Zinc-aluminum-phosphorus-silicon-oxide molecular sieve compositions

FIELD OF THE INVENTION
The instant invention relates to a novel class of crystalline microporous molecular sieves, to the method of their preparation. The invention-oxide relates to novel zinc-aluminum-phosphorus-silicon molecular sieves having zinc, aluminum, phosphorus and silicon in the form of framework tetrahedral oxides. These compositions may be prepared hydrothermally from gels containing reactive compounds of zinc, aluminum, phosphorus and silicon capable of forming a framework tetrahedral oxides, and preferably at least one organic templating agent which functions in part to determine the course of the crystallization mechanism and the structure of the crystalline product.
BACKGROUND OF THE INVENTION
Molecular sieves of the crystalline aluminosilicate zeolite type are well known in the art and now comprise over 150 species of both naturally occurring and synthetic compositions. In general the crystalline zeolites are formed from corner-sharing AlO.sub.2 and SiO.sub.2 tetrahedra and are characterized by having pore openings of uniform dimensions, having a significant ion-exchange capacity and being capable of reversibly desorbing an adsorbed phase which is dispersed throughout the internal voids of the crystal without displacing any atoms which make up the permanent crystal structure.
Other crystalline microporous compositions which are not zeolitic, i.e. do not contain AlO.sub.2 tetrahedra as essential framework constituents, but which exhibit the ion-exchange and/or adsorption characteristics of the zeolites are also known. Metal organosilicates which are said to possess ion-exchange properties, have uniform pores and are capable of reversibly adsorbing molecules having molecular diameters of about 6.ANG. or less, are reported in U.S. Pat. No. 3,941,871 issued Mar. 2, 1976 to Dwyer et al. A pure silica polymorph, silicalite, having molecular sieving properties and a neutral framework containing neither cations nor cation sites is disclosed in U.S. Pat. No. 4,061,724 issued Dec. 6, 1977 to R. W. Grose et al.
A recently reported class of microporous compositions and the first framework oxide molecular sieves synthesized without silica, are the crystalline aluminophosphate compositions disclosed in U.S. Pat. No. 4,310,440 issued Jan. 12, 1982 to Wilson et al. These materials are formed from AlO.sub.2 and PO.sub.2 tetrahedra and have electrovalently neutral frameworks as in the case of silica polymorphs. Unlike the silica molecular sieve, silicalite, which is hydrophobic due to the absence of extra-structural cations, the aluminophosphate molecular sieves are moderately hydrophilic, apparently due to the difference in electronegativity between aluminum and phosphorus. Their intracrystalline pore volumes and pore diameters are comparable to those known for zeolites and silica molecular sieves.
In copending and commonly assigned application Ser. No. 400,438, filed Jul. 26, 1982, now U.S. Pat. No. 4,440,871, there is described a novel class of silicon-substituted aluminophosphates which are both microporous and crystalline. The materials have a three dimensions crystal framework of PO.sub.2.sup.+, AlO.sub.2.sup.- and SiO.sub.2 tetrahedral units and, exclusive of any alkali metal or calcium which may optionally be present, an as-synthesized empirical chemical composition on an anhydrous basis of:
mR:(Si.sub.x Al.sub.y P.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the moles of "R" present per mole of (Si.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of from zero to 0.3, the maximum value in each case depending upon the molecular dimensions of the templating agent and the available void volume of the pore system of the particular silicoaluminophosphate species involved; and "x", "y", and "z" represent the mole fractions of silicon, aluminum and phosphorus, respectively, present as tetrahedral oxides. The minimum value for each of "x", "y", and "z" is 0.01 and preferably 0.02. The maximum value for "x" is 0.98; for "y" is 0.60; and for "z" is 0.52. These silicoaluminophosphates exhibit several physical and chemical properties which are characteristic of aluminosilicate zeolites and aluminophosphates.
In copending and commonly assigned application Ser. No. 480,738, filed Mar. 31, 1983, now U.S. Pat. No. 4,500,651 there is described a novel class of titanium-containing molecular sieves whose chemical composition in the as-synthesized and anhydrous form is represented by the unit empirical formula:
mR:(Ti.sub.x Al.sub.y P.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the moles of "R" present per mole of (Ti.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of between zero and about 5.0; and "x", "y" and "z" represent the mole fractions of titanium, aluminum and phosphorus, respectively, present as tetrahedral oxides.
In copending and commonly assigned application Ser. No. 514,334, filed Jul. 15, 1983, now U.S. Pat. No. 4,567,029, there is described a novel class of crystalline metal aluminophosphates having three-dimensional microporous framework structures of MO.sub.2, AlO.sub.2 and PO.sub.2 tetrahedral units and having an empirical chemical composition on an anhydrous basis expressed by the formula:
mR:(M.sub.x Al.sub.y P.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the moles of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of from zero to 0.3; "M" represents at least one metal of the group magnesium, manganese, zinc and cobalt; and "x", "y" and "z" represent the mole fraction of the metal "M", aluminum and phosphorus, respectively, present as tetrahedral oxides.
In copending and commonly assigned application Ser. No. 514,335, filed Jul. 15, 1983, now U.S. Pat. No. 4,554,143, there is described a novel class of crystalline ferroaluminophosphates having a three-dimensional microporous framework structure of FeO.sub.2, AlO.sub.2 and PO.sub.2 tetrahedral units and having an empirical chemical composition on a anhydrous basis expressed by the formula:
mR:(Fe.sub.x Al.sub.y P.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the moles of "R" present per mole of (Fe.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of from zero to 0.3; and "x", "y" and "z" represent the mole fraction of the iron, aluminum and phosphorous, respectively, present as tetrahedral oxides.
The instant invention relates to new molecular sieve compositions having framework ZnO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 as tetrahedral oxide units.

DESCRIPTION OF THE FIGURES
FIG. 1 is a ternary diagram wherein parameters relating to the instant compositions are set forth as mole fractions.
FIG. 2 is a ternary diagram wherein parameters relating to preferred compositions are set forth as mole fractions.
FIG. 3 is a ternary diagram wherein parameters relating to the reaction mixtures employed in the preparation of the compositions of this invention are set forth as mole fractions.

SUMMARY OF THE INVENTION
The instant invention relates to a new class of molecular sieves having a three-dimensional microporous crystal framework structures of ZnO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral oxide units. These new zinc-aluminum-phosphorus-silicon-oxide molecular sieves exhibit ion-exchange, adsorption and catalytic properties and, accordingly, find wide use as adsorbents and catalysts. The members of this novel class of compositions have crystal framework structures of ZnO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:
mR:(Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value from zero to about 0.3;, and "w", "x", "y" and "z" represent the mole fractions of zinc, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The instant molecular sieve compositions are characterized in several ways as distinct from heretofore known molecular sieves, including the aforementioned ternary compositions. The instant molecular sieves are characterized by the enhanced thermal stability of certain species and by the existence of species heretofore unknown for binary and ternary molecular sieves.
The molecular sieves of the instant invention will be generally referred to by the acronym "ZnAPSO" to designate a crystal framework of ZnO.sub.2.sup.-, AlO.sub.2.sup.-, PO.sub.2.sup.+, SiO.sub.2 and tetrahedral units. Actual class members will be identified as structural species by assigning a number to the species and, accordingly, are identified as ZnAPSO-i wherein "i" is an integer. This designation is an arbitrary one and is not intended to denote structural relationship to another material(s) which may also be characterized by a numbering system.
DETAILED DESCRIPTION OF THE INVENTION
The instant invention relates to a new class of three-dimensional microporous crystalline molecular sieves having a crystal framework structures of ZnO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral oxide units. These new molecular sieves exhibit ion-exchange, adsorption and catalytic properties, and accordingly find wide use as adsorbents and catalysts.
The ZnAPSO molecular sieves of the instant invention comprise framework structures of ZnO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:
mR:(Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2
wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of zinc, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides and each has a value of at least 0.01. The mole fractions "w", "x", "y" and "z" are generally defined being within the pentagonal compositional area defined by points A, B, C, D and E of the ternary diagram of FIG. 1. Points A, B, C, D and E of FIG. 1 have the following values for "w", "x", "y", and "z":
______________________________________Mole FractionPoint x y (z + w)______________________________________A 0.60 0.38 0.02B 0.38 0.60 0.02C 0.01 0.60 0.39D 0.01 0.01 0.98E 0.60 0.01 0.39______________________________________
In the preferred subclass of ZnAPSO molecular sieves the values "w", "x", "y" and "z" in the above formular are within the tetragonal compositional area defined by points a, b, c and d of the ternary diagram which is FIG. 2 of the drawings, said points a, b, c and d representing the following values for "w", "x", "y" and "z".
______________________________________Mole FractionPoint x y (z + w)______________________________________a 0.55 0.43 0.02b 0.43 0.55 0.02c 0.10 0.55 0.35d 0.55 0.10 0.35______________________________________
The ZnAPSOs of this invention are useful as adsorbents, catalysts, ion-exchangers, and the like in much the same fashion as aluminosilicates have been employed heretofore, although their chemical and physical properties are not necessarily similar to those observed for aluminosilicates.
ZnAPSO compositions are generally synthesized by hydrothermal crystallization at effective process conditions from a reaction mixture containing active sources of zinc, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element or Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C. until crystals of the ZnAPSO product are obtained, usually a period of from several hours to several weeks. Generally the effective crystallization period is from about 2 hours to about 30 days with typical periods of from about 4 hours to about 20 days being employed to obtain ZnAPSO products. The product is recovered by any convenient method such as centrifugation or filtration.
In synthesizing the ZnAPSO compositions of the instant invention, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:
aR:(Zn.sub.r Al.sub.s P.sub.t Si.sub.u)O.sub.2 :bH.sub.2 O
wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "b" has a value of from zero (0) to about 500, more preferably between about 2 and about 300; and "r", "s", "t" and "u" represent the mole fractions of zinc, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01. In a preferred embodiment the reaction mixture is selected such that the mole fractions "r", "s", "t" and "u" are generally defined as being within the pentagonal compositional area defined by points F, G, H, I and J of the ternary diagram of FIG. 3. Points F, G, H, I and J of FIG. 3 have the following values for "r", "s", "t" and "u":
______________________________________Mole FractionPoint s t (u + r)______________________________________F 0.60 0.38 0.02G 0.38 0.60 0.02H 0.01 0.60 0.39I 0.01 0.01 0.98J 0.60 0.01 0.39______________________________________
For reasons unknown at present, not every reaction mixture gave crystalline ZnAPSO products when reaction products were examined for ZnAPSO products by X-ray analysis. Those reaction mixtures from which crystalline ZnAPSO products were obtained are reported in the examples hereinafter as numbered examples and those reaction mixtures from which ZnAPSO products were not identified by use of X-ray analysis are reported as lettered examples.
In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "r", "s", "t" and "u" such that (r+s+t+u)=1.00 mole, whereas in the examples the reaction mixtures are expressed in terms of molar oxide ratios and may be normalized to the moles of P.sub.2 O.sub.5. This latter form is readily converted to the former form by routine calculations by dividing the number of moles of each component (including the template and water) by the total number of moles of zinc, aluminum, phosphorus and silicon which results in normalized mole fractions based on total moles of the aforementioned components.
