Crystalline zeolite (ECR-1) and process for preparing it

Claim 2

A synthetic crystalline zeolite characterized by having a composition, in terms of mole ratios of oxides, in the range: 0.5 to 0.02R.sub.2 O:0.90 to 0.98Na.sub.2 O:Al.sub.2 O.sub.3 :5 to 20SiO.sub.2 :xH.sub.2 O wherein R is a tetraalkyl ammonium cation of the type (CH 3 ) 2 R 2 1 N, wherein R 1 is ethyl, propyl, butyl, hydroxyethyl or hydroxypropyl, and x represents 0 or an integer from 1 to 8, and characterized by an x-ray powder diffraction pattern is essentially identical to that given in Table 1.

Claim 3

The zeolite of claim 1 wherein R is partially or fully exchanged with an exchangeable cation selected from Group I through Group VIII of the Periodic Table.

Claim 4

The zeolite of claim 1 having a composition in the range: 0.1 to 0.02R.sub.2 O:0.95 to 0.98Na.sub.2 O:Al.sub.2 O.sub.3 :6 to 10SiO.sub.2.

Claim 5

The zeolite of claim 1 wherein R is bis-(2-hydroxyethyl)dimethyl ammonium.

Claim 6

The zeolite of claim 1 wherein R is bis-(2-hydroxypropyl)dimethyl ammonium.

Claim 7

A process for preparing a crystalline zeolite comprising: (a) preparing a reaction mixture comprising an oxide of sodium, a tetraalkyl ammonium salt, water, a source of silica, a source of alumina and sodium aluminosilicate nucleating seeds, said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges: ______________________________________ R.sub.2 O:Al.sub.2 O.sub.3 0.2 to 1.0 Na.sub.2 O:Al.sub.2 O.sub.3 1.0 to 7 SiO.sub.2 :Al.sub.2 O.sub.3 5 to 20 H.sub.2 O:Al.sub.2 O.sub.3 120 to 300 R.sub.2 O:Na.sub.2 O 0.05 to 0.4 ______________________________________ where R is a tetraalkyl ammonium cation of the type (CH 3 ) 2 R 2 1 wherein R 1 is ethyl, propyl, butyl, hydroxyethyl or hydroxypropyl, and said seeds being present in an amount to yield 1 to 15 mole percent of the total alumina content of the reaction mixture; (b) blending the reaction mixture sufficiently to form a substantially homogeneous mixture; (c) maintaining the reaction mixture at between about 120° and 200° C. under autogeneous pressure for a sufficient period of time to form crystals of a zeolite having a composition, in terms of mole ratios of oxides, in the range:

Claim 8

A process for preparing a crystalline zeolite comprising: (a) preparing a reaction mixture comprising an oxide of sodium, a tetraalkyl ammonium salt, water, a source of silica, a source of alumina and sodium aluminosilicate nucleating seeds, said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges: ______________________________________ R.sub.2 O:Al.sub.2 O.sub.3 0.2 to 1.0 Na.sub.2 O:Al.sub.2 O.sub.3 1.0 to 7 SiO.sub.2 :Al.sub.2 O.sub.3 5 to 20 H.sub.2 O:Al.sub.2 O.sub.3 120 to 300 R.sub.2 O:Na.sub.2 O 0.05 to 0.4 ______________________________________ where R is a tetraalkyl ammonium cation of the type (CH 3 ) 2 R 2 1 wherein R 1 is ethyl, propyl, butyl, hydroxyethyl or hydroxypropyl, and said seeds being present in an amount to yield 1 to 15 mole percent of the total alumina content of the reaction mixture; (b) blending the reaction mixture sufficiently to form a substantially homogeneous mixture; (c) maintaining the reaction mixture at between about 120° and 200° C. under autogeneous pressure for a sufficient period of time to form crystals of a zeolite having a composition, in terms of mole ratios of oxides, in the range:

Claim 9

5 to 0.02R 2 O:0.90 to 0.98Na 2 O:Al 2 O 3 :5 to 20SiO 2 :xH 2 O where R and x are defined above, and such that the x-ray powder diffraction pattern of said zeolite is essentially identical to that given in Table I, and (d) recovering said zeolite crystals.

Claim 10

5 to 0.02R 2 O:0.90 to 0.98Na 2 O:Al 2 O 3 :5 to 20SiO 2 :xH 2 O where R and x are defined above, and such that the x-ray powder diffraction pattern of said zeolite is essentially identical to that given in Table I, and (d) recovering said zeolite crystals.

