This invention relates to a synthetic porous crystalline material, its synthesis and its use as a sorbent or a catalyst component.

Porous inorganic solids have found great utility as catalysts and separation media for industrial application. The openness of their microstructure allows molecules access to the relatively large surface areas of these materials that enhance their catalytic and sorptive activity. The porous materials in use today can be sorted into three broad categories using the details of their microstructure as a basis for classification. These categories are the amorphous and paracrystalline materials, the crystalline molecular sieves and modified layered materials. The detailed differences in the microstructures of these materials manifest themselves as important differences in the catalytic and sorptive behavior of the materials, as well as in differences in various observable properties used to characterize them, such as their surface area, the sizes of their pores and the variability in those sizes, the presence or absence of X-ray diffraction patterns and the details in such patterns, and the appearance of the materials when their microstructure is studied by transmission electron microscopy and electron diffraction.

Amorphous and paracrystalline materials represent an important class of porous inorganic solids that have been used for many years in industrial applications. Typical examples of these materials are the amorphous silicas commonly used in catalyst formulations and the paracrystalline transitional aluminas used as solid acid catalysts and petroleum reforming catalyst supports.

The term "amorphous" is used herein to indicate a material with no long range order so that the pores of the material tend to be distributed over a wide range of sizes. An alternate term that has been used to describe these materials is "X-ray indifferent", since the lack of order also manifests itself in the X-ray diffraction pattern, which is usually featureless. The porosity of amorphous materials, such as the amorphous silicas, generally results from voids between the individual particles.

Paracrystalline materials such as the transitional aluminas also have a wide distribution of pore size, but better defined X-ray diffraction patterns usually consisting of a few broad peaks. The microstructure of these materials consists of tiny crystalline regions of condensed alumina phases and the porosity of the materials results from irregular voids between these regions (K. Wefers and Chanakya Misra, "Oxides and Hydroxides of Aluminum", Technical Paper No. 19 Revised, Alcoa Research Laboratories, p. 54-59, 1987) . The size of the pores in amorphous and paracrystalline materials fall into a regime called the mesoporous range which, for the purposes of this application, is from 1.3 to 20 nm. in sharp contrast to these structurally ill-defined solids are materials whose pore size distribution is very narrow because it is controlled by the precisely repeating crystalline units of the three-dimensional framework of the material. These materials are called "molecular sieves", the most important examples of which are zeolites. The precise crystalline microstructure of most zeolites manifests itself in a well-defined X-ray diffraction pattern that usually contains many sharp maxima and that serves to uniquely define the material. Similarly, the dimensions of pores in these materials are very regular, due to the precise repetition of the

— 4 _ —

crystalline microstructure. All molecular sieves discovered to date have pore sizes in the microporous range, which is usually quoted as 0.2 to 2 nm, with the largest reported being about 1.2 nm.

In layered materials, the interatomic bonding in two directions of the crystalline lattice is substantially different from that in the third direction, resulting in a structure that contains cohesive units resembling sheets. Usually, the bonding between the atoms within these sheets is highly covalent, while adjacent layers are held together by ionic forces or van der Waals interactions. These latter forces can frequently be neutralised by relatively modest chemical means, while the bonding between atoms within the layers remains intact and unaffected.

Thus in certain layered materials, adjacent layers may be urged apart with a swelling agent and then fixed in this separated position by the insertion of pillars to provide a material having a large degree of porosity. For example, certain clays may be swollen with water, whereby the layers of the clay are spaced apart by water molecules. Other layered materials are not swellable with water, but may be swollen with certain organic swelling agents such as amines and quaternary ammonium compounds. Examples of such non-water swellable layered materials are described in U.S. Patent 4,859,648 and include layered silicates, magadiite, kenyaite, trititanates and perovskites. Another example of a non-water swellable layered material, which can be swollen with certain organic swelling agents, is a vacancy-containing titano etallate material, as described in U.S. Patent 4,831,006. The X-ray diffraction patterns of pillared layered materials can vary considerably, depending on the degree that swelling and pillaring disrupt the

