Abstract:
A boron-containing molecular sieve having the CHA crystal structure and comprising (1) silicon oxide and (2) boron oxide or a combination of boron oxide and aluminum oxide, iron oxide, titanium oxide, gallium oxide and mixtures thereof is prepared using a quaternary ammonium cation derived from 1-adamantamine, 3-quinuclidinol or 2-exo-aminonorbornane as structure directing agent. The molecular sieve can be used for gas separation or in catalysts to prepare methylamine or dimethylamine, to convert oxygenates (e.g., methanol) to light olefins, or for the reduction of oxides of nitrogen n a gas stream (e.g., automotive exhaust).

Description:
[0001]     This application claims benefit under 35 USC 119 of Provisional Application No. 60/632008, filed Nov. 30, 2004. 
     
    
     BACKGROUND  
       [0002]     Chabazite, which has the crystal structure designated “CHA”, is a natural zeolite with the approximate formula Ca 6 Al 12 Si 24 O 72 . Synthetic forms of chabazite are described in “Zeolite Molecular Sieves” by D. W. Breck, published in 1973 by John Wiley &amp; Sons. The synthetic forms reported by Breck are: zeolite “K-G”, described in J. Chem. Soc., p. 2822 (1956), Barrer et al.; zeolite D, described in British Patent No. 868,846 (1961); and zeolite R, described in U. S. Pat. No. 3,030,181, issued Apr. 17, 1962 to Milton et al. Chabazite is also discussed in “Atlas of Zeolite Structure Types” (1978) by W. H. Meier and D. H. Olson.  
         [0003]     The K-G zeolite material reported in the J. Chem. Soc. Article by Barrer et al. is a potassium form having a silica:alumina mole ratio (referred to herein as “SAR”) of 2.3:1 to 4.15:1. Zeolite D reported in British Patent No. 868,846 is a sodium-potassium form having a SAR of 4.5:1 to 4.9:1. Zeolite R reported in U. S. Pat. No. 3,030,181 is a sodium form which has a SAR of 3.45:1 to 3.65:1.  
         [0004]     Citation No. 93:66052y in Volume 93 (1980) of Chemical Abstracts concerns a Russian language article by Tsitsishrili et al. in  Soobsch. Akad. Nauk. Gruz.  SSR 1980, 97(3) 621-4. This article teaches that the presence of tetramethylammonium ions in a reaction mixture containing K 2 O-Na 2 O-SiO 2 -Al 2 O 3 -H 2 O promotes the crystallization of chabazite. The zeolite obtained by the crystallization procedure has a SAR of 4.23.  
         [0005]     The molecular sieve designated SSZ-13, which has the CHA crystal structure, is disclosed in U. S. Pat. No. 4,544,538, issued Oct. 1, 1985 to Zones. SSZ-13 is prepared from nitrogen-containing cations derived from 1-adamantamine, 3-quinuclidinol and 2-exo-aminonorbornane. Zones discloses that the SSZ-13 of U. S. Pat. No. 4,544,538 has a composition, as-synthesized and in the anhydrous state, in terms of mole ratios of oxides as follows:  
         [0006]     (0.5 to 1.4)R 2 O:(0 to 0.5)M 2 O:W 2 O 3 :(greater than 5)YO 2  wherein M is an alkali metal cation, W is selected from aluminum, gallium and mixtures thereof, Y is selected from silicon, germanium and mixtures thereof, and R is an organic cation. U. S. Pat. No. 4,544,538 does not, however, disclose boron-containing SSZ-13.  
         [0007]     U. S. Pat. No. 6,709,644, issued Mar. 23, 2004 to Zones et al., discloses zeolites having the CHA crystal structure and having small crystallite sizes. It does not, however, disclose a CHA zeolite containing boron. It is disclosed that the zeolite can be used for separation of gasses (e.g., separating carbon dioxide from natural gas), and in catalysts used for the reduction of oxides of nitrogen in a gas stream (e.g., automotive exhaust), converting lower alcohols and other oxygenated hydrocarbons to liquid products, and for producing dimethylamine.  
       SUMMARY OF THE INVENTION  
       [0008]     In accordance with the present invention there is provided an improved process for separating gasses using a membrane containing a molecular sieve, the improvement comprising using as the molecular sieve a boron-containing molecular sieve having the CHA crystal structure and comprising (1) silicon oxide and (2) boron oxide or a combination of boron oxide and aluminum oxide, iron oxide, titanium oxide, gallium oxide and mixtures thereof. In one embodiment, oxide (2) is more than 50% boron oxide on a molar basis. 
     