In forming reaction mixture from which the instant molecular sieves are formed the organic templating agent can be any of those heretofore proposed for use in the synthesis of conventional zeolite aluminosilicates. In general these compounds contain elements of Group VA of the Periodic Table of Elements, particularly nitrogen, phosphorus, arsenic and antimony, preferably nitrogen or phosphorus and most preferably nitrogen, which compounds also contain at least one alkyl or aryl group having from 1 to 8 carbon atoms. Particularly preferred compounds for use as templating agents are the amines, quaternary phosphonium compounds and quaternary ammonium compounds, the latter two being represented generally by the formula R.sub.4 X.sup.+ wherein "X" is nitrogen or phosphorus and each R is an alkyl or aryl group containing from 1 to 8 carbon atoms. Polymeric quaternary ammonium salts such as [(C.sub.14 H.sub.32 N.sub.2) (OH).sub.2 ].sub.x wherein "x" has a value of at least 2 are also suitably employed. The mono-, di- and tri-amines are advantageously utilized, either alone or in combination with a quaternary ammonium compound or other templating compound. Mixtures of two or more templating agents can either produce mixtures of the desired ZnAPSOs or the more strongly directing templating species may control the course of the reaction with the other templating species serving primarily to establish the pH conditions of the reaction gel. Representative templating agents include: tetramethylammonium; tetraethylammonium; tetrapropylammonium; tetrabutylammonium ions; tetrapentylammonium ions; di-n-propylamine; tripropylamine; triethylamine; triethanolamine; piperidine; cyclohexylamine; 2-methylpyridine; N,N-dimethylbenzylamine; N,N-dimethylethanolamine; choline; N,N'-dimethylpiperazine; 1,4-diazabicyclo (2,2,2) octane; N-methyldiethanolamine, N-methylethanolamine; N-methylpiperidine; 3-methylpiperidine; N-methylcyclohexylamine; 3-methylpyridine; 4-methylpyridine; quinuclidine; N,N'-dimethyl-1,4-diazabicyclo (2,2,2) octane ion; di-n-butylamine, neopentylamine; di-n-pentylamine; isopropylamine; t-butylamine; ethylenediamine; pyrrolidine; and 2-imidazolidone. Not every templating agent will direct the formation of every species of ZnAPSO, i.e., a single templating agent can, with proper manipulation of the reaction conditions, direct the formation of several ZnAPSO compositions, and a given ZnAPSO composition can be produced using several different templating agents.
The source of silicon may be silica, either as a silica sol or as fumed silica, a reactive solid amorphous precipitated silica, silica gel, alkoxides of silicon, silicic acid or alkali metal silicate and the like; such that the formation of reactive silicon in situ is provided to form SiO.sub.2 tetrahedral units.
The most suitable phosphorus source yet found for the present process is phosphoric acid, but organic phosphates such as triethyl phosphate have been found satisfactory, and so also have crystalline or amorphous aluminophosphates such as the AlPO.sub.4 composition of U.S. Pat. No. 4,310,440. Organo-phosphorus compounds, such as tetrabutylphosphonium bromide do not, apparently, serve as reactive sources of phosphorus, but these compounds do function as templating agents. Conventional phosphorus salts such as sodium metaphosphate, may be used, at least in part, as the phosphorus source, but are not preferred.
The preferred aluminum source is either an aluminum alkoxide, such as aluminum isoproproxide, or pseudoboehmite. The crystalline or amorphous aluminophosphates which are a suitable source of phosphorus are, of course, also suitable sources of aluminum. Other sources of aluminum used in zeolite synthesis, such as gibbsite, sodium aluminate and aluminum trichloride, can be employed but are not preferred.
The source of zinc can be introduced into the reaction system in any form which permits the formation in situ of reactive form of zinc, i.e., reactive to form the framework tetrahedral unit ZnO.sub.2.sup.-2. Compounds of zinc which may be employed include oxides, hydroxides, alkoxides, nitrates, sulfates, carboxylates (e.g., acetates), organometallic zinc compounds and the like, and mixtures thereof.
While not essential to the synthesis of ZnAPSO compositions, stirring or other moderate agitation of the reaction mixture and/or seeding the reaction mixture with seed crystals of either the ZnAPSO species to be produced or a topologically similar aluminophosphate, aluminosilicate or molecular sieve composition, facilitates the crystallization procedure.
After crystallization the ZnAPSO product may be isolated and advantageously washed with water and dried in air. The as-synthesized ZnAPSO generally contains within its internal pore system at least one form of the templating agent employed in its formation. Most commonly any organic moiety derived from an organic template is present, at least in part, as a charge-balancing cation as is generally the case with as-synthesized aluminosilicate zeolites prepared from organic-containing reaction systems. It is possible, however, that some or all of the organic moiety is an occluded molecular species in a particular ZnAPSO species. As a general rule the templating agent, and hence the occluded organic species, is too large to move freely through the pore system of the ZnAPSO product and must be removed by calcining the ZnAPSO at temperatures of 200.degree. C. to 700.degree. C. to thermally degrade the organic species. In a few instances the pores of the ZnAPSO product are sufficiently large to permit transport of the templating agent, particularly if the latter is a small molecule, and accordingly complete or partial removal thereof can be accomplished by conventional desorption procedures such as carried out in the case of zeolites. It will be understood that the term "as-synthesized" as used herein does not include the condition of the ZnAPSO phase wherein the organic moiety occupying the intracrystalline pore system as a result of the hydrothermal crystallization process has been reduced by post-synthesis treatment such that the value of "m" in the composition formula
mR:(Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2
has a value of less than 0.02. The other symbols of the formula are as defined hereinabove. In those preparations in which an alkoxide is employed as the source of zinc, aluminum, phosphorus or silicon, the corresponding alcohol is necessarily present in the reaction mixture since it is a hydrolysis product of the alkoxide. It has not been determined whether this alcohol participates in the syntheses process as a templating agent. For the purposes of this application, however, this alcohol is arbitrarily omitted from the class of templating agents, even if it is present in the as-synthesized ZnAPSO material.
Since the present ZnAPSO compositions are formed from ZnO.sub.2, AlO.sub.2, PO.sub.2 and SiO.sub.2 tetrahedral units which, respectively, have a net charge of -2, -1, +1 and 0. The matter of cation exchangeability is considerably more complicated than in the case of zeolitic molecular sieves in which, ideally, there is a stoichiometric relationship between AlO.sub.2.sup.- tetrahedra and charge-balancing cations. In the instant compositions, an AlO.sub.2.sup.- tetrahedron can be balanced electrically either by association with a PO.sub.2.sup.+ tetrahedron or a simple cation such as an alkali metal cation, a proton (H.sup.+), a cation of zinc present in the reaction mixture, or an organic cation derived from the templating agent. Similarly an ZnO.sub.2.sup.-2 tetrahedron can be balanced electrically by association with PO.sub.2.sup.+ tetrahedra, a simple cation such as an alkali metal cation, a proton (H.sup.+), a cation of the zinc present in the reaction mixture, organic cations derived from the templating agent, or other divalent or polyvalent metal cations introduced from an extraneous source. It has also been postulated that non-adjacent AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral pairs can be balanced by Na.sup.+ and OH.sup.- respectively [Flanigen and Grose. Molecular Sieve Zeolites-I, ACS, Washington, D.C. (1971)]
The ZnAPSO compositions of the present invention exhibit cation-exchange capacity when analyzed using ion-exchange techniques heretofore employed with zeolitic aluminosilicates and have uniform pore diameters which are inherent in the lattice structure of each species and which are at least about 3 .ANG. in diameter. Ion exchange of ZnAPSO compositions is ordinarily possible only after the organic moiety present as a result of synthesis has been removed from the pore system. Dehydration to remove water present in the as-synthesized ZnAPSO compositions can usually be accomplished, to some degree at least, in the usual manner without removal of the organic moiety, but the absence of the organic species greatly facilitates adsorption and desorption procedures. The ZnAPSO materials have various degrees of hydrothermal and thermal stability, some being quite remarkable in this regard, and function well as molecular sieve adsorbents and hydrocarbon conversion catalysts or catalyst bases.
In each example a stainless steel reaction vessel was utilized and was lined with the inert plastic material, polytetrafluoroethylene, to avoid contamination of the reaction mixture. In general, the final reaction mixture from which each ZnAPSO composition is crystallized is prepared by forming mixtures of less than all of the reagents and thereafter incorporating into these mixtures additional reagents either singly or in the form of other intermediate mixtures of two or more reagents. In some instances the reagents admixed retain their identity in the intermediate mixture and in other cases some or all of the reagents are involved in chemical reactions to produce new reagents. The term "mixture" is applied in both cases. Further, unless otherwise specified, each intermediate mixture as well as the final reaction mixture was stirred until substantially homogeneous.
X-ray analysis of reaction products are obtained by X-ray analysis, using standard X-ray powder diffraction techniques. The radiation source is a high-intensity, copper target, X-ray tube operated at 50 Kv and 40 ma. The diffraction pattern from the copper K-alpha radiation and graphite monochromator is suitably recorded by an X-ray spectrometer scintillation counter, pulse height analyzer and strip chart recorder. Flat compressed powder samples are scanned at 2.degree. (2 theta) per minute, using a two second time constant. Interplanar spacings (d) in Angstrom units are obtained from the position of the diffraction peaks expressed as 2.theta. where .theta. is the Bragg angle as observed on the strip chart. Intensities are determined from the heights of diffraction peaks after subtracting background, "I.sub.o " being the intensity of the strongest line or peak, and "I" being the intensity of each of the other peaks. Alternatively, the X-ray patterns are obtained from the copper K-alpha radiation by use of computer based techniques using Siemens D-500 X-ray powder diffractometers, Siemens Type K-805 X-ray sources, available from Siemens Corporation, Cherry Hill, N.J., with appropriate computer interface.
As will be understood by those skilled in the art the determination of the parameter 2 theta is subject to both human and mechanical error, which in combination, can impose an uncertainty of about .+-.0.4.degree. on each reported value of 2 theta. This uncertainty is, of course, also manifested in the reported values of the d-spacings, which are calculated from the 2 theta values. This imprecision is general throughout the art and is not sufficient to preclude the differentiation of the present crystalline materials from each other and from the compositions of the prior art. In some of the X-ray patterns reported, the relative intensities of the d-spacings are indicated by the notations vs, s, m, w and vw which represent very strong, strong, medium, weak and very weak respectively.
In certain instances the purity of a synthesized product may be assessed with reference to its X-ray powder diffraction pattern. Thus, for example, if a sample is stated to be pure, it is intended only that the X-ray pattern of the sample is free of lines attributable to crystalline impurities, not that there are no amorphous materials present.
