Abstract:
Agglomerated crystalline zeolites are deagglomerated by treating the zeolite during its formation or shortly thereafter. The particles are contacted with additional basic solution when crystallization is near completion to effect deagglomeration.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of copending application Ser. No. 678,947 filed Dec. 6, 1984 now abandoned, which is a division of application Ser. No. 517,598 filed July 27, 1983, now U.S. Pat. No. 4,497,786 which is incorporated herein by reference. 
    
    
     NATURE OF INVENTION 
     This invention relates to the preparation of porous siliceous crystalline materials. More specifically, it relates to a process for preparing crystalline zeolite compositions wherein the degree of agglomeration of the crystals and the dimensions of agglomerates present are substantially reduced. 
     BACKGROUND OF THE INVENTION 
     Highly siliceous porous crystalline materials (zeolite), often loosely termed molecular sieves, are well known in the art. They are characterized by their highly ordered crystalline structures and have pores of nearly uniform dimensions. The highly ordered dispersion of alumina (if present) and silica tetrahedra present in the crystals make for a large number of active sites and the uniform pore openings of the zeolites allow for easy ingress of certain molecular structures. Processes for producing zeolites synthetically are now well known in the art. For example, U.S. Pat. Nos. 3,702,886 and 3,941,871 (RE 29,948) disclose a process for synthesizing ZSM-5 zeolite in which the zeolite material is crystallized from a reaction mixture of selected reactants. U.S. Pat. No. 3,709,979 discloses a related process for preparing ZSM-11 zeolite by crystallization from a reaction mixture. The preparation of ZSM-12 zeolite by crystallization from a reaction mixture is disclosed in U.S. Pat. No. 3,832,449. The preparation of ZSM-23 is disclosed in U.S. Pat. No. 4,076,842. U.S. Pat. No. 4,016,245 discloses the preparation of ZSM-35 zeolite and U.S. Pat. No. 4,046,859 the preparation of ZSM-38. The preparation of ZSM-48 zeolite is disclosed in U.S. Pat. Nos. 4,397,827 and 4,375,573. 
     The entire contents of U.S. Pat. Nos. 3,702,886; 3,941,871 (RE 29,948); 3,709,979; 3,832,449; 4,076,842; 4,016,245; 4,046,859; 4,397,827 and 4,375,573 are incorporated herein by reference. 
     These disclosures in common describe the preparation of zeolites by crystallizing them from a reaction mixture containing sources of an alkali metal oxide, an organic compound, an oxide of aluminum (if added aluminum is desired), an oxide of silicon, and water. 
     Often in preparing zeolites for use in commercial operations, such as fixed or fluid bed reactors or adsorption systems, the finely divided zeolites can be mixed with a binder material such as clay, alumina, silica-alumina, etc. and formed into porous pellets or fluid particles. In order to achieve maximum dispersion and effectiveness of the zeolite, it is desirable that the zeolite crystallites be as fine as possible and more importantly that they not be agglomerated into relatively larger size particles. Nonagglomerated or deagglomerated crystals are more easily dispersed in the compositing medium and a greater amount of crystallite surface is exposed for catalytic activity if deagglomerated crystals are used. 
     A primary object of this invention therefore is to prepare porous siliceous crystalline zeolite materials characterized by a minimum amount of agglomeration of the individual crystallites. 
     SUMMARY OF THE INVENTION 
     Briefly stated, this invention constitutes a process for preparing porous siliceous crystalline zeolites wherein sources of an alkali metal oxide, an oxide of aluminum (if desired), an oxide of silicon, an organic cation and water are combined, a siliceous crystalline material is crystalized therefrom, and there if added to the crystallizing mixture, or subsequently thereafter, a basic solution such as alkali metal hydroxide, ammonium hydroxide, or a basic organic compound sufficient to maintain the pH between 9.0 and 13.5, and preferably between 11.5 and 13. The crystalline zeolite is then separated from the crystallizing mixture. Alternatively, the crystalline siliceous material formed from the reaction mixture is removed, and subsequently contacted with the basic solution of alkali metal hydroxide, ammonium hydroxide or an organic base to effect deagglomeration of the crystallite particles. 
     DESCRIPTION OF THE INVENTION 
     The porous siliceous crystalline materials are synthesized by preparing a solution containing sources of an alkali metal oxide, preferably sodium oxide, sources of an organic cation, an oxide of aluminum (if the incorporation of aluminum into the zeolite is desired), an oxide of silicon and water. The exact temperature and conditions and ratio of reactants for the particularly desired zeolite is well known to those skilled in the art and is not of itself regarded as a novel part of the process of this invention. 
     In preparing certain zeolites, however, particularly those of the ZSM-5 type, it is not always desirable to include a sourced of an oxide of aluminum. The preparation of these high silica zeolites is described, for example, in U.S. Pat. No. 3,941,871, (RE 29,948, Mar. 27, 1979), which is incorporated herein by reference. 
     At a point where crystallization is complete, a basic solution (preferably sodium hydroxide) is added and/or the temperature of the reaction mass is increased by between 50° and 100° F. While maintaining the reaction mixture at this elevated pH or this elevated temperature which ordinarily will be greater than 150° F., the crystalline zeolite is separated from the mother liquor for example by filtration. The crystalline zeolite recovered is then further treated by washing with water, ion exchange, drying, calcining, etc. 
     Alternatively, the crystallization procedure is allowed to go to completion and the crystalline zeolite is recovered as by filtering. The recovered zeolite crystalline mass is then reslurried and treated with the basic solution at an elevated temperature up to about 100° C., more preferably from room temperature to 65° C. 
     For example, a crystalline zeolite such as ZSM-5 can be suitably synthesized by preparing a solution containing (R 4  N) 2  O, sodium oxide, an oxide of a metal other than a metal of Group IIIA and water and having a composition in terms of mole ratios of oxides falling within the following ranges: 
     