    
     DETAILED DESCRIPTION  
       [0009]     The present invention relates to molecular sieves having the CHA crystal structure and containing boron in their crystal framework.  
         [0010]     Boron-containing CHA molecular sieves can be suitably prepared from an aqueous reaction mixture containing sources of sources of an oxide of silicon; sources of boron oxide or a combination of boron oxide and aluminum oxide, iron oxide, titanium oxide, gallium oxide and mixtures thereof; optionally sources of an alkali metal or alkaline earth metal oxide; and a cation derived from 1-adamantamine, 3-quinuclidinol or 2-exo-aminonorbornane. The mixture should have a composition in terms of mole ratios falling within the ranges shown in Table A below:  
                           TABLE A                                       YO 2 /W a O b      &gt;2-2,000           OH—/YO 2     0.2-0.45           Q/YO 2     0.2-0.45           M 2/n O/YO 2       0-0.25           H 2 O/YO 2      22-80                      
 
 wherein Y is silicon,; W is boron or a combination of boron and aluminum, iron, titanium, gallium and mixtures thereof; M is an alkali metal or alkaline earth metal; n is the valence of M (i.e., 1 or 2) and Q is a quaternary ammonium cation derived from 1-adamantamine, 3-quinuclidinol or 2-exo-aminonorbornane (commonly known as a structure directing agent or “SDA”). 
 
         [0011]     The quaternary ammonium cation derived from 1-adamantamine can be a N,N,N-trialkyl-1-adamantammonium cation which has the formula:  
                         
 
 where R 1 , R 2,  and R 3  are each independently a lower alkyl, for example methyl. The cation is associated with an anion, A − , which is not detrimental to the formation of the molecular sieve. Representative of such anions include halogens, such as fluoride, chloride, bromide and iodide; hydroxide; acetate; sulfate and carboxylate. Hydroxide is the preferred anion. It may be beneficial to ion exchange, for example, a halide for hydroxide ion, thereby reducing or eliminating the alkali metal or alkaline earth metal hydroxide required. 
 
         [0012]     The quaternary ammonium cation derived from 3-quinuclidinol can have the formula:  
                         
 
 where R 1 , R 2 , R 3  and A are as defined above. 
 
         [0013]     The quaternary ammonium cation derived from 2-exo-aminonorbornane can have the formula:  
                         
 
 where R 1 , R 2 , R 3  and A are as defined above. 
 
         [0014]     The reaction mixture is prepared using standard molecular sieve preparation techniques. Typical sources of silicon oxide include fumed silica, silicates, silica hydrogel, silicic acid , colloidal silica, tetra-alkyl orthosilicates, and silica hydroxides. Sources of boron oxide include borosilicate glasses and other reactive boron compounds. These include borates, boric acid and borate esters. Typical sources of aluminum oxide include aluminates, alumina, hydrated aluminum hydroxides, and aluminum compounds such as AlCl 3  and Al 2 (SO 4 ) 3 . Sources of other oxides are analogous to those for silicon oxide, boron oxide and aluminum oxide.  
         [0015]     It has been found that seeding the reaction mixture with CHA crystals both directs and accelerates the crystallization, as well as minimizing the formation of undesired contaminants. In order to produce pure phase boron-containing CHA crystals, seeding may be required. When seeds are used, they can be used in an amount that is about 2-3 weight percent based on the weight of YO 2 .  
         [0016]     The reaction mixture is maintained at an elevated temperature until CHA crystals are formed. The temperatures during the hydrothermal crystallization step are typically maintained from about 120° C. to about 160° C. It has been found that a temperature below 160° C., e.g., about 120° C. to about 140° C., is useful for producing boron-containing CHA crystals without the formation of secondary crystal phases.  
         [0017]     The crystallization period is typically greater than 1 day and preferably from about 3 days to about 7 days. The hydrothermal crystallization is conducted under pressure and usually in an autoclave so that the reaction mixture is subject to autogenous pressure. The reaction mixture can be stirred, such as by rotating the reaction vessel, during crystallization.  
         [0018]     Once the boron-containing CHA crystals have formed, the solid product is separated from the reaction mixture by standard mechanical separation techniques such as filtration. The crystals are water-washed and then dried, e.g., at 90° C. to 150° C. for from 8 to 24 hours, to obtain the as-synthesized crystals. The drying step can be performed at atmospheric or subatmospheric pressures.  
         [0019]     The boron-containing CHA molecular sieve has a composition, as-synthesized and in the anhydrous state, in terms of mole ratios of oxides as indicated in Table B below:  
         [0020]     As-Synthesized Boron-containing CHA Composition  
                           TABLE B                                       YO 2 /W c O d       20-2,000           M 2/n O/YO 2       0-0.03           Q/YO 2     0.02-0.05                      
 
 where Y, W, M, n and Q are as defined above. 
 