The molecular sieves of the instant invention may be characterized by their x-ray powder diffraction patterns and such may have one of the x-ray patterns set forth in the following Tables A through N, wherein said x-ray patterns are for both the as-synthesized and calcined forms unless otherwise noted:
TABLE A______________________________________(ZnAPSO-5)2.theta. d(.ANG.) Relative Intensity______________________________________7.2-7.4 12.28-11.91 vs19.4-19.8 4.58-4.48 m21.0-21.2 4.23-4.19 m22.3-22.5 3.971-3.952 m-s25.7-26.0 3.466-3.427 w-m______________________________________
TABLE B______________________________________(ZnAPSO-11)2.theta. d(.ANG.) Relative Intensity______________________________________9.35-9.45 9.44-9.35 m13.15-13.35 6.67-6.63 m 21.1-21.25 4.21-4.19 s-vs22.75-22.85 3.911-3.896 s-vs23.15-23.3 3.839-3.819 w-m26.8-26.9 3.327-3.313 w-m______________________________________
TABLE C______________________________________(ZnAPSO-20)2.theta. d(.ANG.) Relative Intensity______________________________________13.85-14.0 6.39-6.33 m19.65-19.8 4.52-4.48 m24.15-24.3 3.685-3.663 vs 28.0-28.15 3.187-3.170 w31.35-31.5 2.853-2.840 w 34.5-34.65 2.600-2.589 w-m______________________________________
TABLE D______________________________________(ZnAPSO-31)2.theta. d(.ANG.) Relative Intensity______________________________________8.4-8.5 10.53-10.40 m20.2-20.3 4.40-4.37 m21.3 4.171 w22.0 4.036 m22.5-22.6 3.952-3.934 vs 31.6-31.75 2.831-2.820 w-m______________________________________
TABLE E______________________________________(ZnAPSO-34)2.theta. d(.ANG.) Relative Intensity______________________________________9.4-9.8 9.41-9.03 m-vs12.7-13.2 6.97-6.71 w-m15.8-16.2 5.61-5.47 w-m20.5-20.9 4.33-4.25 m-vs25.0-25.3 3.562-3.520 vw-m30.5-30.9 2.931-2.894 w-m______________________________________
TABLE F______________________________________(ZnAPSO-35)2.theta. d(.ANG.) Relative Intensity______________________________________10.8-11.0 8.19-8.04 m-vs13.30-13.5 6.66-6.56 m-vs 17.2-17.45 5.16-5.08 m20.95-21.2 4.24-4.19 m 21.9-22.15 4.06-4.01 m-vs32.0-32.5 2.797-2.755 m______________________________________
TABLE G______________________________________(ZnAPSO-36)2.theta. d(.ANG.) Relative Intensity______________________________________7.45-8.0 11.14-11.04 vs16.45-16.5 5.38-5.36 w-m19.1-19.2 4.65-4.62 w-m20.8-20.9 4.28-4.25 w-m21.75-21.8 4.09-4.08 w22.05-22.15 4.027-4.017 w______________________________________
TABLE H______________________________________(ZnAPSO-39)2.theta. d(.ANG.) Relative Intensity______________________________________9.35-9.45 9.46-9.36 m13.15-13.35 6.73-6.63 m18.3-18.4 4.85-4.82 w-m21.1-21.2 4.21-4.19 s-vs22.75-22.85 3.909-3.892 s-vs26.8-26.9 3.389-3.314 w-m______________________________________
TABLE J______________________________________(ZnAPSO-43)2.theta. d(.ANG.) Relative Intensity______________________________________ 12.3-12.45 7.20-7.11 m-vs 16.8-16.95 5.28-5.23 vw-w 21.7-21.85 4.095-4.068 vw-m26.95-27.1 3.308-3.291 s-vs 32.4-32.55 2.763-2.751 w-m______________________________________
TABLE K______________________________________(ZnAPSO-44)2.theta. d(.ANG.) Relative Intensity______________________________________ 9.4-9.55 9.41-9.26 vs 12.9-13.05 6.86-6.78 vw-m20.65-20.8 4.30-4.27 m21.4-21.8 4.15-4.08 w-m 24.3-25.15 3.663-3.541 m30.75-30.95 2.908-2.889 m______________________________________
TABLE L______________________________________(ZnAPSO-46)2.theta. d(.ANG.) Relative Intensity______________________________________ 7.6-7.75 11.63-11.42 vs 13.1-13.35 6.76-6.63 w-m21.5-21.6 4.13-4.12 w-m 22.6-22.85 3.934-3.896 m26.75-27.0 3.333-3.302 w______________________________________
TABLE M______________________________________(ZnAPSO-47)2.theta. d(.ANG.) Relative Intensity______________________________________9.45-9.65 9.35-9.17 vs12.85-13.05 6.89-6.78 w-m15.95-16.2 5.55-5.46 w-m20.55-20.85 4.31-4.26 m-vs25.9-26.2 3.439-3.399 w-m30.55-31.0 2.925-2.885 w-m______________________________________
The following examples are provided to further illustrate the invention and are not intended to be limiting thereof:
PREPARATIVE REAGENTS
In the following examples the ZnAPSO compositions were prepared using numerous reagents. The reagents emplyed and abbreviations employed herein, if any, for such reagents are as follows:
(a) Alipro: aluminum isopropoxide;
(b) LUDOX-LS: LUDOX-LS is the trade name of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;
(c) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite.
(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;
(e) ZnAc: Zinc Acetate, Zn(C.sub.2 H.sub.3 O.sub.2).sub.2 .multidot.4H.sub.2 O;
(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;
(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;
(h) TMAOH: Tetramethylammonium hydroxide pentahydrate, (CH.sub.3).sub.4 NOH.multidot.5H.sub.2 O;
(i) TPAOH: 40 weight percent aqueous solution of tetrapropylammonium hydroxide, (C.sub.3 H.sub.7).sub.4 NOH;
(j) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;
(k) Pr.sub.3 N: Tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;
(l) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);
(m) C-hex: cyclohexylamine; and
(n) DEEA: diethylethanolamine, (C.sub.2 H.sub.5).sub.2 NC.sub.2 H.sub.5 OH.
PREPARATIVE PROCEDURE
The ZnAPSO compositions were prepared by preparing reaction mixtures having a molar composition expressed as:
eR:fZnO:gAl.sub.2 O.sub.3 :hP.sub.2 O.sub.5 :iSiO.sub.2 :jH.sub.2 O
wherein e, f, g, h, i and j represent the moles of template R, zinc (expressed as the oxide), Al.sub.2 O.sub.3, P.sub.2 O.sub.5 (H.sub.3 PO.sub.4 expressed as P.sub.2 O.sub.5), SiO.sub.2 and H.sub.2 O, respectively. The values for e, f, g, h, i and j were as set forth in the hereinafter discussed preparative examples where "j" was 50 in each example, and "e" was 1.0.
The reaction mixtures were prepared by forming a starting reaction mixture comprising the H.sub.3 PO.sub.4 and a portion of the water. This mixture was stirred and the aluminum source added. The resulting mixture was blended until a homogeneous mixture was observed. The LUDOX LS was then added to the resulting mixture and the new mixture blended until a homogeneous mixture was observed. The zinc source (zinc acetate) was dissolved in the remaining water and combined with the first mixture. The combined mixture was blended until a homogeneous mixture was observed. The organic templating agent was added to this mixture and blended for about two to four minutes until a homogeneous mixture was observed. The resulting mixture (final reaction mixture) was placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at an effective temperature for an effective time. All digestions were carried out at the autogeneous pressure. The products were removed from the reaction vessel cooled and evaluated as set forth hereinafter.
EXAMPLES 1 TO 41
ZnAPSO molecular sieves were prepared according to the above described procedure and the ZnAPSO products determined by x-ray analysis. The results of preparative examples 1 to 41 are set forth in Tables I and II. The reactive zinc source was zinc acetate. The reactive aluminum source was Al-ipro. The reactive phosphorus source was H.sub.3 PO.sub.4. the reactive silicon source was LUDOX-LS. The organic templating agents are set forth in Tables I and II.
TABLE I__________________________________________________________________________Example.sup.2 Template f g h i Temp (.degree.C.) Time (hrs) ZnAPSO Product(s).sup.1__________________________________________________________________________1 Pr.sub.3 N 0.1 1.0 1.0 0.6 150 42 ZnAPSO-36; ZnAPSO-52 Pr.sub.3 N 0.1 1.0 1.0 0.6 150 183 ZnAPSO-36; ZnAPSO-53 Pr.sub.3 N 0.1 1.0 1.0 0.6 200 42 ZnAPSO-5; ZnAPSO-364 Pr.sub.3 N 0.1 1.0 1.0 0.6 200 183 ZnAPSO-5; ZnAPSO-365 Pr.sub.3 N 0.2 0.9 0.9 0.2 150 48 ZnAPSO-5; ZnAPSO-366 TPAOH 0.2 0.9 0.7 0.6 200 165 ZnAPSO-5;7 TPAOH 0.2 0.9 0.7 0.6 200 165 ZnAPSO-58 Pr.sub.2 N 0.1 1.0 1.0 0.6 150 42 ZnAPSO-46; ZnAPSO-39; ZnAPSO-119 Pr.sub.2 NH 0.1 1.0 1.0 0.6 150 183 ZnAPSO-39; ZnAPSO-11; ZnAPSO-4610 Pr.sub.2 NH 0.1 1.0 1.0 0.6 200 42 ZnAPSO-11; ZnAPSO-46; ZnAPSO-3911 Pr.sub.2 NH 0.1 1.0 1.0 0.6 200 183 ZnAPSO-11; ZNAPSO-39; ZnAPSO-4612 Pr.sub.2 NH 0.2 0.9 0.7 0.6 150 41 ZnAPSO-46; ZnAPSO-31;13 Pr.sub.2 NH 0.2 0.9 0.7 0.6 150 145 ZnAPSO-31; ZnAPSO-4614 Pr.sub.2 NH 0.2 0.9 0.7 0.6 200 41 ZnAPSO-3115 Pr.sub.2 NH 0.2 0.9 0.7 0.6 200 145 ZnAPSO-31__________________________________________________________________________ .sup.1 Major species as identified by xray powder diffraction pattern of product, except that when two or more species were identified the species are listed in the order of their predominance in the product. .sup.2 AlPO.sub.431 (U.S. Pat. No. 4,310,440) seed employed in examples 1 to 15.
