Iron-aluminum-phosphorus-silicon-oxide molecular sieves

Claim 2

Crystalline molecular sieves having framework structures of FeO 2 , A10 2 8 PO 2 and SiO 2 tetrahedral units and having a unit empirical formula: 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 (Fe w Al x P y Si Z )O 2 and has a value of zero to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of iron, aluminum, phosphorus and silicon respectively, present as tetrahedral oxides, said mole fractions being such that they are within the pentagonal compositional area defined by points A, B. C, D and E of FIG. 1.

Claim 3

Crystalline molecular sieves according to claim 1 wherein the mole fractions of iron, aluminum, phosphorus and silicon are within the tetragonal compositional area defined by points a, b, c and d of FIG. 2.

Claim 4

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table A.

Claim 5

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table B.

Claim 6

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table C.

Claim 7

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table D.

Claim 8

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table E.

Claim 9

The crystalline molecular sieves of claims I or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table F.

Claim 10

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table G.

Claim 11

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table H.

Claim 12

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffractions pattern which contains at least the d-spacing set forth in Table J.

Claim 13

The crystalline molecular sieves of claims 1 or 2 having a characteristic x-ray powder diffraction pattern which contains at least the d-spacings set forth in Table K.

Claim 14

Process for preparing the crystalline molecular sieves of claim 1 having three dimensional microporous framework structures which comprises providing at an effective temperature and for an effective time a reaction mixture expressed in terms of molar oxide ratios of: wherein "R" is an organic templating agent; "a" is the amount of "R" and may have a value of zero or be an effective amount greater than zero to about 6; "b" has a value of from zero to about 500: and "w", "x", "y" and "z" represent the mole fractions. respectively, of iron, aluminum, phosphorus and silicon in the (Fe w Al x P y Si z )O 2 constituent, and each has a value of at least 0.01, whereby the molecular sieves of claim 1 are prepared.

Claim 15

The process of claim 13 wherein the values of "w", "x", "y" and "z" are within the pentagonal area defined by points F, G, H, I and J of FIG. 3.

Claim 16

Process according to claim 13 wherein the reactive source of phosphorus in the reaction mixture is orthophosphoric acid.

Claim 17

Process according to claim 13 wherein the reactive source of iron is selected from the group consisting of iron (II) acetate, iron (II) sulfate, and mixture thereof.

Claim 18

Process according to claim 13 wherein the reactive source of silicon is silica.

Claim 19

Process according to claim 13 wherein the reactive source of aluminum in the reaction mixture is at least one compound selected from the group consisting of pseudo-boehmite and aluminum alkoxide, and the source of phosphorus is orthophosphoric acid.

Claim 20

Process according to claim 18 wherein the aluminum alkoxide is aluminum isopropoxide.

Claim 21

Process according to claims 13 where the organic templating agent is selected from the group consisting of quaternary ammonium or quaternary phosphonium compounds of the formula: wherein X is nitrogen or phosphorous and each R is alkyl containing between 1 and about 8 carbon atoms or aryl.

Claim 22

Process according to claims 13 wherein the templating agent is selected from the group consisting of tetrapropylammonium ion: tetraethylammonium ion; tripropylamine; triethylamine: triethanolamine: piperidine: cyclohexylamine; 2-methyl pyridine: N,N-dimethylbenzylamine: N,N-dimethylethanolamine; dicyclohexylamine: N,N-dimethylethanolamine; chlorine: N,N-dimethylpiperazine; 1,4-diazabicyclo-(2,2,2) octane; N-methylpiperidine; 3-methylpiperidine; N-methylcyclohexylamine; 3-methylpyridine: 4-methylpyridine: quinuclidine: N,N-dimethyl-1,4-diazabicyclo (2,2,2) octane ion; tetramethylammonium ion: tetrabutylammonium ion. tetrapentylammonium ion; di-n-butylamine: neopentylamine; di-n-pentylamine:isopropylamine: t-butylamine: ethylenediamine pyrrolidine: 2-imidazolidone; di-n-propylamine; and a polymeric quaternary ammonium salt [(C 14 H 32 N 2 )(oH)] x wherein x is a value of at least 2.

Claim 23

Process of claim 13 wherein the organic templating agent is an amine.

Claim 24

Molecular sieves prepared by calcining the compositions of claims 1 or 2 at a temperature high enough to remove at least some of any organic templating agent present in the intracrystalline pore system.

Claim 25

Process for separating molecular species from admixture with molecular species having a lesser degree of polarity which comprises contacting said mixture of molecular species with a molecular sieve of claim 1 or claim 2 having pore diameters large enough to adsorb at least one of the more polar molecular species, said molecular sieve being at least partially activated whereby molecules of the more polar molecular species are selectively adsorbed into the intracrystalline pore system thereof.

Claim 26

Process for separating a mixture of molecular species having different kinetic diameters which comprises contacting said mixture with a molecular sieve of claim 1 or claim 2 having pore diameters large enought to adsorb at least one but not all molecular species of said mixture, said molecular sieve being at least partially activated whereby at least some molecules whose kinetic diameters are sufficiently small can enter the intracrystalline pore system thereof.

Claim 27

Process for converting a hydrocarbon which comprises contacting said hydrocarbon under hydrocarbon converting conditions with a crystalline molecular sieve as set forth in claims 1 or 2.

Claim 28

Process according to claim 26 wherein the hydrocarbon conversion process is cracking.

Claim 29

Process according to claim 26 wherein the hydrocarbon conversion process is hydrocracking.

Claim 30

Process according to claim 26 wherein the hydrocarbon conversion process is hydrogenation.

Claim 31

Process according to claim 26 wherein the hydrocarbon conversion process is polymerization.

Claim 32

Process according to claim 26 wherein the hydrocarbon conversion process is alkylation.

Claim 33

Process according to claim 26 wherein the hydrocarbon conversion process is reforming.

Claim 34

Process according to claim 26 wherein the hydrocarbon conversion process is hydrotreating.

Claim 35

Process according to claim 26 wherein the hydrocarbon conversion process is isomerization.

Claim 36

Process according to claim 34 wherein the isomerization is xylene isomerization.

Claim 37

Process according to claim 26 wherein the hydrocarbon conversion process is dehydrocyclization.