         [0021]     The boron-containing CHA molecular sieves, as-synthesized, have a crystalline structure whose X-ray powder diffraction (“XRD”) pattern shows the following characteristic lines:  
                                                   TABLE I                           As-Synthesized Boron-Containing CHA XRD                2 Theta (a)     d-spacing (Angstroms)   Relative Intensity (b)                              9.68   9.13   S           14.17   6.25   M           16.41   5.40   VS           17.94   4.94   M           21.13   4.20   VS           25.21   3.53   VS           26.61   3.35   W-M           31.11   2.87   M           31.42   2.84   M           31.59   2.83   M                           (a) ±0.10                  (b) The X-ray patterns provided are based on a relative intensity scale in which the strongest line in the X-ray pattern is assigned a value of 100: W(weak) is less than 20; M(medium) is between 20 and 40; S(strong) is between 40 and 60; VS(very strong) is greater than 60.             
 
         [0022]     Table IA below shows the X-ray powder diffraction lines for as-synthesized boron-containing CHA including actual relative intensities.  
                                           TABLE IA                           As-Synthesized Boron-Containing CHA XRD            2 Theta (a)     d-spacing (Angstroms)   Relative Intensity (%)                    9.68   9.13   55.2       13.21   6.70   5.4       14.17   6.25   33.5       16.41   5.40   81.3       17.94   4.94   32.6       19.43   4.56   6.8       21.13   4.20   100       22.35   3.97   15.8       23.00   3.86   10.1       23.57   3.77   5.1       25.21   3.53   78.4       26.61   3.35   20.2       28.37   3.14   6.0       28.57   3.12   4.4       30.27   2.95   3.9       31.11   2.87   29.8       31.42   2.84   38.3       31.59   2.83   26.5       32.27   2.77   1.4       33.15   2.70   3.0       33.93   2.64   4.7       35.44   2.53   3.9       35.84   2.50   1.2       36.55   2.46   10.9       39.40   2.29   1.8       40.02   2.25   1.3       40.44   2.23   1.0       40.73   2.21   6.0                   (a) ±0.10             
 
         [0023]     After calcination, the boron-containing CHA molecular sieves have a crystalline structure whose X-ray powder diffraction pattern include the characteristic lines shown in Table II:  
                                           TABLE II                           Calcined Boron-Containing CHA XRD            2 Theta (a)     d-spacing (Angstroms)   Relative Intensity                    9.74   9.07   VS       13.12   6.74   M       14.47   6.12   W       16.38   5.41   W       18.85   4.78   M       21.07   4.21   M       25.98   3.43   W       26.46   3.37   W       31.30   2.86   W       32.15   2.78   W                   (a) ±0.10             
 
         [0024]     Table IIA below shows the X-ray powder diffraction lines for calcined boron-containing CHA including actual relative intensities.  
                                           TABLE IIA                           Calcined Boron-Containing CHA XRD            2 Theta (a)     d-spacing (Angstroms)   Relative Intensity (%)                    9.74   9.07   100       13.12   6.74   29.5       14.47   6.12   4.6       16.38   5.41   14.2       18.85   4.78   22.1       19.60   4.53   2.2       21.07   4.21   32.9       22.84   3.89   2.2       23.68   3.75   0.8       25.98   3.43   13.1       26.46   3.37   8.7       28.27   3.15   1.3       29.24   3.05   1.6       30.32   2.95   1.7       31.30   2.86   14.4       32.15   2.78   9.0       32.56   2.75   0.2       35.26   2.54   2.4                   (a) ±0.15             
 
