US4525466A — Process for synthetizing zeolites having a morden…

Claim 1

Independent Claim 169 words

A process for synthesizing mordenites having a high catalytic activity, in which the SiO 2 :Al 2 O 3 molar ratio is in the range 16 to 40, said process comprising the steps of mixing an organic base with H 2 O and at least a Na compound, an Al compound, and a Si compound, and being characterized in that said base is (DEPP) + OH - or a salt thereof, that the crystallization temperature is from 140° C. to 160° C. and both it and the SP factor are selected within the area of AEFD of FIG. 1 of the drawing, the crystallization time being longer than 2 days, and in that the following molar ratios between the abovesaid compounds, expressed as oxides, are employed: Na 2 O:Al 2 O 3 =1 to 10; (DEPP) 2 O:Al 2 O 3 =1 to 15; SiO 2 :Al 2 O 3 =20 to 70; H 2 O:Al 2 O 3 =500 to 3,000; H 2 O:SiO 2 =25 to 45.

Claim 2

Dependent Claim 169 words

A process for synthesizing mordenites having a high catalytic activity, in which the SiO 2 :Al 2 O 3 molar ratio is in the range 16 to 40, said process comprising the steps of mixing an organic base with H 2 O and at least a Na compound, an Al compound, and a Si compound, and being characterized in that said base is (DEPP) + OH - or a salt thereof, that the crystallization temperature is from 140° C. to 160° C. and both it and the SP factor are selected within the area of AEFD of FIG. 1 of the drawing, the crystallization time being longer than 2 days, and in that the following molar ratios between the abovesaid compounds, expressed as oxides, are employed: Na 2 O:Al 2 O 3 =1 to 10; (DEPP) 2 O:Al 2 O 3 =1 to 15; SiO 2 :Al 2 O 3 =20 to 70; H 2 O:Al 2 O 3 =500 to 3,000; H 2 O:SiO 2 =25 to 45.

Claim 3

Dependent Claim 60 words

The process according to claim 1, characterized in that the molar ratios are in the following ranges: Na 2 O:Al 2 O 3 =2 to 8; (DEPP) 2 O:Al 2 O 3 =2 to 10; SiO 2 :Al 2 O 3 =20 to 50; H 2 O:Al 2 O 3 =500 to 3,000; H 2 O:SiO 2 =35 to 45.

Claim 4

Dependent Claim 17 words

The process according to claim 1, in which the crystallization time is from 4 to 6 days.

Claim 5

Dependent Claim 32 words

The process according to claim 1, characterized in that the salt is (DEPP)Br, the Na compound is NaOH, the Al compound is Na aluminate, and the Si compound is a silica sol.

Claim 6

Dependent Claim 195 words

A process for preparing a catalyst for the disproportioning of toluene, containing a mordenite having a SiO 2 :Al 2 O 3 molar ratio from 16 to 40, said process comprising the steps of mixing an organic base with H 2 O and at least a Na compound, an Al compound, and a Si compound, and being characterized in that said base is (DEPP) + OH - or a salt thereof, in that the mixture is crystallized at a temperature from 140° C. to 160° C., in that both said temperature and the SP factor are selected within the area AEFD of FIG. 1 of the drawing, the crystallization time being longer than two days, and in that the following molar ratios between the abovesaid compounds, expressed as oxides, are employed: Na 2 O:Al 2 O 3 =1-10; (DEPP) 2 O:Al 2 O 3 =1-15; SiO 2 :Al 2 O 3 =20-70; H 2 O:Al 2 O 3 =500-3,000; H 2 O:SiO 2 =25-45; thereafter filtering the crystallization mixture, drying it in an oven for 10-12 hours at 120° C. and activating it in air for 2-10 hours at between 400° C. and 600° C.

Claim 7

Dependent Claim 195 words

A process for preparing a catalyst for the disproportioning of toluene, containing a mordenite having a SiO 2 :Al 2 O 3 molar ratio from 16 to 40, said process comprising the steps of mixing an organic base with H 2 O and at least a Na compound, an Al compound, and a Si compound, and being characterized in that said base is (DEPP) + OH - or a salt thereof, in that the mixture is crystallized at a temperature from 140° C. to 160° C., in that both said temperature and the SP factor are selected within the area AEFD of FIG. 1 of the drawing, the crystallization time being longer than two days, and in that the following molar ratios between the abovesaid compounds, expressed as oxides, are employed: Na 2 O:Al 2 O 3 =1-10; (DEPP) 2 O:Al 2 O 3 =1-15; SiO 2 :Al 2 O 3 =20-70; H 2 O:Al 2 O 3 =500-3,000; H 2 O:SiO 2 =25-45; thereafter filtering the crystallization mixture, drying it in an oven for 10-12 hours at 120° C. and activating it in air for 2-10 hours at between 400° C. and 600° C.

Claim 8

Dependent Claim 79 words

The process according to claim 5, characterized in that said mordenite is prepared in the acid form by exchange with NH 4 Cl and successive calcining between 300° C. and 650° C., the zeolite powder so exchanged being then kneaded with 10-50% by weight of another binding material and being extruded in preselected form, the extruded mixture being heated, dried and activated by treatment in air at high temperature of 500° C. to the beginning of mordenite structural collapse.

Claim 9

Dependent Claim 27 words

The process according to claim 6, in which the binding material is selected from the group consisting of clay, SiO 2 and Al 2 O 3 .

Claim 10

Dependent Claim 20 words

The process according to claim 6, in which the calcining is performed at a temperature of 400° to 550° C.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-06-24	1988-12-24	1989-06-25	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-06-24	1992-12-24	1993-06-25	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-06-24	1996-12-24	1997-06-25	$7700.00	Window Closed / Lapsed

Process for synthetizing zeolites having a mordenite structure and having high catalytic activity

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