otherwise usually well-ordered layered microstructure. The regularity of the microstructure in some pillared layered materials is so badly disrupted that only one peak in the low angle region on the X-ray diffraction pattern is observed, at a d-spacing corresponding to the interlayer repeat in the pillared material. Less disrupted materials may show several peaks in this region that are generally orders of this fundamental repeat. X-ray reflections from the crystalline structure of the layers are also sometimes observed. The pore size distribution in these pillared layered materials is narrower than those in amorphous and paracrystalline materials but broader than that in crystalline framework materials. Layered materials frequently adopt sheetlike morphology mirroring the disparity in bonding that exists on the atomic level. Such morphological properties can be revealed by transmission electron microscopy. The present invention resides in an inorganic, porous, crystalline phase material exhibiting after calcination an X-ray diffraction pattern as set out in Table 1 below.

Thus the crystalline material of the present invention after calcination, typically at 540°C in air for at least 1 hour, to remove organic material used in its synthesis exhibits an X-ray diffraction pattern with distinct maxima in the extreme low angle region. The positions of these peaks will vary somewhat according to the pore diameter of the material but the ratios of d-spacings of the peaks will remain fixed. Using d. to indicate the d-spacings of the strongest peak in the X-ray diffraction pattern (relative intensity = 100) , the X-ray diffraction pattern of the calcined material of the present invention exhibits d. at a position greater than about 18 Angstroms d-spacing and at least one additional weaker peak with d-spacing

d _? such that the ratios of these d-spacings relative to d- (i.e. d /d. ) correspond to the ranges give in Table 1.

TABLE 1 d-Spacing, d .Angstroms d /d. Relative Intensity d _χ , > 18 1.0 100 d_ 0.87 + 0.06 w-m

More particularly, the X-ray diffraction pattern of the calcined material of the present invention includes at least two additional weaker peaks at d-spacings d_ and d_ such that the ratios of these d-spacings relative to the strongest peak d. (at a position greater than about 18 Angstroms d-spacing) correspond to the ranges given in Table 2. TABLE 2 d-Spacin , d , Angstroms d /d. Relative Intensity d _χ , > 18 1.0 100 ά. 0.87 + 0.06 w-m d ₃ 0.52 + 0.04 w Still more particularly, the X-ray diffraction pattern of the calcined material of the present invention includes at least four additional weaker peaks at d-spacings d_, d_, d. and d_ such that the ratios of these d-spacings relative to the strongest peak d_ (at a position greater than about 18 Angstroms d-spacing) correspond to the ranges given in Table 3.

TABLE 3 d-Spacing, d . Angstroms d /d- Relative Intensity _χf > 18 1.0 100 d_ 0.87 + 0.06 w-m d_ 0.55 + 0.02 W ά _c 0.50 + 0.01 W

In one preferred embodiment, the calcined material of the present invention has an X-ray diffraction pattern including at least two peaks as identified in

Table 4:

TABLE 4 d-Spacing. Angstroms Relative Intensity

33.0 + 2.0 100

28.7 + 1.5 W or more preferably at least three peaks as identified in Table 5:

TABLE 5 d-Spacing, Angstroms Relative Intensity

33.0 ± 2.0 100

28.7 + 1.5 w

17.2 + 1.2 W and most preferably at least five peaks as identified in Table 6:

TABLE 6 d-Spacing. Angstroms Relative Intensity

33.0 ± 2.0 100

28.7 + 1.5 w

18.2 + 0.5 W

17.2 ± 0.4 W 16.5 ± 0.3 W

X-ray diffraction data were collected on a Scintag PAD X automated diffraction system employing theta-theta geometry, Cu K-alpha radiation, and an energy dispersive X-ray detector. Use of the energy dispersive X-ray detector eliminated the need for incident or diffracted beam monochromators. Both the incident and diffracted X-ray beams were collimated by double slit incident and diffracted collimation systems. The slit sizes used, starting from the X-ray tube source, were 0.5, 1.0, 0.3 and 0.2 mm, respectively. Different slit systems may produce differing intensities for the peaks. The materials of the present invention that have the largest pore sizes may require more highly collimated incident X-ray beams in order to resolve the low angle peak from the transmitted incident X-ray beam.

