aluminium triisopropoxide and mixtures of various aluminium sources. Typically, boehmite or pseudo-boehmite is used as an alumina source. Examples of suitable sources of silicon and optionally cobalt comprise the appropriate chlorides, iodides, bromides, nitrates, sulphates, oxides, hydroxides, alkoxides and acetates, preferably acetates, alkoxides, hydroxides and/or oxides. For preparing the starting mixture, any source or promoter form based on a pyrrolidine can be used as organic template, such as a quaternary ammonium compound of the pyrrolidine, which source or promoter should be such that it can be converted into the pyrrolidine. It is to be understood that the products of the present invention can be prepared by a variety of organic templates, and not necessarily only by a process using pyrrolidine. The organic template R is typically chosen from the group of amines, imines, amides, imides, diamines, piperazines, pyrrolidines, pyrroles, pyrrolidones and pyrrolines. Preferably, the organic template R, chosen from said group, contains not more than a total of 12 carbon and nitrogen atoms. More preferably, R is chosen from the group comprising trimethylamine, pyrrolidine, 1,4-dimethyl piperazine, 3-(di-n-butylamino)-propylamine, N,N,N',N'-tetramethyl1,3-propanediamine, N,N-dimethyl-ethanolamine, n-propylamine, N,N,N',N'-tetramethyl-ethylenediamine, ethylenediamine and N-methyl-ethanolamine. However, it has been found that the reaction conditions necessary for preparing the products of the present invention, may vary considerably, depending inter alia on the template that is used. For example, when N,N,N',N'-tetramethyl-ethylenediamine and ethylenediamine are used in a process for preparing the products of the present invention, typical reaction conditions include a reaction temperature in the range of from 140 to 190 °C and a synthesis time of from 20 to 100 hours. The present invention further relates to a process for preparing a (cobalt) silicoaluminophosphate in the calcined form, as described hereinbefore, which comprises preparing an as-synthesised (cobalt) silicoaluminophosphate by a process as described hereinbefore, followed by calcining the as-synthesised (cobalt) (silicon)aluminophosphate at a temperature in the range of from 300 °C to 800 ° C, in the presence of an oxygen-containing atmosphere. Preferably, the calcination is carried out at a temperature in the range of from 450 °C to 700 °C. The calcined (cobalt) silicoaluminophosphate according to the present invention may be used as molecular sieve, catalyst or catalyst carrier in the operation of a separation process or a catalytic process. If desired, one or more (catalytically) active species, in particular, protons and/or precursors thereof and/or one or metal compound(s) of Group I, II, III and/or the Transition Metals and/or Rare Earth Metals and/or precursors thereof, can be introduced into the (cobalt) silicoaluminophosphate according to the present invention. The (catalytically) active metals can be introduced into the (cobalt) silicoaluminophosphate by well-known techniques such as impregnation and ion-exchange. The invention will now be illustrated by means of the following Examples. Example I A crystalline siliconaluminophosphate in the as-synthesised anhydrous form according to the present invention and referred to as SAPO-21, was prepared by combining two slurries A and B, wherein A is composed of a mixture of 27.9 grammes of pseudoboehmite (Catapal B, 73.2 %), 46.2 grammes of ortho-phosphoric acid (85 %) and 113.1 grammes of water, and B is composed of 14.1 grammes of pyrrolidine (R) and 9.36 grammes of silica sol (Ludox, 38.5%), giving a starting mixture composition on a molar basis of 1 Al₂O₃ : 0.3 SiO₂ : 1 P₂O₅ : 1 R : 40 H₂O. After homogenation, the starting mixture was transferred to a Medimex (tradename) autoclave