TABLE II__________________________________________________________________________Example Template f g h i Temp (.degree.C.) Time (hrs) ZnAPSO Product(s).sup.1__________________________________________________________________________16 TEAOH 0.1 1.0 1.0 0.6 100 134 ZnAPSO-3417 TEAOH 0.1 1.0 1.0 0.6 100 251 ZnAPSO-3418 TEAOH 0.1 1.0 1.0 0.6 150 134 ZnAPSO-5; ZNAPSO-3419 TEAOH 0.1 1.0 1.0 0.6 150 251 ZnAPSO-34; ZnAPSO-520 TEAOH 0.1 1.0 1.0 0.6 200 134 ZnAPSO-5; ZnAPSO-3421 TEAOH 0.1 1.0 1.0 0.6 200 251 ZnAPSO-34; ZnAPSO-522 TEAOH 0.1 0.95 0.7 0.6 100 17 ZnAPSO-3423 TEAOH 0.1 0.95 0.7 0.6 100 66 ZnAPSO-3424 TEAOH 0.1 0.95 0.7 0.6 100 166 ZnAPSO-3425 TEAOH 0.1 0.95 0.7 0.6 100 66 ZnAPSO-3426 TMAOH 0.2 0.9 0.7 0.6 150 46 ZnAPSO-20; ZnAPSO-4327 TMAOH 0.2 0.9 0.7 0.6 150 165 ZnAPSO-20; ZnAPSO-4328 TMAOH 0.2 0.9 0.7 0.6 200 46 ZnAPSO-20; ZnAPSO-4329 TMAOH 0.2 0.9 0.7 0.6 200 165 ZnAPSO-20; ZnAPSO-4330 QUIN 0.2 0.9 0.7 0.6 150 40 ZnAPSO-3531 Quin 0.2 0.9 0.7 0.6 150 158 ZnAPSO-3532 Quin 0.2 0.9 0.7 0.6 200 40 ZnAPSO-3533 Quin 0.2 0.9 0.7 0.6 200 158 ZnAPSO-3534 C-hex 0.2 0.9 0.7 0.6 150 40 ZnAPSO-4435 C-hex 0.2 0.9 0.7 0.6 150 158 ZnAPSO-4436 C-hex 0.2 0.9 0.7 0.6 200 40 ZnAPSO-44; ZnAPSO-537 C-hex 0.2 0.9 0.7 0.6 200 158 ZnAPSO-44; ZnAPSO-538 DEEA 0.2 0.9 0.7 0.6 150 40 ZnAPSO-47; ZnAPSO-539 DEEA 0.2 0.9 0.7 0.6 150 158 ZnAPSO-47; ZnAPSO-540 DEEA 0.2 0.9 0.7 0.6 200 40 ZnAPSO-47; ZnAPSO-541 DEEA 0.2 0.9 0.7 0.6 200 158 ZnAPSO-47__________________________________________________________________________ .sup.1 Major species as identified by xray powder diffraction pattern of product, except that when two or more species were identified the species are listed in the order of their predominance in the product.
EXAMPLE 42
Samples of the products of examples 4, 17, 24, 33, 35 and 39 were subjected to chemical analysis. The chemical analysis for each product is given hereinafter with the example in which the ZnAPSO was prepared being given in parenthesis after the designation of the ZnAPSO species.
(a) The chemical analysis for ZnAPSO-5 (Example 4) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 31.3P.sub.2 O.sub.5 45.7ZnO 2.8SiO.sub.2 5.7Carbon 5.5LOI* 12.8______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios (anhydrous basis) of: 0.17 R; 0.11 ZnO; 1.0 Al.sub.2 O.sub.3 ; 1.05 P.sub.2 O.sub.5 ; 0.31 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.04 R (Zn.sub.0.03 Al.sub.0.44 O.sub.0.47 Si.sub.0.07)O.sub.2
(b) The chemical analysis for ZnAPSO-34 (Example 17) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 32.3P.sub.2 O.sub.5 35.3ZnO 2.8SiO.sub.2 1.6Carbon 5.0LOI* 26.7______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios (anhydrous basis) of: 0.16 R; 0.11 ZnO; 1.0 Al.sub.2 O.sub.3 ; 0.79 P.sub.2 O.sub.5 : 0.08 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.04 R (Zn.sub.0.03 Al.sub.0.54 P.sub.0.41 Si.sub.0.02)O.sub.2
(c) The chemical analysis for ZnAPSO-34 (Example 24) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 36.2P.sub.2 O.sub.5 30.3ZnO 3.8SiO.sub.2 3.7Carbon 5.2LOI* 24.0______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios of 0.15 R; 0.13 ZnO; 1.0 Al.sub.2 O.sub.3 ; 0.60 P.sub.2 O.sub.5 : 0.07 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.04 R (Zn.sub.0.04 Al.sub.0.57 P.sub.0.34 Si.sub.0.05)O.sub.2
(d) The chemical analysis of ZnAPSO-35 (Example 33) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 30.4P.sub.2 O.sub.5 33.2ZnO 5.6SiO.sub.2 7.6Carbon 10.1LOI* 22.1______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios of: 0.40 R; 0.23 ZnO; 1.0 Al.sub.2 O.sub.3 ; 0.78 P.sub.2 O.sub.5 ; 0.42 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.12 R (Zn.sub.0.06 Al.sub.0.47 P.sub.0.37 Si.sub.0.10)O.sub.2
(e) The chemical analysis for ZnAPSO-44 (Example 35) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 27.5P.sub.2 O.sub.5 31.1ZnO 4.8SiO.sub.2 10.6Carbon 11.7LOI* 25.1______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios of: 0.60 R; 0.22 ZnO; 1.0 Al.sub.2 O.sub.3 ; 0.81 P.sub.2 O.sub.5 ; 0.65 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.13 R (Zn.sub.0.05 Al.sub.0.44 P.sub.0.36 Si.sub.0.15)O.sub.2
(f) The chemical analysis of ZnAPSO-47 (Example 39) was:
______________________________________Component Weight Percent______________________________________Al.sub.2 O.sub.3 30.4P.sub.2 O.sub.5 32.6ZnO 5.3SiO.sub.2 6.5Carbon 7.7LOI* 23.4______________________________________ *LOI = Loss on Ignition
The above chemical analysis gives an overall product composition in molar oxide ratios of: 0.35 R; 0.22 ZnO; 1.0 Al.sub.2 O.sub.3 ; 0.77 P.sub.2 O.sub.5 ; 0.36 SiO.sub.2 ; and a formula (anhydrous basis) of:
0.09 R (Zn.sub.0.05 Al.sub.0.49 P.sub.0.37 Si.sub.0.09)O.sub.2
EXAMPLE 43
EDAX (energy dispersive analysis by x-ray) microprobe analysis in conjunction with SEM (scanning electron microscope was carried out on clear crystals from the products of examples 4, 24, 33, 35 and 39. Analysis of crystals having a morphology characteristic of the ZnAPSO products gave the following analysis based on relative peak heights:
______________________________________ Average of Spot Probes______________________________________(a) ZnAPSO-5 (Example 4):Zn 1Al 44P 50Si 5(b) ZnAPSO-34 (Example 24):Zn 3Al 45P 46Si 6(c) ZnAPSO-35 (Example 33):Zn 5Al 43P 46Si 6(d) ZnAPSO-36 (Example 4):Zn 4Al 42P 50Si 4(e) ZnAPSO-44 (Example 35):Zn 2Al 43P 39Si 16(f) ZnAPSO-47 (Example 39):Zn 5Al 42P 44Si 9______________________________________
EXAMPLE 44
Samples of the ZnAPSO products of examples 4, 27, 33, 35 and 39 were for adsorption capacities evaluated in the as-synthesized form or were calcined in air or nitrogen, to remove at least part of the organic templating agent, as hereinafter set forth. The adsorption capacities of each calcined sample were measured using a standard McBain - Bakr gravimetric adsorption apparatus. The samples were activated in a vacuum at 350.degree. C. prior to measurment. The McBain-Bakr data for the aformentioned calcing ZnAPSO products were:
______________________________________(a) ZnAPSO-5 (Example 4): Kinetic Pressure Temp Wt. %Adsorbate Diameter, .ANG. (Torr) (.degree.C.) Adsorbed*______________________________________O.sub.2 3.46 99 -183 11.0O.sub.2 3.46 749 -183 14.9neopentane 6.2 100 23.4 3.5cyclohexane 6.0 57 23.4 7.4H.sub.2 O 2.65 4.6 23.2 13.5H.sub.2 O 2.65 16.8 23.5 17.5______________________________________ *calcined in air at 500.degree. C. for 0.75 hours and at 600.degree. C. for 1.25 hours prior to activation.
The above data demonstrate that the pore size of the calcined product is greater than 6.2.ANG..
______________________________________(b) ZnAPSO-34 (Example 27): Kinetic Pressure Temp Wt. %Adsorbate Diameter, .ANG. (Torr) (.degree.C.) Adsorbed*______________________________________O.sub.2 3.46 99 -183 14.5O.sub.2 3.46 725 -183 25.8isobutane 5.0 100 22.8 0.8n-hexane 4.3 98 23.3 13.3H.sub.2 O 2.65 4.6 23.1 19.9H.sub.2 O 2.65 17.8 23.1 30.1______________________________________ *calcined in air at 500.degree. C. for 2 hours prior to activation
The above data demonstrate that the pore size of the calcined product is about 4.3.ANG..
______________________________________(c) ZnAPSO-35 (Example 33): Kinetic Pressure Temp Wt. %Adsorbate Diameter, .ANG. (Torr) (.degree.C.) Adsorbed*______________________________________O.sub.2 3.46 99 -183 10.2O.sub.2 3.46 725 -183 19.1n-hexane 4.3 98 23.3 8.6isobutane 5.0 100 22.8 0.8H.sub.2 O 2.65 4.6 23.1 17.2H.sub.2 O 2.65 17.8 23.1 26.3______________________________________ *calcined in air at 500.degree. C. for 1.75 hours prior to activation
The above data demonstrate that the pore size of the calcined product is about 4.3.ANG..
______________________________________(d) ZnAPSO-44 (Example 35): Kinetic Pressure Temp Wt. %Adsorbate Diameter, .ANG. (Torr) (.degree.C.) Adsorbed*______________________________________O.sub.2 3.46 99 -183 10.3O.sub.2 3.46 745 -183 19.8n-hexane 4.3 98 23.3 9.7isobutane 5.0 100 22.8 0.8H.sub.2 O 2.65 4.6 23.1 14.0H.sub.2 O 2.65 17.8 23.1 24.0______________________________________ *calcined in air at 500.degree. C. for 67 hours prior to activation
The above data demonstrate that the pore size of the calcined product is about 4.3.ANG..
______________________________________ (e) ZnAPSO-47 (Example 39): Kinetic Pressure Temp Wt. %Adsorbate Diameter, .ANG. (Torr) (.degree.C.) Adsorbed*______________________________________O.sub.2 3.46 99 -183 13.9O.sub.2 3.46 725 -183 23.0isobutane 5.0 100 23.8 0.7n-hexane 4.3 98 23.3 7.8H.sub.2 O 2.65 4.6 23.1 18.8H.sub.2 O 2.65 17.8 23.1 27.0______________________________________ *calcined in air at 500.degree. C. for 1.75 hours prior to activation
The above data demonstrate that the pore size of the calcined product is about 4.3.ANG..