The diffraction data were recorded by step- scanning at 0.04 degrees of two-theta, where theta is the Bragg angle, and a counting time of 10 seconds for each step. The interplanar spacings, d's, were calculated in Angstrom units (A) , and the relative intensities of the lines, I/ 'I_o_, where Io is one-hundredth of the intensity of the strongest line, above background, were derived with the use of a profile fitting routine. Overlap between peaks required the use of deconvolution techniques to determine peak positions in many cases. The intensities were uncorrected for Lorentz and polarization effects. The relative intensities are given in terms of the symbols vs = very strong (75-100) , s = strong (50-74) , m = medium (25-49) and w = weak (0-24) . It should be understood that diffraction data listed as single lines may consist of multiple overlapping lines which under certain conditions, such as very high experimental resolution or crystallographic changes, may appear as resolved or partially resolved lines. Typically, crystallographic changes can include minor changes in unit cell parameters and/or a change in crystal symmetry, without a substantial change in structure. These minor effects, including changes in relative intensities, can also occur as a result of differences in cation content, framework composition, nature and degree of pore filling, thermal and/or hydrothermal history, and peak width/shape variations due to particle size/shape effects, structural disorder or other factors known to those skilled in the art of X-ray diffraction.

In its calcined form, the crystalline material of the invention may be further characterized by an equilibrium benzene adsorption capacity usually greater than about 10 grams benzene/100 grams crystal at 50 torr and 25°C. The equilibrium benzene adsorption capacity is measured on the basis of no pore blockage

by incidental contaminants. For instance, the sorption test will be conducted on the crystalline material phase having any pore blockage contaminants and water removed by ordinary methods. Water may be removed by dehydration techniques, e.g. thermal treatment. Pore blocking inorganic amorphous materials, e.g. silica, and organics may be removed by contact with acid or base or other chemical agents such that the detrital material will be removed without detrimental effect on the crystal of the invention.

The equilibrium benzene adsorption capacity is determined by contacting the material of the invention, after dehydration or calcination at, for example, about 540°C for at least about one hour, e.g. about 6 hours, and other treatment, if necessary, in an attempt to remove any pore blocking contaminants, at 25"C and 50 torr benzene until equilibrium is reached. The weight of benzene sorbed is then determined as more particularly described hereinafter. The crystalline material of the invention is generally mesoporous, by which is meant that it has pores with a diameter range of 13 to 200 Angstroms, usually 15 to 100 Angstroms.

The inorganic, non-layered, mesoporous crystalline material of this invention typically has the following composition:

^M n/q ^(W a ^X b ^Y c ^Z d V wherein W is a divalent element, such as a divalent first row transition metal, e.g. manganese, cobalt and iron, and/or magnesium, preferably cobalt; X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum; Y is a tetravalent element such as silicon and/or germanium, preferably silicon; Z is a pentavalent element, such as phosphorus; M is one or more ions, such as, for example, ammonium, Group IA, IIA and VIIB ions, usually hydrogen, sodium and/or fluoride ions; n is the charge

of the composition excluding M expressed as oxides; q is the weighted molar average valence of M; n/q is the number of moles or mole fraction of M; a, b, c, and d are mole fractions of W, X, Y and Z, respectively; h is a number of from 1 to 2.5; and (a+b+c+d) = 1.

A preferred embodiment of the above crystalline material is when (a+b+c) is greater than d, and h = 2. A further embodiment is when a and d = 0, and h = 2.

In the as-synthesized form, the material of this invention has a composition, on an anhydrous basis, expressed empirically as follows: wherein R s the total organ c material not included in M as an ion, and r is the coefficient for R, i.e. the number of moles or mole fraction of R.

The M and R components are associated with the material as a result of their presence during crystallization, and are easily removed or, in the case of M, replaced by post-crystallization methods hereinafter more particularly described.

To the extent desired, the original M, e.g. sodium or chloride, ions of the as-synthesized material of this invention can be replaced in accordance with techniques well known in the art, at least in part, by ion exchange with other ions. Preferred replacing ions include metal ions, hydrogen ions, hydrogen precursor, e.g. ammonium, ions and mixtures thereof. Particularly preferred ions are those which tailor the catalytic activity for certain hydrocarbon conversion reactions. These include hydrogen, rare earth metals and metals of Groups IA (e.g. K) , IIA (e.g. Ca) , VIIA (e.g. Mn) , VIIIA (e.g. Ni),IB (e.g. Cu) , IIB (e.g. Zn) , IIIB (e.g. In), IVB (e.g. Sn) , and VIIB (e.g. F) of the Periodic Table of the Elements (Sargent-Welch Scientific Co. Cat. No. S-18806, 1979) and mixtures thereof.

