PRIORITY CLAIM OF EARLIER NATIONAL APPLICATION

[0001] This application claims priority to U.S. Application No. 13/718,003 filed

December 18, 2012.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to zeolite UZM-43, the process of making it and its use as a catalyst in hydrocarbon conversion processes. This zeolite is represented by the empirical formula:

M m ₊ R1 r .lR2 i.2A1.1-x E x Si y O z

where M represents sodium or a combination of sodium and potassium exchangeable cations, "m" is the mole ratio of M to (Al + E) and varies from 0.05 to 5, Rl is a singly charged propyltrimethylammonium cation, "rl" is the mole ratio of R to (Al +E) and has a value of 0.25 to 8.0, R2 is an amine, "r2" is the mole ratio of R to (Al +E) and has a value of 0.0 to 5, E is an element selected from the group consisting of gallium, iron, boron and mixtures thereof, "x" is the mole fraction of E and has a value from 0 to 1.0, "y" is the mole ratio of Si to (Al + E) and varies from greater than 5 to 40 and "z" is the mole ratio of O to (Al + E) and has a value determined by the equation: z = (m + rl + r2 + 3 + 4 * y)/2. The zeolite UZM-43 has an intergrowth of framework EUO-NES-NON. It may be present in the catalyst as unmodified zeolite UZM-43 or as UZM-43 modified zeolite. The UZM-43 containing catalyst may take one of several forms, including for example, a spherical oil-dropped catalyst or an extruded catalyst.

[0003] Zeolites are crystalline aluminosilicate compositions which are microporous and which are formed from corner sharing A10 ₂ and Si0 ₂ tetrahedra. Numerous zeolites, both naturally occurring and synthetically prepared, are used in various industrial processes.

Synthetic zeolites are prepared via hydrothermal synthesis employing suitable sources of Si, Al and structure directing agents such as alkali metals, alkaline earth metals, amines, or organoammonium cations. The structure directing agents reside in the pores of the zeolite and are largely responsible for the particular structure that is ultimately formed. These species balance the framework charge associated with aluminum and can also serve as space fillers. Zeolites are characterized by having pore openings of uniform dimensions, having a significant ion exchange capacity, and being capable of reversibly desorbing an adsorbed phase which is dispersed throughout the internal voids of the crystal without significantly displacing any atoms which make up the permanent zeolite crystal structure. Zeolites can be used as catalysts for hydrocarbon conversion reactions, which can take place on outside surfaces as well as on internal surfaces within the pore.

[0004] The three structure types EUO, NON and NES are closely related and can be constructed from the same two layer building units, LBU A and LBU B, shown below extending in the a' and b' axis directions. LBU A consists of TOzj-tetrahedra connected in two dimensions to generate a silicate sheet with 12-ring openings. LBU B consists of linear chains of TOzj-tetrahedra. To generate the 3-dimensional framework structures for EUO,

NON and NES, the two layer types are stacked in characteristic sequences in the c' axis direction.

[0005] Diagrams above show the layer-like building units of the EUO-NES-NON family as seen normal to (0 0 1). (a) Layer A consists of [T04]-tetrahedra interconnected to form 12- rings and (b) layer B consists of rods of [T04]-tetrahedra running parallel to a'

[0006] The above diagrams show representations of the framework structures and stacking sequences for (a) NON, (b) EUO and (c) NES as seen normal to (1 0 0).

[0007] For NON, only LBU A layers are stacked a). The stacking sequence is AA'AA' where every other A layer is shifted by l/2a' and is designated as A'. Although the individual layers contain 12-rings, the alternating shift of l/2a' blocks access and the resulting NON framework is a dense phase. It is not really a zeolite, but a clathrasil, since it contains cages (designated nns by J.V.Smithl) accessible by pores no larger than 6-rings.

[0008] The EUO framework type can be formed b) by inserting a B layer between AA' double layers giving a stacking sequence AA'BAA'B The resulting framework contains one- dimensional 10-ring channels with side pockets into truncated nns cages.

