Process for preparing crystalline aluminosilicate zeolites using a carboxylic acid

Claim 2

A process for preparing a crystalline aluminosilicate zeolite, which process comprises reacting an aqueous reaction mixture containing a silica source, an alumina source, an alkali source and a single type of organic template, said single type of organic template consisting essentially of an organic compound having 3 to 6 carbon atoms and 1 to 3 carboxyl groups and not containing an aromatic ring, and the composition, in terms of mole ratios, of said reaction mixture being as follows: ______________________________________ SiO.sub.2 /Al.sub.2 O.sub.3 above 20 H.sub.2 O/SiO.sub.2 5 to 100 OH--/SiO.sub.2 0.05 to 0.40 A/Al.sub.2 O.sub.3 0.10 to 200 ______________________________________ wherein A represents said organic compound, said process being conducted at a crystallization temperature of 140°-180° C. to form a crystalline aluminosilicate zeolite having the following X-ray diffraction pattern: ______________________________________ d(Å) 100 I/Io ______________________________________ 11.2 ± 0.2 S 10.1 ± 0.2 S 9.8 ± 0.2 M 6.37 ± 0.1 W 6.00 ± 0.1 W 5.71 ± 0.1 W 5.58 ± 0.1 W 4.37 ± 0.08 W 4.27 ± 0.08 W 3.86 ± 0.08 VS 3.82 ± 0.02 VS 3.75 ± 0.08 S 3.72 ± 0.08 S 3.66 ± 0.05 M 3.00 ± 0.05 M 2.00 ± 0.05 W ______________________________________ wherein VS=very strong, S=strong, M=medium strength and W=weak.

Claim 3

A process for preparing a crystalline aluminosilicate zeolite, which process comprises reacting an aqueous reaction mixture containing a silica source, an alumina source, an alkali source and a single type of organic template, said single type of organic template consisting essentially of an organic compound having 3 to 6 carbon atoms and 1 to 3 carboxyl groups and not containing an aromatic ring, and the composition, in terms of mole ratios, of said reaction mixture being as follows: ______________________________________ SiO.sub.2 /Al.sub.2 O.sub.3 15 to 75 H.sub.2 O/SiO.sub.2 10 to 50 OH--/SiO.sub.2 0.14 to 0.40 A/Al.sub.2 O.sub.3 0.10 to 50 ______________________________________ wherein A represents said organic compound, said process being conducted at a crystallization temperature of 140°-180° C. to form a crystalline aluminosilicate zeolite having the following X-ray diffraction pattern: ______________________________________ d(Å) 100 I/Io ______________________________________ 13.6 ± 0.2 M 10.2 ± 0.2 W 9.0 ± 0.2 S 6.56 ± 0.1 S 6.40 ± 0.1 M 6.05 ± 0.1 W 5.80 ± 0.1 M 4.52 ± 0.08 M 3.99 ± 0.08 S 3.83 ± 0.08 W 3.76 ± 0.08 W 3.53 ± 0.05 W 3.46 ± 0.05 VS 3.38 ± 0.05 S 3.28 ± 0.05 W 3.20 ± 0.05 S 3.15 ± 0.05 W 2.89 ± 0.05 M 2.51 ± 0.05 W ______________________________________ wherein VS=very strong, S=strong, M=medium strength and W=weak.

Claim 4

A process for preparing a crystalline aluminosilicate zeolite, which process comprises reacting an aqueous reaction mixture containing a silica source, an alumina source, an alkali source and a single type of organic template, said single type of organic template consisting essentially of an organic compound having 3 to 6 carbon atoms and 1 to 3 carboxyl groups and not containing an aromatic ring, and the composition, in terms of mole ratios, of said reaction mixture being as follows: ______________________________________ SiO.sub.2 /Al.sub.2 O.sub.3 15 to 75 H.sub.2 O/SiO.sub.2 10 to 50 OH--/SiO.sub.2 0.14 to 0.40 A/Al.sub.2 O.sub.3 0.10 to 50 ______________________________________ wherein A represents said organic compound, said process being conducted at a crystallization temperature of 140°-180° C. to form a crystalline aluminosilicate zeolite having the following X-ray diffraction pattern: ______________________________________ d(Å) 100 I/Io ______________________________________ 13.6 ± 0.2 M 10.2 ± 0.2 W 9.0 ± 0.2 S 6.56 ± 0.1 S 6.40 ± 0.1 M 6.05 ± 0.1 W 5.80 ± 0.1 M 4.52 ± 0.08 M 3.99 ± 0.08 S 3.83 ± 0.08 W 3.76 ± 0.08 W 3.53 ± 0.05 W 3.46 ± 0.05 VS 3.38 ± 0.05 S 3.28 ± 0.05 W 3.20 ± 0.05 S 3.15 ± 0.05 W 2.89 ± 0.05 M 2.51 ± 0.05 W ______________________________________ wherein VS=very strong, S=strong, M=medium strength and W=weak.

Claim 5

A process according to claim 1 or 2, in which said organic compound is an aliphatic carboxylic acid containing a hydroxyl group.

Claim 6

A process according to claim 1 or 2, in which said organic compound is a member selected from the group consisting of lactic, hydracrylic, hydroxybutyric, tartronic, malic, tartaric, citric, propionic, butyric, valeric, caproic, acrylic, crotonic, methacrylic, malonic, succinic, glutaric, adipic, maleic and fumaric acids.

Claim 7

A process according to claim 1 or 2, in which said organic compound is a compound that is water soluble in its alkali metal salt form.

Claim 8

A process according to claim 1 or 2, in which said organic compound is tartaric acid.

Claim 9

A process according to claim 1 or 2, in which said process requires 5 hours to 30 days for completion.