When used as a sorbent or catalyst component, the composition of the invention should be subjected to

treatment to remove part or all of any organic constituent. The product composition can also be used as a catalyst component in intimate combination with a hydrogenating component such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal such as platinum or palladium or mixtures thereof where a hydrogenation- dehydrogenation function is to be performed. Such component can be in the composition by way of co-crystallization, exchanged into the composition to the extent a Group IIIB element, e.g. aluminum, is in the structure, impregnated therein or intimately physically admixed therewith. Such component can be impregnated in or on to it such as, for example, by, in the case of platinum, treating the silicate with a solution containing a platinum metal-containing ion. Thus, suitable platinum compounds for this purpose include chloroplatinic acid, platinous chloride and various compounds containing platinum amine complexes. The present crystalline material can be prepared by the following method:

(1) Combine the primary organic directing agent (R'), hereinafter more particularly described, optional additional organic directing agent (R") , hereinafter more particularly described, optional source of alkali or alkaline earth metal (M) , e.g. sodium or potassium, cations, and a solvent or solvent mixture, such as, for example, C.-C ₈ alcohols, C_-C ₆ diols and/or water, especially water, such that the mole ratio Solvent/(R' ₂ 0+M ₂ 0) is from 45 to less than 100, preferably 45 to 92. When this ratio is between 92 and 100, impurity products form mixtures with the desired crystalline material. (2) Add one or a combination of oxides of tetravalent element Y, e.g. silicon, and optionally one or a combination of oxides of elements selected from

the group consisting of divalent element W, e.g. cobalt, trivalent element X, e.g. aluminum and pentavalent element Z, e.g. phosphorus, to the mixture of step (1) , such that the mole ratio .

R ₂ 0/(Y0 ₂ +X ₂ 0 ₃ +Z ₂ 0 ₅ +W0) is in the range of 0.3 to 1, preferably from 0.3 to 0.6, where R is the total organic directing agent, i.e. R'+R".

(3) Agitate the mixture resulting from step (2) for from 10 minutes to 6 hours, preferably from 30 minutes to 2 hours, at a temperature of 0 ^β C to 50'C, and a pH of 7 to 14.

(4) Crystallize the product from step (3) at a temperature of 50°C to 200°C, preferably 95 ^β C to 150°C, for 4 to 72 hours, preferably 16 to 60 hours.

Batch crystallization of the present crystalline material can be carried out under either static or agitated, e.g. stirred, conditions in a suitable reactor vessel, such as for example, polypropylene jars or teflon lined or stainless steel autoclaves.

Crystallization may also be conducted continuously in suitable equipment. Following crystallization, the crystalline product is separated from the liquid and recovered. When a source of silicon is used in the synthesis method, it may be, at least in part, an organic silicate, such as, for example, a quaternary ammonium silicate. Non-limiting examples of such a silicate include tetramethylammonium silicate and tetraethylorthosilicate.

By adjusting conditions of the synthesis reaction like temperature, pH and time of reaction within the above limits, embodiments of the present non-layered crystalline material with a desired average pore size may be prepared. In particular, changing the pH, the temperature or the reaction time may promote formation of product crystals with different average pore size.

Non-limiting examples of various combinations of W, X, Y and Z contemplated for the procedure of the present invention include: w X X Z — Al Si

Al Si P

Co Al Si P

Si including the combinations of W being Mg, or an element selected from the divalent first row transition metals, e.g. Mn, Co and Fe; X being B, Ga or Fe; and Y being Ge.