                       TABLE II______________________________________           Broad   Preferred______________________________________OH.sup.- /SiO.sub.2             .01-5     .05-1.0R.sub.4 N.sup.+ /(R.sub.4 N.sup.+  + Na.sup.+)             .05-1.0   .1-.8H.sub.2 O/OH.sup.-              50-1000   50-500SiO.sub.2 /M.sub.2 /.sub.n O             ≧1 ≧3______________________________________ 
    
     wherein R is an alkyl radical, preferably between 2 and 5 carbon atoms and M is a total metal. Thereafter, the mixture is maintained until crystals of the zeolite are formed. Preferably, crystallization is performed under pressure in an autoclave or static bomb reactor. The temperature ranges from 100° C. to 200° C. generally, but at lower temperatures, e.g. about 100° C., crystallization time is longer. Typical reaction conditions consist of heating the foregoing reaction mixture to a temperature from about 100° C. to 175° C. for a period of time of from about 6 hours to 60 days. The more preferred temperature range is from about 100° C. to 175° C. with the amount of time at a temperature in such range being from about 12 hours to 30 days. 
     The treatment of the amorphous mixture is carried out until crystals form. 
     The desired ZSM-5 can be prepared utilizing materials which supply the appropriate oxide. Such compositions include sodium silicate, colloidal silica, silica hydrosol, silica gel, silicic acid, sodium hydroxide, compounds of the desired metal, other than a metal of Group IIIA and tetraalkylammonium compounds, e.g. tetrapropylammonium bromide. In addition to tetrapropylammonium compounds, it is contemplated that tetramethyl, tetraethyl or tetrabutyl ammonium compounds may similarly be employed. It will be understood that each oxide component utilized in the reaction mixture for preparing the crystalline zeolite of this invention can be supplied by one or more initial reactants and they can be mixed together in any order. For example, sodium oxide can be supplied by an aqueous solution of sodium hydroxide or by an aqueous solution of sodium silicate; tetrapropylammonium can be supplied in the form of its hydroxide as can the other tetralkylammonium radicals noted hereinabove. The reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time of the crystalline composition will vary with the nature of the reaction mixture employed. 
     The crystalline materials thus described are substantially free of alumina, but may contain very minor amounts of such oxide attributable primarily to the presence of aluminum impurities in the reactants and/or equipment employed. Thus, the molar ratio of alumina to silica will be in the range of 0 to less than 0.005 Al 2  O 3  to more than 1 mole of SiO 2 . Generally, the latter may range from 1SiO 2  up to 500 or more. 
     In a similar manner, other crystalline zeolite materials are prepared particularly those having a constraint index of between 1 and 12 and a silica to alumina ratio greater than 12, more particularly the zeolites ZSM-11, ZSM-12, ZSM-21, ZSM-23, ZSM-35, and ZSM-38. 
     Although it is preferred to use aqueous solutions of sodium hydroxide as the washing medium or to add to the crystallizing reaction mixture, the hydroxides of other alkali metals such as potassium, lithium or mixtures thereof can be used. Ammonium hydroxide as well as aqueous solutions of basic organic compounds such as amines can also be used. 
    