EXAMPLE 45
(a) ZnAPSO-5, as prepared in example 4, was subjected to x-ray analysis. ZnAPSO-5 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.4 11.91 1007.9** 11.17 2912.85 6.88 1013.5* 6.56 114.85 5.96 1915.85** 5.60 316.45** 5.39 819.1** 4.65 919.7 4.51 3820.3** 4.38 420.8** 4.27 1021.05 4.22 3021.5** 4.14 521.65** 4.10 522.4 3.973 7322.95* 3.876 323.85** 3.730 124.75 3.596 225.9 3.442 2527.2** 3.279 427.75** 3.212 128.3** 3.154 229.0 3.078 1529.95 2.981 1530.35** 2.947 232.0** 2.798 333.6 2.666 434.45 2.602 1234.8** 2.577 435.45** 2.532 235.9 2.501 l36.95 2.434 337.7 2.386 741.45* 2.177 242.2 2.141 342.8 2.112 l43.4 2.085 145.0 2.013 147.6 1.910 451.4 1.778 251.95 1.760 155.6* 1.654 2______________________________________ *peak may contain impurity **impurity peak
(b) A portion of the as-synthesized ZnAPSO-5 of part (a) was calcined in air at 500.degree. C. for about 0.75 hours and then in air at 600.degree. C. for about 1.5 hours. The calcined product was characterized by the x-ray powder diffraction pattern below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.45 11.91 1007.85* 11.23 218.2* 10.79 712.9 6.87 2013.45* 6.57 314.9 5.95 616.5* 5.37 519.35* 4.58 519.75 4.49 2420.3 4.38 1020.7 4.29 421.1 4.21 2821.4 4.14 1122.4 3.962 6922.75* 3.907 524.85 3.584 226.0 3.430 2427.25* 3.275 427.45* 3.252 227.8* 3.207 228.15* 3.168 328.35* 3.146 229.1 3.068 1630.1 2.970 1433.7 2.658 334.6 2.592 1335.45* 2.532 437.05 2.427 337.85 2.378 642.4 2.132 247.8 1.903 251.5 1.774 355.8 1.647 1______________________________________ *Impurity Peak (c) The ZnAPSO-5 compositions are generally characterized by the data of Table III below.
TABLE III______________________________________2.theta. d (.ANG.) Relative Intensity______________________________________7.2-7.4 12.28-11.91 vs19.4-19.8 4.58-4.48 m21.0-21.2 4.23-4.19 m22.3-22.5 3.971-3.952 m-s25.7-26.0 3.466-3.427 w-m______________________________________
(d) The ZnAPSO-5 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table IV, below.
TABLE IV______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.2-7.4 12.28-11.91 10012.61-13.0 7.03-6.81 8-2114.6-14.9 6.07-5.95 9-2019.4-19.8 4.58-4.48 24-3821.0-21.2 4.23-4.19 20-3522.3-22.5 3.971-3.952 47-8224.7-24.9 3.604-3.576 1-225.7-26.0 3.466-3.427 18-2728.9-29.1 3.089-3.069 10-2029.9-30.1 2.988-2.969 12-1733.6-33.8 2.667-2.652 3-434.4-34.6 2.607-2.592 10-1436.9-37.0 2.436-2.430 2-337.6-37.9 2.392-2.374 5-841.45 2.177 0-242.2-42.4 2.141-2.132 2-342.8 2.113 0-143.4 2.090 0-145.0 2.014 0-147.5-47.8 1.914-1.903 2-451.3-51.6 1.781 2-351.95 1.760 0-155.5-55.8 1.656-1.647 0-2______________________________________
EXAMPLE 46
(a) ZnAPSO-11, as prepared in example 10 was subjected to x-ray analysis. ZnAPSO-11 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________6.6** 13.44 107.7** 11.46 978.1 10.89 268.45** 10.44 69.45* 9.35 6013.3* 6.66 2213.8** 6.43 414.9** 5.94 515.3** 5.80 815.7 5.64 2416.2 5.47 316.65** 5.33 718.35** 4.83 1619.0 4.66 419.8** 4.49 420.45* 4.35 2921.1* 4.20 10021.55** 4.123 2422.2* 4.008 3222.75 3.905 8523.2 3.830 4524.2** 3.674 524.45** 3.643 324.8 3.590 526.55 3.355 1426.8* 3.327 1227.8** 3.212 428.7* 3.109 2029.05* 3.075 529.8* 3.000 1130.15* 2.966 1130.75** 2.909 331.1** 2.874 531.6 2.832 632.85* 2.725 1134.3* 2.615 734.5** 2.598 535.9* 2.501 636.55* 2.459 537.85* 2.377 1039.7* 2.270 143.0* 2.103 444.85 2.022 348.85* 1.864 350.8 1.797 154.8 1.675 1______________________________________ *Peak may contain impurity **Impurity Peak
(b) The ZnAPSO-11 compositions are generally characterized by the data of Table V below.
TABLE V______________________________________2.theta. d (.ANG.) Relative Intensity______________________________________9.35-9.45 9.44-9.35 m13.15-13.35 6.67-6.63 m 21.1-21.25 4.21-4.19 s-vs22.75-22.85 3.911-3.896 s-vs23.15-23.3 3.839-3.819 w-m26.8-26.9 3.327-3.313 w-m______________________________________
(c) The ZnAPSO-11 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table VI, below:
TABLE VI______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________8.05-8.1 10.98-10.92 8-269.35-9.45 9.44-9.35 54-7213.15-13.35 6.67-6.63 22-4015.65-15.75 5.66-5.62 10-2716.05-16.2 5.53-5.47 0-319.0 4.66 0-419.85 4.49-4.46 4-1420.4-20.5 4.35-4.33 19-38 21.1-21.25 4.21-4.19 83-100 22.1-22.25 4.018-3.998 12-3222.75-22.85 3.911-3.896 85-10023.15-23.3 3.839-3.819 12-4526.45-26.55 3.369-3.354 8-1426.8-26.9 3.327-3.313 12-4028.7-28.8 3.111-3.100 20-3629.75-29.85 3.005-2.993 11-2331.6-31.8 2.832-2.813 0-10 32.8-32.95 2.731-2.719 7-1534.2-34.3 2.620-2.615 6-935.85-36.0 2.503-2.495 6-1236.45-36.55 2.464-2.459 4-837.65-37.7 2.389-2.387 0-737.85 2.377 0-1039.7 2.271 0-1 43.0-43.05 2.103-2.100 0-444.85-44.9 2.022-2.018 0-348.75-48.85 1.867-1.864 0-350.8-50.9 1.797- 1.794 0-354.8 1.675 0-1______________________________________
EXAMPLE 47
(a) ZnAPSO-20, as prepared in example 29, was subjected to x-ray analysis. ZnAPSO-20 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________12.35* 7.17 613.9 6.37 4714.35* 6.16 214.5* 6.10 114.65* 6.04 114.85* 5.96 119.75 4.50 4020.8* 4.27 121.05* 4.22 121.7* 4.09 322.1 4.024 224.25 3.672 10024.85* 3.582 127.0* 3.302 528.05 3.181 1228.65* 3.116 131.45 2.845 1232.45* 2.758 134.55 2.596 2037.45 2.402 238.4* 2.248 140.1 2.344 442.65 2.121 445.13* 2.009 147.4 1.917 549.35* 1.846 151.8 1.765 9______________________________________ *Impurity peak
(b) The ZnAPSO-20 compositions are generally characterized by the data of Table VII below:
TABLE VII______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________13.85-14.0 6.39-6.33 m19.65-19.8 4.52-4.48 m24.15-24.3 3.685-3.663 vs 28.0-28.15 3.187-3.170 w31.25-31.5 2.853-2.840 w 34.5-34.65 2.600-2.589 w-m______________________________________
(c) The ZnAPSO-20 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table VIII, below:
TABLE VIII______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________13.85-14.0 6.39-6.33 45-4719.65-19.8 4.52-4.48 40-41 22.0-22.15 4.040-4.013 2-324.15-24.3 3.685-3.663 100 28.0-28.15 3.187-3.170 12-1331.35-31.5 2.853-2.840 11-12 34.5-34.65 2.600-2.589 16-2037.35-37.5 2.408-2.398 2 40.0-40.2 2.254-2.243 442.55-42.7 2.125-2.118 447.35-47.5 1.920-1.914 551.75-51.9 1.767-1.762 8-9______________________________________
EXAMPLE 48
(a) ZnAPSO-31, as prepared in example 14, was subjected to x-ray analysis. ZnAPSO-31 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________6.6** 13.40 147.7** 11.45 108.1** 10.94 118.5 10.40 509.5* 9.32 89.85* 8.96 212.45** 7.12 2513.4 6.60 1017.05 5.21 517.4** 5.10 318.25 4.86 820.3 4.38 5221.3* 4.17 1621.6** 4.11 1022.0 4.036 3022.6 3.394 10023.55* 3.779 224.25** 3.668 325.15* 3.543 427.0** 3.302 327.75* 3.213 1227.95 3.192 1328.2* 3.162 428.7** 3.109 329.75 3.004 1030.3 2.950 431.75 2.810 2032.95 2.718 434.2** 2.623 335.15 2.554 1235.7* 2.515 335.9* 2.500 336.2 2.481 437.25* 2.413 337.65* 2.390 238.25 2.353 339.3 2.291 240.3 2.238 245.0* 2.014 246.6 1.949 447.4** 1.918 248.6 1.873 251.5 1.774 7______________________________________ *peak may contain impurity **impurity peak
(b) The ZnAPSO-31 compositions are generally characterized by the data of Table IX below:
TABLE IX______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________8.4-8.5 10.35-10.40 m20.2-20.3 4.40-4.37 m21.3 4.171 w22.0 4.036 m22.5-22.6 3.952-3.934 vs 31.6-31.75 2.831-2.820 w-m______________________________________
(c) The ZnAPSO-31 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table X, below:
TABLE X______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________8.4-8.5 10.53-10.40 50-539.45-9.5 9.35-9.32 7-813.2-13.4 6.76-6.60 10-11 18.2-18.25 4.87-4.86 5-820.2-20.3 4.39-4.37 49-5221.3 4.171 16-1822.0 4.036 3022.5-22.6 3.952-3.934 10026.9-27.0 3.314-3.302 3-727.95-28.25 3.192-3.529 13-1729.6-29.7 3.018-3.008 8-1030.2-30.3 2.959-2.950 0-4 31.6-31.75 2.831-2.820 18-2032.95 2.718 4-935.15-35.2 2.554-2.550 1236.1-36.2 2.489-2.481 4-737.25-37.35 2.413-2.409 2-338.25 2.353 339.3 2.291 240.3 2.238 2 46.6-46.65 1.949-1.948 4-6 47.4-47.45 1.918-1.916 2-451.5 1.774 7______________________________________
EXAMPLE 49
(a) ZnAPSO-34, as prepared in example 24, was subjected to x-ray analysis. ZnAPSO-34 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
TABLE XIII______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.6 9.19 10012.95 6.84 1614.2 6.25 1416.1 5.50 4218.1 4.90 2220.65 4.30 9122.4 3.978 523.15 3.842 525.3 3.521 2525.9 3.437 1827.7 3.218 528.45 3.135 629.65 3.015 530.6 2.920 3331.3 2.856 2332.5 2.755 234.45 2.602 736.4 2.468 538.8 2.320 439.75 2.267 543.15 2.097 443.55* 2.077 447.65 1.908 549.10 1.856 849.9 1.827 451.0 1.791 453.15 1.723 354.65 1.679 355.9 1.645 3______________________________________ *impurity peak
(b) A portion of the as-synthesized ZnAPSO-34 of part (a) was calcined in air at 500.degree. C. for about 2 hours. The calcined product was characterized by the x-ray powder diffraction pattern below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.55 9.27 10012.95 6.85 2416.15 5.49 1317.95 4.94 1020.75 4.28 3022.2 4.004 223.25 3.828 525.2 3.533 926.15 3.411 1228.45 3.138 430.9 2.896 1631.35 2.852 9______________________________________
(c) The ZnAPSO-34 compositions are generally characterized by the data of Table XI below.