[0009] The NES framework type can be formed c) by alternating A and B layers to give a stacking sequence AB'A'BAB'A'B where A' and B' are shifted by l/2a'. The resulting framework contains 2-dimensional 10-ring channels normal to the b' axis.

[0010] Several related molecular sieves have been disclosed but there are significant differences between those molecular sieves and those of the present invention. In US 6,123,914 is disclosed an EU-1 and intergrowths of EUO-NES type of molecular sieve that is used to remove amorphous B and aluminum from the channels by using a mild treatment with sodium hydroxide. The present invention involves a silica/alumina material that does not contain boron.

[0011] US 7,459,073 discloses a molecular sieve SSZ-47B that is made using templates that have rings and are rigid (N-cyclopentyl-l,4-diaabicyclo[2.2.2] octane cation) that would be more expensive to produce and would produce a zeolite with more EUO character than other materials.

[0012] US 5,910,299 discloses a ERS-10 zeolite that is made using a template like 6- azonia spiro-[5,5]-undecane hydroxide. It is claimed to have a Si/Al ₂ ratio from 50 to pure silica. The present invention is made at lower Si/Al ₂ ratios than ERS-10.

[0013] A new material has been made comprising of an EUO-NES-NON framework intergrowth that has application in hydrocarbon processes.

SUMMARY OF THE INVENTION [0014] As stated, the present invention relates to a new aluminosilicate zeolite designated UZM-43 that comprises an EUO-NES-NON framework intergrowth. Accordingly, one embodiment of the invention is a microporous crystalline zeolite having a three-dimensional framework of at least A10 ₂ and Si0 ₂ tetrahedral units and an empirical composition in the as synthesized and anhydrous basis expressed by an empirical formula of: M m ₊ R1 r ,lR2 i2 Al, 1-x E x Si y O z

where M represents sodium or a combination of sodium and potassium exchangeable cations, "m" is the mole ratio of M to (Al + E) and varies from 0.05 to 5, Rl is a singly charged propyltrimethylammonium cation, "rl" is the mole ratio of R to (Al +E) and has a value of 0.25 to 8.0, R2 is an amine, "r2" is the mole ratio of R to (Al +E) and has a value of 0.0 to 5, E is an element selected from the group consisting of gallium, iron, boron and mixtures thereof, "x" is the mole fraction of E and has a value from 0 to 1.0, "y" is the mole ratio of Si to (Al + E) and varies from greater than 5 to 40 and "z" is the mole ratio of O to (Al + E) and has a value determined by the equation: z = (m + rl+r2 + 3 + 4 · y)/2 and is characterized in that it has the x-ray diffraction pattern having at least the d-spacing's and intensities set forth in Table A.

TABLE A

[0015] After being calcined, the x-ray diffraction pattern shown in Table B was observed.

TABLE B

[0016] Another aspect of the invention is the process of making the material by use of propyltrimethylammonium cation (SACHEM) or propyltrimethylammonium cation and an amine. Prior art SSZ-47 materials are made by using N,N-Dimethyl-3-azoniabicyclo[4.2.1] nonane cation or N,N-Dimethyl-3-azoniabicyclo[3.2.1] octane cation which are much more expensive and produce a material that has more EUO character than the materials produced by the present invention. ERS-10 is made with another expensive template 6-azonia spiro- [5,5]-undecane hydroxide and makes a zeolite material that a higher Si/Al ₂ ratio than UZM-43.

[0017] Yet another embodiment of the invention is a hydrocarbon conversion process using the above-described zeolite. The process comprises contacting the hydrocarbon with the zeolite at conversion conditions to give a converted hydrocarbon product. The hydrocarbon conversion processes include paraffin cracking, aromatic conversions such as xylene isomerization, toluene disproportionation, ring opening and cracking to remove benzene co-boilers and alkylation of aromatics with paraffins. BRIEF DESCRIPTION OF THE DRAWING

[0018] FIG. 1 shows the layer-like building unties of the EUO-NES-NON family as seen normal to (0 0 1).