    
     In the following examples, Examples 1-10 cover the synthesis of and caustic (NaOH) treatment of ZSM-5 zeolite. In these examples the effect of the caustic treatment on the chemical composition and degree of crystal agglomeration is examined. Examples 11 and 12 compare the relative stability of ZSM-5 zeolite and amorphous silica gel as a function of caustic concentration, time and temperature. Examples 13-16 show treatment with basic materials other than sodium hydroxide. Examples 17 and 18 deal with the use of physical methods for reducing ZSM-5 agglomerate while Examples 19 and 20 examine combined chemical and physical treatments. 
     EXAMPLE 1 
     Synthesis of ZSM-5 Zeolite 
     A sodium silicate solution was prepared by mixing 16 parts water and 27.7 parts sodium silicate (28.7 wt. % SiO 2 , 8.9 wt. % Na 2  O, 62.4 wt. % H 2  O) followed by addition of 0.08 parts Daxad 27 (W. R. Grace Chemical Division). The solution was cooled to approximately 15° C. 
     An acid solution was prepared by adding 1 part aluminum sulfate (17.2 wt. % Al 2  O 3 ) to 16.4 parts water followed by 2.4 parts sulfuric acid (93 wt. % H 2  SO 4 ) and 1.2 parts NaCl. 
     These solutions were mixed in an agitated vessel while 3.9 parts of NaCl were added. The molar ratios expressed as oxides were as follows in the resultant mixture: 
     