TABLE XI______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________9.4-9.8 9.41-9.03 m-vs12.7-13.2 6.97-6.71 w-m15.8-16.2 5.61-5.47 w-m20.5-20.9 4.33-4.25 m-vs25.0-25.3 3.562-3.520 vw-m30.5-30.9 2.931-2.894 w-m______________________________________
(d) The ZnAPSO-34 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XII, below:
TABLE XII______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.4-9.8 9.41-9.03 77-10012.7-13.2 6.97-6.71 16-3114.0-14.3 6.33-6.19 0-2215.8-16.2 5.61-5.47 16-4717.8-18.2 4.98-4.87 13-2920.5-20.9 4.33-4.25 36-10022.2-22.5 4.004-3.952 5.823.0-23.3 3.867-3.818 5-625.0-25.3 3.562-3.520 9-32 25.7-26.25 3.466-3.395 12-2027.45-27.7 3.249-3.220 5-8 28.1-28.45 3.175-3.137 4-829.4-29.8 3.038-2.998 0-530.5-30.9 2.931-2.894 16-35 31.0-31.65 2.885-2.827 9-2532.2-32.5 2.780-2.755 0-234.3-34.8 2.614-2.578 5-836.1-36.4 2.488-2.468 0-538.65-38.8 2.330-2.321 0-439.5-39.8 2.281-2.265 4-743.0-43.4 2.103-2.085 447.5-48.0 1.914-1.895 3-648.8-49.1 1.866-1.855 8-1049.9 1.859 0-450.8-51.0 1.797-1.791 0-4 53.1-53.15 1.725-1.723 0-354.5-54.8 1.684-1.675 0-355.8-55.9 1.647- 1.645 0-4______________________________________
EXAMPLE 50
(a) ZnAPSO-35, as prepared in example 33, was subjected to x-ray analysis. ZnAPSO-35 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________8.6 10.27 2010.5* 8.44 sh10.95 8.08 4711.35 7.80 413.30 6.66 3915.9 5.57 1017.3 5.13 7217.8 4.98 sh21.15 4.20 4821.9 4.06 10023.15 3.841 1923.65 3.762 325.05 3.552 426.8 3.325 2228.7 3.107 3029.1 3.069 sh32.1 2.788 4334.75 2.582 935.5 2.530 335.8 2.507 537.75 2.382 539.35 2.889 442.35 2.134 643.15 2.096 448.6 1.873 1149.4 1.845 851.55 1.773 655.3 1.661 6______________________________________ *impurity peak
(b) A portion of the as-synthesized ZnAPSO-35 of part (a) was calcined in air at 500.degree. C. for about 1.75 hours. The calcined product was characterized by the x-ray powder diffraction pattern below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.45* 11.85 108.7 10.15 2211.0 8.04 9113.5 6.55 10017.45 5.08 3521.0 4.23 2122.15 4.011 6023.5 3.782 1925.15 3.542 1327.2 3.278 2028.6 3.122 2829.35 3.041 1432.45 2.759 28______________________________________ *impurity peak
(c) The ZnAPSO-35 compositions obtained to date have patterns which are generally characterized by the data of Table XIII below.
TABLE XIII______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________10.8-11.0 8.19-8.04 m-vs13.30-13.5 6.66-6.56 m-vs 17.2-17.45 5.16-5.08 m20.95-21.2 4.24-4.19 m 21.9-22.15 4.06-4.01 m-vs32.0-32.5 2.797-2.755 m______________________________________
(d) The ZnAPSO-35 composition for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XIV below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________8.6-8.7 10.27-10.16 18-2210.8-11.0 8.19-8.04 43-9111.35 7.80 0-413.30-13.5 6.66-6.56 39-10015.8-15.9 5.61-5.57 0-10 17.2-17.45 5.16-5.08 35-7517.8-17.9 4.98-4.96 0-sh20.95-21.2 4.24-4.19 21-49 21.9-22.15 4.06-4.01 60-10023.0-23.5 3.867-3.786 0-1923.65 3.762 0-324.85-25.15 3.583-3.541 4-1326.6-27.2 3.351-3.278 20-2228.5-28.8 3.132-3.100 26-30 29.1-29.35 3.069-3.043 sh-1432.0-32.5 2.797-2.755 28-4334.55-34.9 2.596-2.571 0-935.7-35.8 2.515-2.507 0-537.75 2.382 0-539.35 2.889 0-4 42.1-42.35 2.146-2.134 0-643.0-43.2 2.103-2.094 0-448.5-48.7 1.877-1.870 0-1149.35-49.4 1.847-1.845 0-851.4-51.6 1.778-1.771 0-755.3-55.4 1.661-1.658 0-6______________________________________
EXAMPLE 51
(a) ZnAPSO-36, as prepared in example 1, was subjected to x-ray analysis. ZnAPSO-36 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.45** 11.85 767.95 11.13 1008.2 10.76 sh12.9** 6.87 313.6 6.52 414.9** 5.95 1015.9 5.58 1016.45 5.38 2519.1 4.64 1619.75** 4.50 1520.8* 4.27 3221.05** 4.22 sh21.75 4.09 1422.1 4.025 1422.4* 3.966 2423.0 3.863 323.95 3.716 525.9** 3.440 927.3 3.269 1128.35 3.147 729.05* 3.074 930.0** 2.978 830.35 2.944 432.0 2.796 833.2 2.698 l33.65** 2.663 l34.5** 2.599 634.8 2.575 735.9 2.500 237.75 2.383 240.3 2.237 241.45 2.178 242.2 2.142 147.6* 1.910 251.35 1.779 254.0 1.697 155.65 1.652 2______________________________________ *peak may contain impurity **impurity peak
(b) The ZnAPSO-36 compositions obtained to date have patterns which are generally characterized by the data of Table XV below.
TABLE XV______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________7.45-8.0 11.14-11.04 vs16.45-16.5 5.38-5.36 w-m19.1-19.2 4.65-4.62 w-m20.8-20.9 4.28-4.25 w-m21.75-21.8 4.09-4.08 w22.05-22.15 4.027-4.017 w______________________________________
(c) The ZnAPSO-36 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XVI below:
TABLE XVI______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.45-8.0 11.14-11.04 1008.2-8.3 10.76-10.68 0-sh13.55-13.6 6.53-6.50 3-415.85-15.95 5.60-5.56 10-1216.45-16.5 5.38-5.36 18-3119.1-19.2 4.65-4.62 19-2220.8-20.9 4.28-4.25 17-3921.75-21.8 4.09-4.08 10-1722.05-22.15 4.027-4.017 14-17 23.0-23.05 3.865-3.859 3-423.85-24.0 3.728-3.707 3-627.25-27.35 3.273-3.260 9-1528.3-28.4 3.152-3.142 6-930.1-30.4 2.970-2.940 4-631.95-32.1 2.803-2.788 6-1133.2-33.6 2.698-2.665 1-234.75-34.9 2.580-2.572 7-1035.85-35.95 2.504-2.497 2-637.75-37.8 2.384-2.380 240.15-40.4 2.246-2.232 1-341.45-41.5 2.180-2.176 1-242.2-42.3 2.142-2.137 0-2 51.4-51.45 1.779-1.776 254.0 1.697 0-155.4-55.8 1.658-1.648 1-2______________________________________
EXAMPLE 52
(a) ZnAPSO-39, as referred to in example 9, was subjected to x-ray analysis. ZnAPSO-39 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________6.5** 13.59 177.65** 11.56 1738.05** 10.99 128.35** 10.58 49.35* 9.44 7213.25* 6.67 3513.7** 6.46 814.9** 5.95 815.2** 5.82 1215.65** 5.66 1216.6** 5.34 1318.3 4.85 3619.8** 4.48 420.4** 4.35 1921.1* 4.21 8321.5** 4.13 3622.1** 4.018 1222.75* 3.911 10023.15** 3.839 1923.95** 3.716 424.2** 3.681 924.8** 3.593 326.45** 3.369 826.8* 3.324 2127.75** 3.215 628.2** 3.162 528.7* 3.111 1929.7* 3.005 1530.1* 2.970 2230.6** 2.922 431.05** 2.881 732.8* 2.731 834.3* 2.615 634.55** 2.597 1035.9** 2.502 836.45* 2.464 438.05* 2.365 540.7* 2.217 4______________________________________ *peak may contain impurity **impurity peak
(b) The ZnAPSO-39 compositions are generally characterized by the data of Table XVII below.