where it was kept under stirring at 145 °C and autogeneous pressure for a period of 24 hours. After synthesis, the crystalline compound produced was separated from the mother liquor by centrifugation, water washed and dried. The crystalline compound obtained, had in the anhydrous form the chemical composition 0.16 R (Si 0.01 Al 0.51 P 0.48 )O₂ and an X-ray diffraction pattern containing the lines given in Table III. d (Å) Intensity (I/I₀) 8.805 40 7.845 5 7.491 4 7.211 21 6.207 26 6.027 24 5.578 20 4.334 17 4.152 20 3.925 61 3.918 63 3.882 100 3.754 24 3.532 86 2.716 42 Examples II and III The experiment described in Example I was repeated but applying a synthesis temperature of 150 °C (not according to the invention) and times as indicated in Table IV. Example Synthesis Time [h] Synthesis Temp. [°C] Product XRD II 144 150 SAPO-20 III 24 150 SAPO-20 The comparative experiments described in Examples II and III yielded SAPO-20 instead of SAPO-21 according to the invention. It can be seen from Example I that at a synthesis temperature and time lying within the scope of the present invention, a product (SAPO-21) in accordance with the present invention is obtained. However, as shown in Examples II and III, SAPO-20 is obtained at a synthesis temperature just outside the range as claimed in the process of the present invention. Example IV The experiment described in Example I was repeated but using a starting mixture composition on a molar basis of 0.6 SiO₂ : 1 Al₂O₃ : 1 P₂O₅ : 1 R : 40 H₂O. After working up (synthesis, separation, washing, drying) SAPO-21 was obtained with, in the anhydrous form, the chemical composition 0.15 R (Si 0.1 Al 0.48 P 0.42 )O₂ and having essentially the same lines in its X-ray diffraction pattern as shown in Table III. Example V The experiment described in Example I was repeated but using a starting mixture composition on a molar basis of 0.3 SiO₂ : 0.8 Al₂O₃ : 1 P₂O₅ : 1 R : 40 H₂O. After working up (synthesis, separation, washing, drying) SAPO-21 was obtained with, in the anhydrous form, the chemical composition 0.15 R (Si 0.09 Al 0.45 P 0.46 )O₂ and having essentially the same lines in its X-ray diffraction pattern as shown in Table III. Examples VI and VII The SAPO-21 obtained in Example I was calcined in air at 600 °C for 3 hours. After calcination of the SAPO-21 a silico aluminophosphate was obtained, in the calcined form according to the present invention and referred to as SAPO-25. The SAPO-25 had the same chemical composition as the product obtained in Example I, but with no organic template R present, and an X-ray diffraction pattern containing the lines given in Table V. d (Å) Intensity (I/I₀) 9.371 28 7.574 4 5.891 56 4.684 45 4.180 100 3.818 7 3.780 6 3.636 9 3.505 40 3.407 15 3.117 12 2.885 29 2.686 8

Claims: (Cobalt) silicoaluminophosphate, having in the as-synthesized anhydrous form an X-ray diffraction pattern containing at least the lines given in Table A, d (A) Intensity (I/I₀) 8.8 ± 0.2 m/s 5.58 ± 0.2 w/m 3.88 ± 0.1 vs 3.53 ± 0.1 m/s 2.72 ± 0.05 m and having the chemical composition mR(Co c Si s Al q P x )O₂, wherein R represents an organic template and wherein m = 0.03 - 0.3 c = 0 - 0.4 0 < s ≦ 0.4 q = 0.3 - 0.6 x = 0.3 - 0.6 and wherein c + s + q + x = 1 and c + s > 0 . (Cobalt) silicoaluminophosphate as claimed in claim 1, wherein the chemical composition mR(Co c Si s Al q P x )O₂, m = 0.05 - 0.2, c = 0 - 0.2, 0 < s ≦ 0.4, q = 0.4 - 0.6, and x = 0.4 - 0.6. (Cobalt) silicoaluminophosphate as claimed in claim 1 or 2, having in the as-synthesized anhydrous form an X-ray diffraction pattern containing at least the lines given in Table I. d (A) Intensity (I/I₀) 8.8 ± 0.2 m/s 6.0 ± 0.2 w/m 5.58 ± 0.2 w/m 4.16 ± 0.1 w/m 3.88 ± 0.1 vs 3.76 ± 0.1 w/m 3.53 ± 0.1 m/s 2.72 ± 0.05 m (Cobalt) silicoaluminophosphate as claimed in any one of claims 1-3, wherein R is an