         SiO.sub.2 /Al.sub.2 O.sub.3 =78.5 
    
     
         Na.sub.2 O/Al.sub.2 O.sub.3 =49.5 
    
     The gel was then heated to about 93° C., agitation was reduced and an organic solution containing 0.8 parts n-propyl bromide and 1.5 parts methyl ethyl ketone was added above the gel. After these organics were added, 2.3 parts of n-propyl amine was added to the organic phase above the gel. This mixture was held at about 93° C. for 6 hours, then severe agitation was resumed. Crystallization was conducted at 93°-99° C. until the gel was 80% crystallized, at which time temperature was increased to 150°-160° C. Unreacted organics were removed by flashing and the remaining contents cooled. The zeolite slurry product was diluted with 4-5 parts water per part slurry and 0.0002 parts of flocculent (Rohm and Haas, Primafloc C-7) per part slurry, and allowed to settle. Supernatant liquid was drawn off. The settled solids were reslurried to the original volume of the preceeding step with water and 0.00005 parts of flocculent per part slurry. After settling, the aqueous phase was decanted. This was repeated until the sodium level of the zeolite was less than 0.10 wt. %. Then 0.1 parts ammonium nitrate per part slurry were added to the settled solids and the water from the previous decantation. The mixture was reslurried and the solids were allowed to settle. The washed zeolite solids were filtered, identified as ZSM-5 by X-ray diffraction, and analyzed as having a SiO 2  /Al 2  O 3  mole ratio of 62.6 and a sodium content of 0.02 wt. % (dry basis). 
     The detailed chemical analysee are listed in Table 1 along with the results following mild caustic treatment (Examples 2-5). 
     EXAMPLES 2-5 
     To the filtered wetcake from Example 1 was added 1 part deionized water and 2.1 parts of a 0.42 wt. % NaOH solution per part of filtered wetcake. The treatment was carried out at room temperature for 0, 4, 18 and 90 hours for Examples 2-5, respectively. The details of the caustic treatment along with chemical analysis of the treated zeolite and filtrate are shown in Table 1. The filtrates from these caustic treatments (Examples 2-5) each contained 5-25 times the silicon content (330-1600 ppm Si) as the filtrate from a H 2  O washed zeolite (64 ppm Si), indicating dissolution of some amorphous and/or crystalline SiO 2 . The effect of the caustic treatment on crystal agglomeration is illustrated in FIG. 1, a comparison of scanning electron micrographs of the ZSMl-5 before (Example 1) and after (Example 4) an 18 hr. caustic treatment at an initial pH of 11.9. The size and degree of crystal agglomeration was significantly reduced. 
      EXAMPLE 6 
     An aluminate solution was prepared by dissolving 11 parts of aluminum sulfate, 15.6 parts of sodium hydroxide and 1 part of ZSM-5 seed (100% solid basis) in 268 parts of water. One hundred and ten parts of Hi-Sil 233 (an amorphous precipitated silica manufactured by PPG Industries) was then gradually added to the solution followed by 5 parts of sodium chloride crystal and 13.3 parts n-propylamine. The mixture was agitated for at least 4 hours to obtain a homogeneous slurry. The mixture was then heated to 215° F. for approximately 50 hours under constant agitation. The filtered, water-washed and dried solid product had an X-ray crystallinity of 75% based on a specific standard. The detailed chemical analyses are listed in Table 2 along with the results following caustic treatment (Examples 7-9). 
     EXAMPLE 7 
     To the filtered wetcake of Example 6 was added 1 part deionized water and 4.20 parts of a 0.42 wt. % NaOH solution per part of filtered wetcake. The treatment was carried out at room temperature for 24 hours. The caustic treated zeolite was then filtered and both the filtrate and the remaining zeolite were analyzed. The details of the caustic treatment and the chemical analysis results are given in Table 2 along with the results from the caustic treatments of Examples 8 and 9. 
     EXAMPLE 8 
     Procedure was identical to Example 7 except that a 2 wt. % NaOH solution was used for the caustic treatment. 
     EXAMPLES 9 AND 10 
     The procedure of Example 9 was identical to Example 7 except that a 10 wt. % NaOH solution was used for the caustic treatment. Example 10 is a blank comparison run using deionized water only. The effect of the caustic treatments on crystal agglomeration is clearly illustrated in FIG. 2, a comparison of scanning electron micrographs of ZSM-5 zeolite before treatment (Example 6) and after a 24 hour caustic treatment at initial pH&#39;s of 11.97, 12.71 and 13.30 (Examples 7-9). As the treatment pH increases the degree of agglomeration is reduced significantly. In comparison with the ZSM-5 synthesized by the procedure of Example 1, FIG. 1, the micrographs indicate that to reduce crystal agglomeration to a comparable level a higher pH is required for the ZSM-5 prepared as in Example 6, FIG. 2. The chemical analyses data of Table 2 indicate increasing Si and Al in the filtrate as the caustic treatment pH is increased. In addition, the SiO 2  /Al 2  O 3  ratio corresponding to the filtrate Si and Al content is 99.3, 123.5 and 55.3 for pH&#39;s of 11.97, 12.71 and 13.3 (Examples 7-9), respectively. In comparison, the untreated ZSM-5 zeolite has a SiO 2  /AL.sub. 2 O 3  ratio of 53.5. These filtrate chemical analyses indicate that at pH 11.97 and 12.71 the material which is dissolved is highly silicious--possibly amorphous SiO 2 , while at pH 13.3 the lower filtrate SiO 2  /Al 2  O 3  ratio suggests dissolution of a portion of the zeolite as well. This result is also supported by the reduction in the zeolite SiO 2  /Al 2  O 3  ratio following the caustic treatments and the apparent reduced X-ray crystallinity of the sample treated at pH 13.3. 
     EXAMPLE 11 
     To demonstrate ZSM-5 crystal is more stable than amorphous siliceous material, the following experiment was carried out. The ZSM-5 zeolite crystals were prepared by the method described in Example 1. The amorphous silica-alumina gel was prepared by the same method except no heat was applied. Four grams each of the above three samples (based on 100% solids) were treated with 100 ml of H 2  O, 0.1N, 0.2N, 0.5N and 1.0N of NaOH solution respectively at 100° C. for a period of 1 hour. The remaining solid after the treatment was separated from the solution using a centrifuge. The weight of washed and dried samples were plotted against the concentration of the caustic solutions in FIG. 3. The solubility of amorphous silica gel and Hi-Sil is much greater than crystalline ZSM-5. 
     EXAMPLE 12 
     The ZSM-5 crystal and silica amorphous gel described in Example 11 were treated in four gram samples with 100 ml of 0.5N NaOH at 25° C. and 100° C. for 1 hour, 2 hours, 4 hours, 8 hours, 24 hours and 72 hours. The undissolved solid was separated from caustic solution by centrifuge after treatment. The result is plotted in FIG. 4. Amorphous silica gel was more soluble at both temperatures. The weight of undissolved solid stabilized after about 2 hours. 
     