[0019] FIG. 2 shows representations of the framework structures and stacking sequences for (a) NON, (b) EUO and (c) NES as seen normal to (1 0 0).

DETAILED DESCRIPTION OF THE INVENTION

[0020] Applicants have prepared an aluminosilicate zeolite whose topological structure fits within an EUO-NES-NON framework and are similar to RUB-35, SSZ-47 and ERS-10 types of zeolites as described in ATLAS OF ZEOLITE FRAMEWORK TYPES, which is maintained by the International Zeolite Association Structure Commission at http://topaz.ethz.ch/IZA- SC/StdAtlas.htm. These new zeolites have been designated as UZM-43. As will be shown in detail, UZM-43 is different from the known zeolites in a number of its characteristics.

[0021] As will be shown in detail in the examples, the UZM-43 material is thermally stable up to a temperature of at least 600°C and in another embodiment, up to at least 800°C. Also as shown in the examples, the UZM-43 material may have a micropore volume as a percentage of total pore volume of greater than 60%.

[0022] The UZM material is made from a reaction mixture having a composition expressed in terms of mole ratios of the oxides of: aM ₂ 0 : bR _2/p O : l-cAl ₂ 0 ₃ : cE ₂ 0 ₃ : dSi0 ₂ : eH ₂ 0 where "a" has a value of 0.05 to 5.0,"b" has a value of 1.5 to 40, "c" has a value of 0 to 1.0, "d" has a value of 4 to 40, "e" has a value of 25 to 4000. The source of M is selected from the group consisting of halide salts, nitrate salts, acetate salts, hydroxides, sulfate salts and mixtures thereof.

[0023] The source of E is selected from the group consisting of alkali borates, boric acid, precipitated gallium oxyhydroxide, gallium sulfate, ferric sulfate, ferric chloride and mixtures thereof. The aluminum source is selected from the group consisting of aluminum

isopropoxide, aluminum sec-butoxide, precipitated alumina, Al(OH) ₃ , aluminum metal and aluminum salts. The silicon source is selected from the group consisting of

tetraethyorthosilicate, fumed silica, colloidal silica and precipitated silica. The reaction mixture is reacted at a temperature of 150° to 185°C for a time of 1 day to 3 weeks. Preferably, the reaction mixture is reacted at a temperature of 165° to 175°C for a time of 1 day to 3 weeks. Rl is a singly charged propyltrimethylammonium cation, "rl" is the mole ratio of R to (Al +E) and has a value of 0.25 to 8.0, and R2 is an amine, r2 is morpholines. The process may further comprise adding UZM-43 seeds to the reaction mixture. EXAMPLE 1

[0024] An aluminosilicate reaction gel was prepared by first mixing 48.92 g of liquid sodium aluminate (LSA) (46.55% solution), 225.23 g of propyltrimethylammonium hydroxide (20% SACHEM), 36.11 g of morpholine (Aldrich) and 865.38 g of water while stirring vigorously. After thorough mixing, 224.36 g of Ultrasil VN SP 89%> was added. After the addition was completed, the resulting reaction mixture was homogenized for 1 hour, transferred to a 2-L Parr stainless steel stir autoclave. The mixture was crystallized at 175°C with stirring at 250 RPM for 160 hours. The solid product was recovered by centrifugation, washed with de-ionized water and dried at 95°C. The product was identified as UZM-43 by XRD. Representative diffraction lines observed for the product are shown in Table 1. The product composition was determined by elemental analysis to consist of the following mole ratios: Si/Al = 13.76, Na/Al = 0.23. A portion of the material was calcined by ramping to 600°C for 2 hours followed by a 6 hour dwell in air. The BET surface area 176 m ² /g and the micropore volume was 0.07 cc/g. Scanning Electron Microscopy (SEM) revealed crystals of round (grape-like) shape less than 100 nm. Chemical analysis was as follows: 3.06% Al, 42.9% Si, 0.99% Na, N/A1=0.78, Na/Al=0.38, Si/Al ₂ =27. The diffraction lines that were observed for UZM-43 are as follows in Table 1.

