Molecular sieve compositions

Claim 2

Crystalline molecular sieves having three-dimensional microporous framework structures of ELO 2 , AlO 2 , PO 2 , SiO 2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula: mR:(EL.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 (EL w AL x P y Si z )O 2 and has a value of zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus, and silicon, respectively, present as framework oxides, said mole fractions being within the pentagonal compositional area defined by points A, B, C, D and E of FIG. 1, wherein element "EL" and each of aluminum, phosphorus and silicon are present such that "w", "x", "y" and "z" are at least 0.01 and each element "EL" is present as a tetrahedral oxide unit ELO 2 in an amount of at least 0.01, said crystalline molecular sieves having a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth in one of the following Tables A and B: TABLE A ______________________________________ (ELAPSO-5) 2θ d(Å) Relative Intensity ______________________________________ 7.2-7.7 12.28-11.48 m-vs 19.4-19.9 4.58-4.46 w-m 20.85-21.3 4.26-4.17 w-vs 22.1-22.6 4.02-3.93 m-vs 25.6-26.1 3.480-3.414 vw-m ______________________________________ TABLE B ______________________________________ (ELAPSO-11) 2θ d(Å) Relative Intensity ______________________________________ 7.8-8.2 11.19-10.85 m-s 9.0-9.8 9.83-9.03 vw-vs 12.8-13.6 6.92-6.51 vw-m 19.9-20.5 4.46-4.33 m-s 20.8-21.8 4.27-4.08 m-vs 22.0-22.6 4.04-3.93 m-vs 22.6-23.1 3.93-3.85 vw-vs 23.1-23.5 3.85-3.79 w-vs ______________________________________

Claim 3

Process for preparing the crystalline molecular sieves having three-dimensional microporous framework structures of ELO 2 , AlO 2 , PO 2 , SiO 2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula: mR:(EL.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 (EL w Al x P y Si z )O 2 and has a value of zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus, and silicon, respectively, present as framework oxides, said mole fractions being within the pentagonal compositional area defined by points A, B, C, D and E of FIG. 1, wherein element "EL" and each of aluminum, phosphorus and silicon are present such that "w", "x", "y" and "z" are at least 0.01 and each element "EL" is present as a tetrahedral oxide unit ELO 2 in an amount of at least 0.01, said crystalline molecular sieves having a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth in one of the following Tables A and B: TABLE A ______________________________________ (ELAPSO-5) 2θ d(Å) Relative Intensity ______________________________________ 7.2-7.7 12.28-11.48 m-vs 19.4-19.9 4.58-4.46 w-m 20.85-21.3 4.26-4.17 w-vs 22.1-22.6 4.02-3.93 m-vs 25.6-26.1 3.480-3.414 vw-m ______________________________________ TABLE B ______________________________________ (ELAPSO-11) 2θ d(Å) Relative Intensity ______________________________________ 7.8-8.2 11.19-10.85 m-s 9.0-9.8 9.83-9.03 vw-vs 12.8-13.6 6.92-6.51 vw-m 19.9-20.5 4.46-4.33 m-s 20.8-21.8 4.27-4.08 m-vs 22.0-22.6 4.04-3.93 m-vs 22.6-23.1 3.93-3.85 vw-vs 23.1-23.5 3.85-3.79 w-vs ______________________________________ which process comprises providing a reaction mixture composition at an effective temperature and for an effective time sufficient to produce said molecular sieves, said reaction mixture composition being expressed in terms of molar oxide ratios as follows: aR:(EL.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 "R" and is an effective amount greater than zero to about 6; "b" has a value of from zero to about 500; "EL" represents at least one element capable of forming a three-dimensional oxide, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "r", "s", "t" and "u" represent mole fractions, respectively, of "EL", aluminum, phosphorus and silicon in the (EL r Al s P t Si u )O 2 constituent, and each has a value of at least 0.01.