                       TABLE 1______________________________________Effect of Caustic Treatment on the Chemical Compositionof ZSM-5 Zeolite       Example Number       1     2      3       4     5______________________________________Treatment Conditions:Wt. of Reagents, gmZeolite Wetcake         --      200    200   200   200Deionized H.sub.2 O         --      200    200   200   200NaOH Soln (0.42 wt %)         --      420    420   420   420Treatment Temp, °F.         --      R.T.   R.T.  R.T.  R.T.Treatment Time, hrs.         --       0      4     18    90Filtrate AnalysispH            --      11.88  11.0  10.87 9.89Al, ppm       --      --      34    20    33Si, ppm       --      --     685   1600   330Na, ppm       --      --     880   --    1100ZSM-5 Zeolite AnalysisWt. %: SiO.sub.2         81.2    --     87.6  84.0  88.8Al.sub.2 O.sub.3         2.20    --     2.3   2.2   2.8C             4.77    --     5.56  6.17  5.83N             1.36    --     1.23  1.50  1.36Na            0.02    --     &lt;0.09 &lt;0.09 &lt;.05Ash           86.4    --     91.3  89.2  91.1Mole RatiosSiO.sub.2     62.6    --     64.6  64.8  53.8Al.sub.2 O.sub.3         1       --     1     1     1C             18.4    --     20.54 23.8  17.7N             4.50    --     3.89  4.97  3.54Na            0.04    --     &lt;.17  &lt;.17  &lt;.08C/N           4.09    --     5.28  4.79  5.0______________________________________ 
    
     
                       TABLE 2______________________________________Effect of Caustic Treatment on theChemical Compostion of ZSM-5       Example Number       6    7       8       9     10______________________________________Treatment Conditions:Wt. of Reagents, gmsZeolite Wetcake (1)         --      50      50     50   50Deionized H.sub.2 O         --      50      50     50  260NaOH Soln (0.42 wt %)         --     210     210    210  --                (0.42   (2    (10                wt. %)  wt. %)                              wt. %)Treatment Temp, °F.         --     R.T.    R.T.  R.T.  R.T.Treatment Time, hrs.         --      24      24     24   24Initial Slurry pH         --     11.97   12.71 13.30 8.87Filtrate AnalysispH            --     10.87   12.34 13.13 8.46Al, ppm       --      31      53    390  &lt;1Si, ppm       --     1600    3400  11200  80Na, ppm       --     0.13    0.58  2.74  0.026ZSM-5 Zeolite AnalysisWt. %: SiO.sub.2         85.2   86.4    85.2  84.0  86.4Al.sub.2 O.sub.3         2.7    2.9     3.1   3.0   2.8C             5.30   5.47    5.40  5.37  5.31N             1.97   1.83    1.89  --    1.96Na            0.39   &lt;.05    0.15  2.20  &lt;0.05Ash           90.5   90.5    90.4  88.1  90.5Mole RatiosSiO.sub.2     53.5   50.6    46.6  47.5  52.4Al.sub.2 O.sub.3         1      1       1     1     1C             16.7   16.0    14.8  15.2  16.1N             5.31   4.60    4.44  --    5.10Na            0.64   &lt;0.08   0.21  3.25  &lt;.08C/N           3.15   3.48    3.33  --    3.16X-ray Crystallinity (2)         75     75      80    65    75______________________________________ (1) 36 weight % solids (2) Based on a specific standard 
    