TABLE 1

Representative diffractions lines observed for the calcined UZM-43 are shown in Table 2.

TABLE 2

EXAMPLE 2

[0025] An aluminosilicate reaction gel was prepared by first mixing 48.92 g of liquid sodium aluminate (LSA) (46.55% solution), 225.23 g of propyltrimethylammonium hydroxide (20% SACHEM), 36.1 1 g of morpholine (Aldrich) and 865.38 g of water while stirring vigorously. After thorough mixing, 224.36 g of Ultrasil VN SP 89%> was added. After the addition was completed, the resulting reaction mixture was homogenized for 1 hour, transferred to a 2-L Parr stainless steel stir autoclave. The mixture was crystallized at 175°C with stirring at 350 RPM for 160 hours. The solid product was recovered by centrifugation, washed with de-ionized water and dried at 95°C. The product was identified as UZM-43 by XRD. Representative diffraction lines observed for the product are shown in Table 3. The product composition was determined by elemental analysis to consist of the following mole ratios: Si/Al = 13.5, Na/Al = 0.38 and N/A1=0.78. A portion of the material was calcined by ramping to 600°C for 2 hours followed by a 6 hour dwell in air. The BET surface area 192 m ² /g and the micropore volume was 0.07 cc/g. Scanning Electron Microscopy (SEM) revealed crystals of round shape less than 100 nm.

TABLE 3

EXAMPLE 3

[0026] An aluminosilicate reaction gel was prepared by first mixing 36.61 g of liquid sodium aluminate (LSA) (46.55% solution), 24.3 g of sodium hydroxide (50%> solution) and 749.05 g of water while stirring vigorously. After thorough mixing, 421.53 g of

propyltrimethylammonium bromide (25% SACHEM) was added, and then 167.99 g of Ultrasil VN SP 89%> was added. After the addition was completed, the resulting reaction mixture was homogenized for 1 hour, transferred to a 2-L Parr stainless steel stir autoclave. The mixture was crystallized at 175°C with stirring at 350 RPM for 132 hours. The solid product was recovered by centrifugation, washed with de-ionized water and dried at 95°C. The product was identified as UZM-43 by XRD. Representative diffraction lines observed for the product are shown in Table 4. The product composition was determined by elemental analysis to consist of the following mole ratios: Si/Al = 13.05, Na/Al = 0.34. A portion of the material was calcined by ramping to 600°C for 2 hours followed by a 6 hour dwell in air. The BET surface area 292 m ² /g and the micropore volume was 0.101 cc/g. Scanning Electron Microscopy (SEM) revealed crystals of round shape less than 100 nm.

TABLE 4

Representative diffractions lines observed for the calcined UZM-43 are shown in Table 5.

TABLE 5

[0027] UZM-43 synthesized as per Examples 1 and 2 were formulated into a catalyst containing 70% UZM-43 and 30% alumina. In the catalyst preparation Catapal B alumina was first peptized with nitric acid using 0.17 g of HNO ₃ per gram of Catapal B alumina. The peptized alumina was then added to the muller, while mixing, until the dough with a proper texture for extrusion was formed. The dough was then extruded to form 1/16" diameter cylinders, which were dried at 100°C overnight and then sized to a length to diameter ratio of 3. The dry extrudates were calcined in a box oven with a flowing air at 600°C x 5 hours to remove the template. The calcined support was then exchanged using a 10 wt-%> NH ₄ NO ₃ solution at 75 °C for 1 hour. This was followed by water wash using 10 g of water per g of zeolite. The NH ₄ NO ₃ exchange and water wash was repeated two more times. The extrudate was then dried at 120°C for 4 hours and then activated at 550°C.