organic template chosen from the group of amines, imines, amides, imides, diamines, piperazines, pyrrolidines, pyrroles, pyrrolidones and pyrrolines, preferably, the organic template R, chosen from said group, contains not more than a total of 12 carbon and nitrogen atoms, more preferably, R is an organic template chosen from the group comprising trimethylamine, pyrrolidine, 1,4-dimethyl piperazine, 3-(di-n-butylamino)propylamine, N,N,N',N'-tetramethyl- 1,3-propanediamine, N,N-dimethyl-ethanolamine, n-propylamine, N,N,N',N'-tetramethyl-ethylenediamine, ethylenediamine and N-methyl-ethanolamine, even more preferably, pyrrolidine. (Cobalt) silicoaluminophosphate, having in the calcined form an X-ray diffraction pattern containing at least the lines given in Table B, d (A) Intensity (I/I₀) 9.4 ± 0.2 w/s 5.89 ± 0.2 m/s 4.68 ± 0.2 m/vs 4.18 ± 0.1 s/vs 3.51 ± 0.1 w/m 2.88 ± 0.05 m and having the chemical composition (Co c Si s Al q P x )O₂, wherein c = 0 - 0.4 0 < s ≦ 0.4 q = 0.3 - 0.6 x = 0.3 - 0.6 and wherein c + s + q + x = 1 . (Cobalt) silicoaluminophosphate as claimed in claim 5, wherein the chemical composition (Co c Si s Al q P x )O₂, c = 0 - 0.2, 0 < s ≦ 0.4, q = 0.4 - 0.6, and x = 0.4 - 0.6. (Cobalt)silicoaluminophosphate as claimed in claim 5 or 6, having in the calcined form an X-ray diffraction pattern containing at least the lines given in Table II. d (A) Intensity (I/I₀) 9.4 ± 0.2 w/s 5.89 ± 0.2 m/s 4.68 ± 0.2 m/vs 4.18 ± 0.1 s/vs 3.51 ± 0.1 w/m 3.41 ± 0.05 w 3.12 ± 0.05 w 2.88 ± 0.05 m (Cobalt) silicoaluminophosphate as claimed in any one of claims 5-7, comprising one or more (catalytically) active species, in particular, protons and/or precursors thereof and/or one or metal compound(s) of Group I, II, III and/or the Transition Metals and/or Rare Earth Metals and/or precursors thereof. Process for preparing a (cobalt) silicoaluminophosphate as claimed in claim 1, from a starting mixture comprising a source of phosphorus, a source of aluminium, a source of pyrrolidine and a source of silicon and optionally a source of cobalt, keeping the starting mixture at a temperature below 150 °C, preferably at a temperature of from 100 °C to 145 °C and a synthesis time of at most 90 hours, preferably at a synthesis time of from 10 to 90 hours, separating the (cobalt)silicoaluminophosphate product from the starting mixture and drying. Process as claimed in claim 9, wherein the various components of the starting mixture are initially present in the following molar ratios: R:Al 2 O 3 = 0.1 - 3 P 2 O 5 :Al 2 O 3 = 0.5 - 1.5 0 < SiO 2 :Al 2 O 3 ≦ 1 CoO:Al 2 O 3 = 0 - 1 H 2 O:Al 2 O 3 = 25 - 500. Process as claimed in claim 10, wherein the various components of the starting mixture are initially present in the following molar ratios: R:Al 2 O 3 = 0.1 - 2 P 2 O 5 :Al 2 O = 0.8 - 1.5 0 < SiO 2 :Al 2 O 3 ≦ 0.8 CoO:Al 2 O 3 =0 - 0.6 H 2 O:Al 2 O 3 = 30 - 350. Process as claimed in any one of claims 9-11, wherein phosphoric acid is used as phosphorus source. Process for preparing a (cobalt) silicoaluminophosphate as claimed in claim 5, which comprises preparing an as-synthesised (cobalt) silicoaluminophosphate by a process as claimed in any one of claims 9-12, followed by calcining the as-synthesised (cobalt) silicoaluminophosphate at a temperature in the range of from 300 °C to 800 °C, in the presence of an oxygen-containing atmosphere, preferably at a temperature in the range of from 450 °C to 700 °C. Use of a (cobalt) silicoaluminophosphate as claimed in any one of claims 5-8, as a catalyst or catalyst carrier or as a molecular sieve.

Inventors: HOOGERVORST WILLEMINA GERARDA, KRAUSHAAR-CZARNETZKI BETTINA, HOOGERVORST, WILLEMINA GERARDA MARIA, KRAUSHAAR-CZARNETZKI, BETTINA
Applicants: SHELL INT RESEARCH, SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1993
Main classification: C01B25
IPC codes: C01B37, B01J29