         [0025]     The X-ray powder diffraction patterns were determined by standard techniques. The radiation was the K-alpha/doublet of copper and a scintillation counter spectrometer with a strip-chart pen recorder was used. The peak heights I and the positions, as a function of 2 Theta where Theta is the Bragg angle, were read from the spectrometer chart. From these measured values, the relative intensities, 100 ×I/Io, where Io is the intensity of the strongest line or peak, and d, the interplanar spacing in Angstroms corresponding to the recorded lines, can be calculated.  
         [0026]     Variations in the diffraction pattern can result from variations in the mole ratio of oxides from sample to sample. The molecular sieve produced by exchanging the metal or other cations present in the molecular sieve with various other cations yields a similar diffraction pattern, although there can be shifts in interplanar spacing as well as variations in relative intensity. Calcination can also cause shifts in the X-ray diffraction pattern. Also, the symmetry can change based on the relative amounts of boron and aluminum in the crystal structure. Notwithstanding these perturbations, the basic crystal lattice structure remains unchanged.  
         [0027]     The molecular sieve of the present invention can be used to separate gasses. For example, it can be used to separate carbon dioxide from natural gas. Typically, the molecular sieve is used as a component in a membrane that is used to separate the gasses. Examples of such membranes are disclosed in U. S. Pat. No. 6,508,860, issued Jan. 21, 2003 to Kulkarni et al., which is incorporated by reference herein in its entirety.  
       EXAMPLES  
     Examples 1-14  
       [0028]     Boron-containing CHA is synthesized by preparing the gel compositions, i.e., reaction mixtures, having the compositions, in terms of mole ratios, shown in the table below. The resulting gel is placed in a Parr bomb reactor and heated in an oven at the temperature indicated below while rotating at the speed indicated below. Products are analyzed by X-ray diffraction (XRD) and found to be boron-containing molecular sieves having the CHA structure. The source of silicon oxide is Cabosil M-5 fumed silica or HiSil 233 amorphous silica (0.208 wt.% alumina). The source of boron oxide is boric acid and the source of aluminum oxide is Reheis F 2000 alumina.  
                                                                                                             Ex. #   SiO 2 /B 2 O 3     SiO 2 /Al 2 O 3     H 2 O/SiO 2     OH—/SiO 2     Na+/SiO 2     SDA/SiO 2     Rx Cond. 1     Seeds   %1-ada 2                                  1   2.51   1,010   23.51   0.25   0.20   0.25   140/43/5 d   yes   100       2   12.01   1,010   22.74   0.25   0.08   0.25   140/43/5 d   yes   100       3   12.33   1,010   22.51   0.25   0.08   0.25   140/43/5 d   yes   100       4   12.07   288,900   23.00   0.26   0.09   0.26   140/43/5 d   no   100       5   12.33   37,129   22.51   0.25   0.09   0.25   140/43/5 d   yes   100       6   12.33   248,388   22.51   0.25   0.09   0.25   140/43/5 d   yes   100       7   12.33   248,388   22.53   0.25   0.09   0.25   140/43/5 d   yes   100       8   12.33   248,388   22.53   0.25   0.00   0.25   140/43/5 d   yes   100       9   12.33   248,388   22.51   0.25   0.09   0.25   160/43/4 d   yes   100       10   11.99   288,900   23.18   0.26   0.09   0.26   160/43/4 d   no   100       11   12.13   288,900   32.22   0.43   0.21   0.21   160/43/4 d   no   100       12   11.99   288,900   23.16   0.26   0.00   0.26   160/43/4 d   no   100       13   11.99   288,900   23.18   0.26   0.09   0.26   160/43/4 d   no   100       14   3.08   248,388   22.51   0.25   0.00   0.25   160/43/6 d   yes   100                   1 ° C./RPM/Days              2 1-ada = Quaternary ammonium cation derived from 1-adamantamine             
 
       Examples 15-20  
     Deboronation  
       [0029]     Boron is removed from samples of the molecular sieves prepared as described in Example 13 above and then calcined. The sample is heated in an acid solution under the conditions indicated in the table below. The results are shown in the table.  
                                                                                                                                                   Ex. No.                Starting   Deboronation Rx                (B) SSZ-13   15   16   17   18   19   20               Acid used   —   Acetic acid   acetic acid   acetic acid   HCl   HCl   HCl       Acid Molarity   —   1.0 M   0.01 M   0.0001 M   0.01 M   0.001 M   0.0001 M       Rx Cond.   —   45 C./0 rpm/19 hr   45 C./0 rpm/19 hr   45 C./0 rpm/19 hr   45 C./0 rpm/19 hr   45 C./0 rpm/19 hr   45 C./0 rpm/19 hr                        Analysis Results                    Untreated   Treated   Treated   Treated   Treated   Treated   Treated               Boron   0.66%   614 ppm   513 ppm   420 ppm   421 ppm   506 ppm   552 ppm