Claim 4

Process for preparing the crystalline molecular sieves having three-dimensional microporous framework structures of ELO 2 , AlO 2 , PO 2 , SiO 2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula: mR:(EL.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 (EL w Al x P y Si z )O 2 and has a value of zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus, and silicon, respectively, present as framework oxides, said mole fractions being within the pentagonal compositional area defined by points A, B, C, D and E of FIG. 1, wherein element "EL" and each of aluminum, phosphorus and silicon are present such that "w", "x", "y" and "z" are at least 0.01 and each element "EL" is present as a tetrahedral oxide unit ELO 2 in an amount of at least 0.01, said crystalline molecular sieves having a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth in one of the following Tables A and B: TABLE A ______________________________________ (ELAPSO-5) 2θ d(Å) Relative Intensity ______________________________________ 7.2-7.7 12.28-11.48 m-vs 19.4-19.9 4.58-4.46 w-m 20.85-21.3 4.26-4.17 w-vs 22.1-22.6 4.02-3.93 m-vs 25.6-26.1 3.480-3.414 vw-m ______________________________________ TABLE B ______________________________________ (ELAPSO-11) 2θ d(Å) Relative Intensity ______________________________________ 7.8-8.2 11.19-10.85 m-s 9.0-9.8 9.83-9.03 vw-vs 12.8-13.6 6.92-6.51 vw-m 19.9-20.5 4.46-4.33 m-s 20.8-21.8 4.27-4.08 m-vs 22.0-22.6 4.04-3.93 m-vs 22.6-23.1 3.93-3.85 vw-vs 23.1-23.5 3.85-3.79 w-vs ______________________________________ which process comprises providing a reaction mixture composition at an effective temperature and for an effective time sufficient to produce said molecular sieves, said reaction mixture composition being expressed in terms of molar oxide ratios as follows: aR:(EL.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 "R" and is an effective amount greater than zero to about 6; "b" has a value of from zero to about 500; "EL" represents at least one element capable of forming a three-dimensional oxide, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "r", "s", "t" and "u" represent mole fractions, respectively, of "EL", aluminum, phosphorus and silicon in the (EL r Al s P t Si u )O 2 constituent, and each has a value of at least 0.01.

Claim 5

Process according to claim 2 wherein the source of phosphorus in the reaction mixture is orthophosphoric acid.

Claim 6

Process according to claim 2 wherein the source of phosphorus in the reaction mixture is orthophosphoric acid and the source of aluminum is at least one compound selected from the group of pseudo-boehmite and aluminum alkoxide.

Claim 7

Process according to claim 4 wherein the aluminum alkoxide is aluminum isopropoxide.

Claim 8

Process according to claim 2 wherein the source of silicon is silica.

Claim 9

Process according to claim 2 wherein the source of "EL" is selected from the group consisting of oxides, hydroxides, alkoxides, nitrates, halides, sulfates, carboxylates, organometallic compounds and mixtures thereof.

Claim 10

Process according to claim 2 wherein the organic templating agent is a quaternary ammonium or quaternary phosphonium compound having 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.

Claim 11

Process according to claim 2 wherein the organic templating agent is an amine.

Claim 12

Process according to claim 2 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; 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; 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) 2 ] x wherein x is a value of at least 2.

Claim 13

The process of claim 2 wherein "b" has a value between about 2 and about 300.

Claim 14

Process for preparing the crystalline molecular sieves having three-dimensional microporous framework structures of ELO 2 , AlO 2 , PO 2 , SiO 2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula: mR:(EL.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 (EL w Al x P y Si z )O 2 and has a value of zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus, and silicon, respectively, present as framework oxides, said mole fractions being within the pentagonal compositional area defined by points A, B, C, D and E of FIG. 1, wherein element "EL" and each of aluminum, phosphorus and silicon are present such that "w", "x", "y" and "z" are at least 0.01 and each element "EL" is present as a tetrahedral oxide unit ELO 2 in an amount of at least 0.01, which process comprises providing a reaction mixture composition at an effective temperature and for an effective time sufficient to produce said molecular sieves, said reaction mixture composition being expressed in terms of molar oxide ratios as follows: aR:(EL.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 "R" and is an effective amount greater than zero to about 6; "b" has a value of from zero to about 500; "EL" represents at least one element capable of forming a three-dimensional oxide, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "r", "s", "t" and "u" represent mole fractions, respectively, of "EL", aluminum, phosphorus and silicon in the (EL r Al s P t Si u )O 2 constituent, and each has a value of at least 0.01.