TABLE XVII______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________9.35-9.45 9.46-9.36 m13.15-13.35 6.73-6.63 m18.3-18.4 4.85-4.82 w-m21.1-21.2 4.21-4.19 s-vs22.75-22.85 3.909-3.892 s-vs26.8-26.9 3.389-3.314 w-m______________________________________
(c) The ZnAPSO-39 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XVIII below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.35-9.45 9.46-9.36 60-7213.15-13.35 6.73-6.63 22-4018.3-18.4 4.85-4.82 16-4021.1-21.2 4.21-4.19 83-10022.75-22.85 3.909-3.892 85-10026.8-26.9 3.389-3.314 12-4028.2-28.3 3.164-3.153 5-828.7-28.8 3.110-3.100 19-2029.7-29.8 3.008-2.998 11-3230.1-30.2 2.979-2.959 11-2532.8-32.95 2.730-2.718 8-1234.5-34.65 2.600-2.589 5-636.45-36.5 2.465-2.462 4-1237.85-38.1 2.377-2.362 3-1040.6-40.95 2.222-2.204 0-4______________________________________
EXAMPLE 53
(a) ZnAPSO-43, as referred to in example 28, was subjected to x-ray analysis. ZnAPSO-43 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________12.45 7.11 7614.0* 6.32 19416.95 5.24 819.8* 4.48 16020.95 4.24 1321.15* 4.20 1321.85 4.07 4822.15* 4.010 824.3* 3.659 40027.1 3.291 10028.15* 3.171 5228.75 3.104 431.55* 2.837 4932.55 2.751 2032.75* 2.733 934.25* 2.620 834.65* 2.590 6837.5* 2.399 838.5* 2.340 640.2* 2.244 1641.2 2.190 442.7* 2.117 1645.1 2.010 847.5* 1.914 1849.45* 1.843 751.15 1.787 751.9* 1.761 3653.8 1.704 7______________________________________ *Impurity peak
(b) ZnAPSO-43 compositions are generally characterized by the data of Table XIX below:
TABLE XIX______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________12.3-12.45 7.20-7.11 m-vs16.8-16.95 5.28-5.23 vw-w21.7-21.85 4.095-4.068 vw-m26.95-27.1 3.308-3.291 s-vs32.4-32.55 2.763-2.751 w-m______________________________________
(c) The ZnAPSO-43 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XX below:
TABLE XX______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________12.3-12.45 7.20-7.11 66-10016.8-16.95 5.28-5.23 0-1020.8-20.95 4.27-4.24 10-1321.7-21.85 4.095-4.068 0-4826.95-27.1 3.308-3.290 82-10028.65-28.75 3.116-3.105 11-2332.4-32.55 2.763-2.751 18-2041.2 2.191 0-444.95-45.1 2.017-2.010 8-1550.95-51.15 1.792-1.786 0-753.7-53.8 1.710-1.707 0-8______________________________________
EXAMPLE 54
(a) ZnAPSO-44 as prepared in example 34, was subjected to x-ray analysis. ZnAPSO-44 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________4.95* 17.93 118.75* 10.09 sh9.25* 9.56 sh9.55 9.25 10013.05 6.77 1313.8 6.41 316.15 5.49 2117.4 5.10 319.05 4.65 719.6* 4.53 220.8 4.27 4621.8 4.08 1822.65 3.923 423.15 3.845 524.45 3.638 4726.25 3.395 1427.3* 3.266 127.9 3.197 729.8 2.999 330.15 2.962 1330.9 2.895 3132.65 2.745 233.0 2.716 634.9 2.571 235.15 2.553 235.6 2.523 938.7 2.329 239.25 2.295 240.1 2.247 142.25 2.139 342.55 2.124 243.7 2.072 148.2 1.887 348.8 1.866 450.4 1.811 552.0 1.759 154.0 1.698 7______________________________________ *Impurity Peak
(b) A portion of the as-synthesized ZnAPSO-44 part (a) was calcined in air at 500.degree. C. for about 67 hours. The calcined product was characterized by the x-ray powder diffraction pattern below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.6 9.23 10013.0 6.81 3414.05 6.29 516.2 5.48 1617.95 4.95 3020.3** 4.37 2220.8 4.27 5221.4 4.15 3222.3 3.987 722.75* 3.906 723.25 3.826 1024.75** 3.599 525.15 3.538 2226.15 3.406 1128.4 3.142 928.75** 3.107 730.95 2.888 2331.35* 2.852 1535.3* 2.542 9______________________________________ *Peak may contain impurity **Impurity peak
(c) The ZnAPSO-44 compositions are generally characterized by the data of Table XXI below:
TABLE XXI______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________9.4-9.55 9.41-9.26 vs12.9-13.05 6.86-6.78 vw-m20.65-20.8 4.30-4.27 m21.4-21.8 4.15-4.08 w-m24.3-25.15 3.663-3.541 m30.75-30.95 2.908-2.889 m______________________________________
(d) The ZnAPSO-44 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XXII below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.4-9.55 9.41-9.25 10012.9-13.05 6.86-6.78 8-3413.6-14.05 6.51-6.30 3-516.0-16.2 5.54-5.47 14-2117.25-17.95 5.14-4.94 0-618.95-19.05 4.68-4.66 0-520.65-20.8 4.30-4.27 35-5221.4-21.8 4.15-4.08 18-3222.55-22.65 3.943-3.926 423.15-23.25 3.842-3.826 5-1024.3-25.15 3.663-3.541 22-4726.1-26.25 3.414-3.395 8-1427.7-28.4 3.220-3.143 7-929.8 2.998- 0-330.05-30.15 2.974 0-1330.75-30.95 2.908-2.889 23-3132.65-32.8 2.743-2.730 0-333.0 2.714 0-634.9 2.571 0-235.15 2.553 0-235.3-35.6 2.543-2.522 9-1038.7 2.327-2.327 0-239.3-40.2 2.292-2.243 0-240.1 2.249 0-142.1-42.3 2.146-2.137 0-342.55 2.127 0-243.7 2.071 0-148.2 1.888 0-348.65-48.8 1.872-1.866 0-550.2-50.4 1.817-1.811 0-552.0 1.759 0-153.8-54.0 1.704-1.698 0-7______________________________________
EXAMPLE 55
(a) ZnAPSO-46, as referred to in example 8 was subjected to x-ray analysis. ZnAPSO-46 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________ 6.6 13.39 8 7.75 11.42 100 8.1** 10.90 3 9.45** 9.34 1810.2 8.67 113.35* 6.63 1013.8 6.41 414.95 5.92 415.75** 5.62 316.7 5.31 717.5 5.07 118.4** 4.83 1019.85 4.47 320.5* 4.33 621.25** 4.19 2521.6 4.12 1822.25** 3.998 322.8 3.896 3223.3** 3.818 424.05 3.700 324.25* 3.669 525.3* 3.523 126.55** 3.354 326.9 3.313 1027.8 3.207 328.3 3.152 228.8* 3.100 829.85* 2.993 630.2** 2.961 731.15 2.870 331.8* 2.813 132.95* 2.719 334.3* 2.612 234.65** 2.590 336.0* 2.495 336.55 2.459 236.8* 2.442 137.3 2.410 138.1** 2.361 139.7* 2.271 140.95* 2.204 143.2** 2.093 144.1* 2.054 146.1* 1.969 147.65* 1.908 149.45** 1.844 149.65* 1.836 151.55* 1.772 152.45* 1.745 1______________________________________ *Peak may contain impurity **Impurity peak
(b) The ZnAPSO-46 compositions are characterized by the data of Table XXIII below:
TABLE XXIII______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________7.6-7.75 11.63-11.42 vs13.1-13.35 6.76-6.63 w-m21.5-21.6 4.13-4.12 w-m22.6-22.85 3.934-3.896 m26.75-27.0 3.333-3.302 w______________________________________
(c) The ZnAPSO-46 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XXIV below:
TABLE XXIV______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________6.5-6.7 13.60-13.19 7-10 7.6-7.75 11.63-11.42 10010.2 8.67 0-1 13.1-13.35 6.76-6.63 10-2013.7-13.8 6.46-6.41 4-514.9-15.0 5.95-5.91 4-5 15.2-15.35 5.83-5.77 5-716.6-16.8 5.34-5.28 717.35-17.5 5.11-5.07 0-119.7-20.0 4.51-4.44 2-320.3-20.5 4.37-4.33 6-1121.5-21.6 4.13-4.12 18-21 22.6-22.85 3.934-3.896 32-58 23.9-24.05 3.723-3.700 2-325.1-25.3 3.548-3.520 0-126.75-27.0 3.333-3.302 10-1227.7-28.0 3.220-3.187 3-428.2-28.3 3.175-3.152 2-328.6-28.9 3.121-3.089 8-1129.7-29.9 3.008-2.988 6-9 31.0-31.15 2.885-2.870 3-431.6-31.8 2.831-2.813 0-132.8-33.2 2.730-2.706 3-434.15-34.4 2.626-2.607 2-435.8-36.0 2.508-2.495 3-436.45-36.55 2.464-2.459 2-337.3-37.7 2.410-2.386 0-239.7 2.271 0-140.9-41.1 2.206-2.196 0-143.85-44.1 2.065-2.054 0-146.1 1.969 0-147.4-47.7 1.918-1.908 0-149.7-49.8 1.834-1.831 0-151.4-51.7 1.778-1.768 0-1 52.2-52.45 1.752-1.745 0-1______________________________________
EXAMPLE 56
(a) ZnAPSO-47, as referred to in example 38, was subjected to x-ray analysis. ZnAPSO-47 was determined to have a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.45* 11.88 29.45 9.35 9312.9 6.87 1713.9 6.38 716.0 5.54 4217.65 5.03 1119.0* 4.67 320.6 4.31 10021.85 4.07 722.4* 3.97 623.0 3.867 1124.75 3.600 2125.9 3.439 2327.65 3.228 1028.0 3.188 329.5 3.029 530.6 2.922 4930.9 2.894 sh31.5 2.839 332.3 2.772 233.3 2.689 334.5 2.600 1034.9 2.573 235.7 2.516 438.4 2.344 339.65 2.273 442.5 2.126 343.3 2.089 244.9 2.019 247.6 1.909 448.6 1.873 550.5 1.807 553.25 1.721 554.5 1.684 256.0 1.642 5______________________________________ *Impurity peak
(b) A portion of the as-synthesized ZnAPSO-47 of part (a) was calcined in air at 500.degree. C. for about 1.75 hours. The calcined product was characterized by the x-ray powder diffraction pattern below:
______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________7.5* 11.78 119.65 9.17 10013.05 6.78 2514.15 6.26 316.2 5.46 1018.0 4.93 819.25 4.61 319.8* 4.49 220.85 4.26 2721.25* 4.18 sh22.5* 3.950 823.3 3.816 425.2 3.533 826.2 3.399 1028.0 3.187 228.55 3.126 329.8 2.998 231.0 2.885 1831.4 2.849 sh34.9 2.571 2______________________________________ *Impurity peak
(c) The ZnAPSO-47 compositions are characterized by the date in Table XXV below:
TABLE XXV______________________________________2.theta. d, (.ANG.) Relative Intensity______________________________________9.45-9.65 9.35-9.17 vs12.85-13.05 6.89-6.78 w-m15.95-16.2 5.55-5.46 w-m20.55-20.85 4.31-4.26 m-vs25.9-26.2 3.439-3.399 w-m30.55-31.0 2.925-2.885 w-m______________________________________
(d) The ZnAPSO-47 compositions for which x-ray powder diffraction data have been obtained to date have patterns which are characterized by the x-ray powder diffraction pattern shown in Table XXVI below:
TABLE XXVI______________________________________2.theta. d, (.ANG.) 100 .times. I/Io______________________________________9.45-9.65 9.35-9.17 93-10012.85-13.05 6.89-6.78 17-2513.85-14.15 6.39-6.26 3-715.95-16.2 5.55-5.46 10-4217.45-18.0 5.09-4.93 2-1120.55-20.85 4.31-4.26 27-10021.85 4.07 0-722.95-23.3 3.867-3.816 4-1124.75-25.2 3.600-3.533 8-2125.9-26.2 3.439-3.399 16-29 27.6-28.55 3.231-3.126 3-1027.9-28.0 3.196-3.188 0-329.45-29.8 3.031-2.998 2-530.55-31.0 2.925-2.885 18-4930.9-31.4 2.894-2.849 sh31.5 2.839 0-332.3 2.772 0-233.3 2.689 0-334.45-34.9 2.603-2.600 2-1934.9 2.573 0-235.7-35.9 2.516-2.503 0-5 38.4-38.55 2.344-2.336 0-3 39.6-39.65 2.273 0-442.25-42.5 2.139-2.126 0-343.3 2.089 0-244.9 2.019 0-247.6 1.909 0-648.6-48.7 1.873-1.870 0-550.45-50.5 1.807 0-5 53.2-53.25 1.722-1.721 0-554.5 1.684 0-256.0 1.642 0-5______________________________________
EXAMPLE 57
In order to demonstrate the catlaytic activity of calcined ZnAPSO compositions were tested for catalytic cracking of n-butane using a bench-scale apparatus.
