Patent ID: 7578993

Claim:
A process for preparing a crystalline aluminosilicate composition having an empirical composition on an as synthesized and anhydrous basis expressed by an empirical formula of: M m n+ C g h+ R r p+ Al 1-x E x Si y O z where M is at least one exchangeable cation selected from the group consisting of alkali and alkaline earth metals, “m” is the mole ratio of M to (Al+E) and varies from 0 to about 3, C is at least one organic nitrogen containing cation, having a C/N>4 characterized in that it is a charge density mismatch template, selected from the group consisting of quaternary ammonium ions, diquaternary ammonium ions, and quaternized alkanolammonium cations, “g’ is the mole ratio of C to (Al+E) and varies from 0 to about 5, R is at least one crystallization-inducing organic cation which differs from C and is selected from the group consisting of quaternary ammonium ions, diquaternary ammonium ions, protonated amines, protonated alkanolamines and quaternized alkanolamnionium ions, “r” is the mole ratio of R to (Al+E) and has a value from 0 to about 5, where g+r>0.25, “n” is the weighted average valence of M and has a value of about 1 to about 2, “h” is the weighted average valence of C and has a value of about 1 to about 2, “p” is the weighted average valence of R and has a value of about 1 to about 2, E is an element selected from the group consisting of gallium, iron, boron and mixtures thereof, “x” is the mole fraction of E and has a value from 0 to about 1, “y” is the mole ratio of Si to (Al+E) and varies from greater than 1 to about 25; the process comprising forming a charge density mismatch (CDM) reaction mixture solution containing reactive sources of Al, Si, optionally E and at least one C organic cation in the hydroxide form, adding to this mixture a solution comprising a crystallization inducing templating agent selected from the group consisting of an R organic cation, a source of M and mixtures thereof to provide a final reaction mixture having a composition expressed in terms of mole ratios of the oxides of: aM 2/n O:bC 2/h O:cR 2/p O:1-dAl 2 O 3 :dE 2 O 3 :eSiO 2 :fH 2 O where “a” has a value from 0 to about 5, “b” has a value of 1 to about 25, “c” has a value from 0 to about 5, c+a>0.15, “d” has a value from 0 to about 1, “e” has a value of about 2 to about 50 and “f” has a value of about 10 to about 5000, and reacting the final reaction mixture at a reaction temperature of about 75° C. to about 225° C. for a time sufficient to form the zeolite, wherein the CDM reaction mixture solution is not capable of crystallizing a crystalline aluminosilicate composition at the reaction temperature at which the aluminosilicate synthesis is carried out.