     EXAMPLE 13-16 
     Treating ZSM-5 with Basic Materials Other Than Sodium Hydroxide 
     ZSM-5 (synthesized as in Example 6) was treated with sodium aluminate solutions of varied concentrations similar to the caustic treatments described previously. The pH of these solutions were similar to the forementioned caustic solutions. Table 3 lists the conditions and results of these treatments. Within the pH range used in the sodium hydroxide experiments, the sodium aluminate solutions do not appear to be effective in reducing agglomeration. As noted in the silica to alumina ratio of the filtered product, much of the alumina remains with the zeolite after treatment. Furthermore the level of crystallinity decreased with increasing both time and/or severity of treatment. FIG. 5 (Examples 13-16) supports the conclusions that no reduction in zeolite agglomeration took place in the sodium aluminate treatments. 
     
                                           TABLE 3__________________________________________________________________________NaAlO.sub.2 Treatment of ZSM-5 ZeoliteWeight %      Normality            Total                pH    pH           Silica toExampleZeolite in      of    Mixing                Before                      After %      aluminaNumberSolution      NaAlO.sub.2            Time                Treatment                      Treatment                            Crystallinity                                   Ratio__________________________________________________________________________ 6                               75     53.513   11    3      4  12.8  13.6  50     514   11    3     24  12.8  13.4  35     415   11    0.75   4  11.7  12.1  65     1316   11    0.75  24  11.7  12.1  65     13__________________________________________________________________________ 
    
     EXAMPLES 17 and 18 
     ZSM-5 wetcake (refer to Example 6) was added to water to a solids content of approximately 19%. This mixture was stired until homogeneous and then subjected to a four hour high speed mixing on a Cowles Dissolver Model W-24 at 1600 rpm. Example 17 (FIG. 6) shows that the high speed mixing did reduce the extent of zeolite agglomeration somewhat but not to the extent of the previously described sodium hydroxide treatments. 
     An equivalent zeolite mixture was prepared and processed through a Gaulin Homogenizer at 1000 psig twice and the filtered. Example 18 (FIG. 6) shows that this type of physical treatment did little to reduce the zeolite agglomeration. 
     EXAMPLES 19 and 20 
     ZSM-5 wetcake (refer to Example 6) was added to water to a solids content of approximately 22%. To this mixture enough (2% wt.) sodium hydroxide was added to reduce the solids content to 11%. The pH of this solution was 12.7. This solution was mixed for 2 hours before a sample was taken, filtered and dried. Example 19 (FIG. 7) shows that as claimed previously the mild caustic treatment did reduce the zeolite agglomeration. To the remaining solution additional 2% (wt.) sodium hydroxide was added to reduce the solids content to 5.5%. The pH of this solution was 12.9. This solution was subjected to two hours of high speed mixing by a Cowles Dissolver Model W-24 at 1600 rpm before a sample was taken, filtered and dried. Example 20 (FIG. 7) illustrates that there was little improvement resulting from the high speed mixing compared to the caustic treatment (Example 19). These results indicate that any improvement in reducing zeolite agglomeration caused by physical treatments is insignificant compared to the chemical treatments.