The reactor was a cylindrical quartz tube 254 mm. in length and 10.3 mm. I.D. In each test the reactor was loaded with particles of the test ZnAPSO which were 20-40 mesh (U.S. std.) in size and in an amount of from 0.5 to 5 grams, the quantity being selected so that the conversion of n-butane was at least 5% and not more than 90% under the test conditions. The ZnAPSO samples had been previously calcined in air to remove organic materials from the pore system, and were activated in situ in the reactor in a flowing stream of helium at 500.degree. C. for one hour. The feedstock was a helium n-butane mixture containing 2 mole percent n-butane and was passed through the reactor at a rate of 50 cc./minute. Analysis of the feedstock and the reactor effluent were carried out using conventional gas chromatography techniques. The reactor effluent was analyzed after 10 minutes of on-stream operation.
The pseudo-first-order rate constant (k.sub.A) was calculated to determine the relative catalytic activity of the ZnAPSO compositions. The k.sub.A value (cm.sup.3 /g min) obtained for the ZnAPSO compositions are set forth, below, in Table XXVII:
TABLE XXVII______________________________________ Prepared inZnAPSO Example No. Rate Constant (k.sub.A)*______________________________________ZnAPSO-5 4 1.5ZnAPSO-34 24 12.7ZnAPSO-35 33 1.0ZnAPSO-44 35 5.0ZnAPSO-47 39 5.6______________________________________ *ZnAPSO were calcined prior to in situ activation as follows: (a) ZnAPSO5: in air at 500.degree. C. for 0.75 and at 600.degree. C. for 1.25 hours; (b) ZnAPSO34: in air at 500.degree. C. for 2 hours; (c) ZnAPSO35: in air at 500.degree. C. for 1.75 hours; (d) ZnAPSO44: in air at 500.degree. C. for 67 hours; and (e) ZnAPSO47: in air at 500.degree. C. for 1.75 hours.
PROCESS APPLICATIONS
The ZnAPSO compositions of the present invention are, in general, hydrophilic and adsorb water preferentially over common hydrocarbon molecules such as paraffins, olefins and aromatic species, e.g., benzene, xylenes and cumene. Thus, the ZnAPSOs as a class are useful as desiccants in such adsorption separation/purification processes as natural gas drying, cracked gas drying. Water is also preferentially adsorbed over the so-called permanent gases such as carbon dioxide, nitrogen, oxygen and hydrogen. These ZnAPSOs are therefore suitably employed in the drying of reformer hydrogen streams and in the drying of oxygen, nitrogen or air prior to liquifaction.
The present ZnAPSO compositions also exhibit novel surface selectivity characteristics which render them useful as catalyst or catalyst bases in a number of hydrocarbon conversion and oxidative combustion reactions. They can be impregnated or otherwise loaded with catalytically active metals by methods well known in the art and used, for example, in fabricating catalyst compositions having silica or alumina bases. Of the general class, those species having pores larger than about 4.ANG. are preferred for catalytic applications.
Among the hydrocarbon conversion reactions catalyzed by ZnAPSO compositions are cracking, hydrocracking, alkylation for both the aromatic and isoparaffin types,isomerization including xylene isomerization, polymerization, reforming, hydrogenation, dehydrogenation, transalkylation, dealkylation, hydrodecyclization and dehydrocyclization.
Using ZnAPSO catalyst compositions which contain a hydrogenation promoter such as platinum or palladium, heavy petroleum residual stocks, cyclic stocks and other hydrocrackable charge stocks, can be hydrocracked at temperatures in the range of 400.degree. F. to 825.degree. F. using molar ratios of hydrogen to hydrocarbon in the range of between 2 and 80, pressures between 10 and 3500 p.s.i.g., and a liquid hourly space velocity (LHSV) of from 0.1 to 20, preferably 1.0 to 10.
The ZnAPSO catalyst compositions employed in hydrocracking are also suitable for use in reforming processes in which the hydrocarbon feedstocks contact the catalyst at temperatures of from about 700.degree. F. to 1000.degree. F., hydrogen pressures of from 100 to 500 p.s.i.g., LHSV values in the range of 0.1 to 10 and hydrogen to hydrocarbon molar ratios in the range of 1 to 20, preferably between 4 and 12.
These same catalysts, i.e. those containing hydrogenation promoters, are also useful in hydroisomerizations processes in which feedstocks such a normal paraffins are converted to saturated branched chain isomers. Hydroisomerization is carried out at a temperature of from about 200.degree. F. to 600.degree. F., preferably 300.degree. F. to 550.degree. F. with an LHSV value of from about 0.2 to 1.0. Hydrogen is supplied to the reactor in admixture with the hydrocarbon feedstock in molar proportions (hydrogen to hydrocarbon) of between 1 and 5.
At somewhat higher temperatures, i.e. from about 650.degree. F. to 1000.degree. F., preferably 850.degree. F. to 950.degree. F. and usually at somewhat lower pressures within the range of about 15 to 50 p.s.i.g., the same catalyst compositions are used to hydroisomerize normal paraffins. Preferably the paraffin feedstock comprises normal paraffins having a carbon number range of C.sub.7 -C.sub.20. Contact time between the feedstock and the catalyst is generally relatively short to avoid undesireable side reactions such as olefin polymerization and paraffin cracking. LHSV values in the range of 0.1 to 10, preferably 1.0 to 6.0 are suitable.
The unique crystal structure of the present ZnAPSO catalysts and their availability in a form totally void of alkali metal content favor their use in the conversion of alkylaromatic compounds, particularly the catalytic disproportionation of toluene, ethylene, trimethyl benzenes, tetramethyl benzenes and the like. In the disproportionation process, isomerization and transalkylation can also occur. Group VIII noble metal adjuvants alone or in conjunction with Group VI-B metals such as tungsten, molybdenum and chromium are preferably included in the catalyst composition in amounts of from about 3 to 15 weight-% of the overall composition. Extraneous hydrogen can, but need not, be present in the reactin zone which is maintained at a temperature of from about 400.degree. to 750.degree. F., pressures in the range of 100 to 2000 p.s.i.g. and LHSV values in the range of 0.1 to 15.
Catalytic cracking processes are preferably carried out with ZnAPSO compositions using feedstocks such as gas oils, heavy naphthas, deasphalted crude oil residua, etc., with gasoline being the pricipal desired product. Temperature conditions of 850.degree. to 1100.degree. F., LHSV values of 0.5 to 10 and pressure conditions of from about 0 to 50 p.s.i.g. are suitable.
Dehydrocyclization reactions employing paraffinic hydrocarbon feedstocks, preferably normal paraffins having more than 6 carbon atoms, to form benzene, xylenes, toluene and the like are carried out using essentially the same reaction conditions as for catalytic cracking. For these reactions it is preferred to use the ZnAPSO catalyst in conjunctin with a Group VIII non-noble metal cation such as zinc and nickel.
In catalytic dealkylation wherein it is desired to cleave paraffinic side chains from aromatic nuclei without substantially hydrogenating the ring structure, relatively high temperatures in the range of about 800.degree.-1000.degree. F. are employed at moderate hydrogen pressures of about 300-1000 p.s.i.g., other conditions being similar to those described above for catalytic hydrocracking. Preferred catalysts are of the same type described above in connection with catalytic dehydrocyclization. Particularly desirable dealkylation reactions contemplated herein include the conversion of methylnaphthalene to naphthalene and toluene and/or xylenes to benzene.
In catalytic hydrofining, the primary objective is to promote the selective hydrodecomposition of organic sulfur and/or nitrogen compounds in the feed, without substantially affecting hydrocarbon molecules therein. For this purpose it is preferred to employ the same general conditions described above for catalytic hydrocracking, and catalysts of the same general nature described in connection with dehydrocyclization operations. Feedstocks include gasoline fractions, kerosenes, jet fuel fractions, diesel fractions, light and heavy gas oils, deasphalted crude oil residua and the like any of which may contain up to about 5 weight-percent of sulfur and up to about 3 weight-percent of nitrogen.
Similar conditions can be employed to effect hydrofining, i.e., denitrogenation and desulfurization, of hydrocarbon feeds containing substantial proportions of organonitrogen and organosulfur compounds. It is generally recognized that the presence of substantial amounts of such constituents markedly inhibits the activity of hydrocracking catalysts. Consequently, it is necessary to operate at more extreme conditions when it is desired to obtain the same degree of hydrocracking conversion per pass on a relatively nitrogenous feed than are required with a feed containing less organonitrogen compounds. Consequently, the conditions under which denitrogenatin, desulfurization and/or hydrocracking can be most expeditiously accomplished in any given situation are necessarily determined in view of the characteristics of the feedstocks in particular the concentration of organonitrogen compounds in the feed stock. As a result of the effect of organonitrogen compounds on the hydrocracking activity of these compositions it is not at all unlikely that the conditions most suitable for denitrogenation of a given feedstock having a relatively high organonitrogen content with minimal hydrocracking, e.g., less than 20 volume percent of fresh feed per pass, might be the same as those preferred for hydrocracking another feedstock having a lower concentration of hydrocracking inhibiting constituents e.g., organonitrogen compounds. Consequently, it has become the practice in this art to establish the conditions under which a certain feed is to be contacted on the basis of preliminary screening tests with the specific catalyst and feedstock.
Isomerization reactions are carried out under conditions similar to those described above for reforming, using somewhat more acidic catalysts. Olefins are preferably isomerized at temperatures of 500.degree.-900.degree. F., while paraffins, naphthenes and alkyl aromatics are isomerized at temperatures of 700.degree.-1000.degree. F. Particularly desirable isomerization reactions contemplated herein include the conveersion of n-heptene and/or n-octane to isoheptanes, iso-octanes, butane to iso-butane, methylcyclopentane to cyclohexane, meta-xylene and/or ortho-xylene to paraxylene, 1-butene to 2-butene and/or isobutene, n-hexene to isohexene, cyclohexene to methylcyclopentene etc. The preferred from of the catalyst is a combination of the ZnAPSO with polyvalent metal compounds (such as sulfides) of metals of Group II-A, Group II-B and rare earth metals. For alkylation and dealkylation processes the ZaAPSO compositions having pores of at least 5A are preferred. When employed for dealkylation of alkyl aromatics, the temperature is usually at least 350.degree. F. and ranges up to a temperaure at which substantial cracking of the feedstock or conversion products occurs, generally up to about 700.degree. F. The temperature is preferably at least 450.degree. F. and not greater than the critical temperature of the compound undergoing dealkylation. Pressure conditions are applied to retain at least the aromatic feed in the liquid state. For alkylation the temperature can be as low as 250.degree. F. but is preferably at least 350.degree. F. In the alkylatin of benzene, toluene and xylene, the preferred alkylating agents are olefins such as ethylene and propylene.

Number	Name	Date
3941871	Dwyer et al.	Mar 1976
4310440	Wilson et al.	Jan 1982
4420467	Whittam	Dec 1983
4440871	Lok et al.	Apr 1984
4456582	Marosi et al.	Jun 1984
4486397	Eshraghi et al.	Dec 1984
4500651	Lok et al.	Feb 1985
4567029	Wilson et al.	Jan 1986

Number	Date	Country
0054364	Jun 1982	EPX
0055046	Jun 1982	EPX
0055529	Jul 1982	EPX
0059059	Sep 1982	EPX

Zinc-aluminum-phosphorus-silicon-oxide molecular sieve compositions

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