Claim 15

Process for preparing the crystalline molecular sieves having three-dimensional microporous framework structures of ELO 2 , AlO 2 , PO 2 , SiO 2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula: mR:(EL.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 (EL w Al x P y Si z )O 2 and has a value of zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus, and silicon, respectively, present as framework oxides, said mole fractions being within the pentagonal compositional area defined by points A, B, C, D and E of FIG. 1, wherein element "EL" and each of aluminum, phosphorus and silicon are present such that "w", "x", "y" and "z" are at least 0.01 and each element "EL" is present as a tetrahedral oxide unit ELO 2 in an amount of at least 0.01, which process comprises providing a reaction mixture composition at an effective temperature and for an effective time sufficient to produce said molecular sieves, said reaction mixture composition being expressed in terms of molar oxide ratios as follows: aR:(EL.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 "R" and is an effective amount greater than zero to about 6; "b" has a value of from zero to about 500; "EL" represents at least one element capable of forming a three-dimensional oxide, "EL" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" has a cation electronegativity between about 125 kcal/g-atom to about 310 kcal/g-atom and "EL" is capable of forming stable M-O-P, M-O-Al or M-O-M bonds in crystalline three dimensional oxide structures having an "M-O" bond dissociation energy greater than about 59 kcal/mole at 298° C.; and "r", "s", "t" and "u" represent mole fractions, respectively, of "EL", aluminum, phosphorus and silicon in the (EL r Al s P t Si u )O 2 constituent, and each has a value of at least 0.01.

Claim 16

Process according to claim 12 wherein the source of phosphorus in the reaction mixture is orthophosphoric acid.

Claim 17

Process according to claim 12 wherein the source of phosphorus in the reaction mixture is orthophosphoric acid and the source of aluminum is at least one compound selected from the group consisting of pseudo-boehmite and aluminum alkoxide.

Claim 18

Process according to claim 14 wherein the aluminum alkoxide is aluminum isopropoxide.

Claim 19

Process according to claim 12 wherein the silicon source is silica.

Claim 20

Process according to claim 12 wherein the source of "EL" is selected from the group consisting of oxides, hydroxides, alkoxides, nitrates, halides, sulfates, carboxylates, organometallic compounds and mixtures thereof.

Claim 21

Process according to claim 12 wherein the organic templating agent is a quaternary ammonium or quaternary phosphonium compound having 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.

Claim 22

Process according to claim 12 wherein the organic templating agent is an amine.

Claim 23

Process according to claim 12 wherein the templating agent is selected from the group consisting of tetrapropylammonium ion; tetraethylammonium ion; tripropylamine; triethylamine; triethanolamine; piperidine; cyclophexylamine; 2-methyl pyridine; N,N-dimethylbenzylamine; N,N-dimethylethanolamine; choline; N,N-dimethylpiperazine; 1,4-diaziabicyclo-(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; tetramethylammonium ion; tetrabutylammonium ion; tetrapentylammonium ion; di-n-butylamine; neopentylamine; di-n-pentylamine; isopropylamine; t-butylamine; ethylenendiamine; pyrrolidine; 2-imidazolidone; di-n-propylamine; and a polymeric quaternary ammonium salt [(C 14 H 32 N 2 )(OH) 2 ] x wherein x has a value of at least 2.

Claim 24

The process of claim 12 wherein "b" has a value between about 2 and about 300.