[0028] For each of the samples listed in Table 1 , comparison was made of the observed diffraction pattern with DIFFaX simulated patterns to give estimates of the N and aS transition probabilities, which indicate EUO, NES, and NON clustering tendencies. Percentages of EUO, NES, and NON were calculated from the transition probabilities. Best fits to the simulations are summarized in Table 6.

TABLE 6

Results from DIFFaX simulations of experimental patterns

[0029] Samples 1 and 2: The synthesized samples 1 and 2 have very similar diffraction patterns and can be matched to the same DIFFaX simulated patterns. They both show only a slight tendency to cluster in NES-like regions and slightly more tendency to cluster in EUO- and NON-like regions leading to structures with slightly more EUO and NON than NES character.

[0030] Sample 3: Synthesized sample 3 has a slightly different diffraction pattern than the first two. The pattern can be fit with a simulated pattern that indicates the sample contains a little more NON character and less EUO character than the first two samples.

[0031] Regarding the diffraction of the prior art samples, the following observations were made.

[0032] ERS-10. Of the literature samples, ERS-10 has a diffraction pattern most similar to the present invention, although there are distinct differences. The pattern can be fit with a simulation indicating a similar composition, but with slightly more EUO content and Si/Al ₂ ratio is higher than UZM-43.

[0033] The diffraction pattern for SSZ-47 is different from those for Samples 1, 2 and 3 and is consistent with a structure containing more NON character.

[0034] RUB-35 has a diffraction pattern most different from those for the samples illustrating the present invention. Its pattern is consistent with a structure with high EUO character. A model for the faulting in RUB-35 was developed which did not consider clustering. Their best fit was to a structure with 78% EUO-type and 22% NON-type character. The model reported here gives a similar result (82% EUO, 12% NON, 8% NES) but also indicates some NES-type character is present.

SPECIFIC EMBODIMENTS

[0035] While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.

[0036] An embodiment of the invention involves a hydrocarbon conversion process comprising contacting a hydrocarbon stream with a catalyst at hydrocarbon conversion conditions to give a converted product, the catalyst comprising a modified UZM-43 microporous crystalline zeolite, wherein the modified UZM-43 has a three-dimensional framework of at least A10 ₂ and Si0 ₂ tetrahedral units and an empirical composition on an anhydrous basis expressed by an empirical formula of

Mm+RlriiUtfAli.xExSiyOz where M represents sodium or a combination of sodium and potassium exchangeable cations, "m" is the mole ratio of M to (Al + E) and varies from 0.05 to 5, Rl is a singly charged propyltrimethylammonium cation, "rl" is the mole ratio of R to (Al +E) and has a value of 0.25 to 8.0, R2 is an amine, "r2" is the mole ratio of R to (Al +E) and has a value of 0.0 to 5, E is an element selected from the group consisting of gallium, iron, boron and mixtures thereof, "x" is the mole fraction of E and has a value from 0 to 1.0, "y" is the mole ratio of Si to (Al + E) and varies from greater than 5 to 40 and "z" is the mole ratio of O to (Al + E) and has a value determined by the equation z = (m + rl + Γ2 + 3 + 4 · y)/2 and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A

TABLE A

and is thermally stable up to a temperature of at least 600°C and has a BET surface area of less than 420 m ² /g. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the hydrocarbon conversion process is selected from the group consisting of alkylation, de-alkylation, trans- alkylation of aromatics, isomerization of aromatics, alkylation of olefins with isoparaffin, olefin dimerization, olefin oligomerization, catalytic cracking, and dewaxing. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the modified UZM-43 microporous crystalline zeolite has an EUO-NES-NON framework structure comprising from 33-34 wt-% EUO, 24-31 wt-% NES and 34-43 wt-% NON. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the catalyst further comprises alumina.

[0037] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. [0038] In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.

[0039] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.