Claim 11

The process of claim 6 wherein R is bis-(2-hydroxyethyl)dimethyl ammonium.

Claim 12

The process of claim 6 where R is bis-(2-hydroxypropyl)dimethyl ammonium.

Claim 13

The process of claim 6 further comprising exchanging the R group with an exchangeable cation selected from Group I through Group VIII of the Periodic Table.

Claim 14

The process of claim 6 wherein the crystalline zeolite product has a composition in the range: 0.1 to 0.02R.sub.2 O:0.95 to 0.98Na.sub.2 O:Al.sub.2 O.sub.3 :6 to 10SiO.sub.2.

Claim 15

The process of claim 6 wherein the source of silica is sodium silicate and the sources of alumina are hydrated alumina and an aluminum salt selected from the group consisting of the chloride, sulfate and nitrate salts.

Claim 16

The process of claim 6 wherein the reaction mixture is maintained at between 140° and 180° C.

Claim 17

The process of claim 6 wherein the seeds are present in an amount to yield 1 to 10 mole percent of the total alumina content of the reaction mixture.

Claim 18

The process of claim 6 wherein said seeds comprise the crystalline zeolite product.

Claim 19

A process for preparing a crystalline zeolite comprising: (a) preparing a reaction mixture comprising sodium aluminate, alum, water, sodium, silicate, aluminum sulfate, bis-(2-hydroxyethyl)dimethylammonium halide, and nucleating seeds of the composition: 13.33Na.sub.2 O:Al.sub.2 O.sub.3 :12.5SiO.sub.2 :267H.sub.2 O said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges: ______________________________________ R.sub.2 O:Al.sub.2 O.sub.3 0.1 to 1.0 Na.sub.2 O:Al.sub.2 O.sub.3 1 to 7 SiO.sub.2 :Al.sub.2 O.sub.3 5 to 20 H.sub.2 O:Al.sub.2 O.sub.3 120 to 300 ______________________________________ where R represents a bis-(2-hydroxyethyl)dimethylammonium group, and said seeds being present in an amount to yield 2 to 6 mole percent of the total final alumina content of the reaction mixture; (b) blending the reaction mixture sufficiently to form a substantially homogeneous mixture; (c) maintaining the reaction mixture at between 140° and 200° C. under autogenous pressure for a sufficient period of time to form crystals of a zeolite having a composition, in terms of mole ratios of oxides, in the range: 0.5 to 0.02R.sub.2 O:0.95 to 0.98Na.sub.2 O:Al.sub.2 O.sub.3 :6 to 10SiO.sub.2 where R is defined above, and having atoms arranged such that the x-ray powder diffraction pattern of said zeolite is essentially identical to that given in Table I; and (d) recovering said zeolite crystals.

Claim 20

A process for preparing a crystalline zeolite comprising: (a) preparing a reaction mixture comprising sodium aluminate, alum, water, sodium, silicate, aluminum sulfate, bis-(2-hydroxyethyl)dimethylammonium halide, and nucleating seeds of the composition: 13.33Na.sub.2 O:Al.sub.2 O.sub.3 :12.5SiO.sub.2 :267H.sub.2 O said reaction mixture having a composition, in terms of mole ratios of oxides, within the following ranges: ______________________________________ R.sub.2 O:Al.sub.2 O.sub.3 0.1 to 1.0 Na.sub.2 O:Al.sub.2 O.sub.3 1 to 7 SiO.sub.2 :Al.sub.2 O.sub.3 5 to 20 H.sub.2 O:Al.sub.2 O.sub.3 120 to 300 ______________________________________ where R represents a bis-(2-hydroxyethyl)dimethylammonium group, and said seeds being present in an amount to yield 2 to 6 mole percent of the total final alumina content of the reaction mixture; (b) blending the reaction mixture sufficiently to form a substantially homogeneous mixture; (c) maintaining the reaction mixture at between 140° and 200° C. under autogenous pressure for a sufficient period of time to form crystals of a zeolite having a composition, in terms of mole ratios of oxides, in the range: 0.5 to 0.02R.sub.2 O:0.95 to 0.98Na.sub.2 O:Al.sub.2 O.sub.3 :6 to 10SiO.sub.2 where R is defined above, and having atoms arranged such that the x-ray powder diffraction pattern of said zeolite is essentially identical to that given in Table I; and (d) recovering said zeolite crystals.