The primary organic directing agent, R ¹ , for use in the above method for synthesizing the present material from the reaction mixture is an ammonium or phosphonium ion of the formula R.R-R-R.Q , wherein Q is nitrogen or phosphorus and wherein at least one of R., R_, R_ and R. is aryl or alkyl of from 8 to about 36 carbon atoms, e.g. ~ ₁₀ ^H 21 ' "" ^C 16 ^H 33' ^and ~ ^C 1 ₈ ^H 37' ^or combinations thereof, the remainder of R_, R_, R„ and R. being selected from the group consisting of hydrogen, alkyl of from 1 to 7 carbon atoms and combinations thereof. The compound from which the above ammonium or phosphonium ion is derived may be, for example, the hydroxide, halide, silicate, or mixtures thereof.

Non-limiting examples of the primary organic directing agent R ¹ include cetyltrimethylammonium, cetyltrimethylphosphonium, octadecyltrimethyl- phosphonium, cetylpyridinium, yristyltrimethyl- ammonium, decyltrimethylammonium, dodecyltrimethyl- ammonium and dimethyldidodecylammonium.

If an additional organic directing agent, R", is used in the above method, it is the ammonium or phosphonium ion of the above directing agent formula wherein R_, R,, R_ and R. together or separately are selected from the group consisting of hydrogen and

alkyl of 1 to 7 carbon atoms and combinations thereof. Examples of the additional organic directing agent include tetramethylammonium, tetraethylammonium, tetrapropylammonium, tetrabutylammonium and pyrrolidinium compounds. The molar ratio of the first-mentioned organic directing agent R' to the additional organic directing agent R" can be in the range 100/1 to 0.01/1.

The material of the invention is useful as a catalyst component for catalyzing the conversion of organic compounds, e.g. oxygenates and hydrocarbons, by acid-catalyzed reactions. The size of the pores is also such that the spatiospecific selectivity with respect to transition state species is minimized in reactions such as cracking (Chen et al., "Shape

Selective Catalysis in Industrial Applications", 36 Chemical Industries, pgs. 41-61 (1989)) to which reference is made for a discussion of the factors affecting shape selectivity) . Diffusional limitations are also minimized as a result of the very large pores in the present materials. For these reasons, the present compositions are especially useful for catalyzing reactions which occur in the presence of acidic sites on the surface of the catalyst and which involve reactants, products or transitional state species which have large molecular sizes, too great for undergoing similar reactions with conventional large pore size solid catalysts, for example, large pore size zeolites such as zeolite X, Y, L, ZSM-4, ZSM-18, and ZSM-20.

Thus, the present catalytic compositions will catalyze reactions such as cracking, and hydrocracking, and other conversion reactions using hydrocarbon feeds of varying molecular sizes, but with particular applicability to feeds with large molecular sizes such as highly aromatic hydrocarbons with substituted or unsubstituted polycyclic aromatic components, bulky

naphthenic compounds or highly substituted compounds with bulky steric configurations, e.g. molecular sizes of about 13 Angstroms or more. The present catalytic compositions are particularly useful for reactions in which the molecular weight of the feed is reduced to a lower value, i.e. to reactions involving cracking such as cracking or hydrocracking. Cracking may be conducted at a temperature of 200°C to 800°C, a pressure of 100 to 800 kPa (atmospheric to 100 psig) and a contact time of 0.1 second to 60 minutes.

Hydrocracking may be conducted at a temperature of

150°C to 550°C, a pressure of 800 to 21000 kPa (100 to

3000 psig) , a weight hourly space velocity of 0.1 hr -1

-1 to 100 hr , and a hydrogen/hydrocarbon molar ratio of o.l to 100.

The catalytic compositions prepared according to the present invention may also be used for selective conversion of inorganic compounds such as oxides of nitrogen in mixtures of gases which contain nitrogen oxides (NO ) , for example, industrial exhaust gases and the gases formed during the oxidative regeneration of catalysts used in the processing of hydrocarbons, especially in catalytic cracking operations. The porous crystalline material may be used in a matrixed or unmatrixed form for this purpose and may suitably be formed into extrudates, pellets or other shapes to permit the passage of gases over the catalyst with the minimum pressure drop. The crystalline material is preferably at least partly in the hydrogen form, but it may advantageously contain a minor amount of a noble metal as a catalytic component, especially a metal of Periods 5 and 6 of Group VIIIA of the Periodic Table, especially platinum, palladium, ruthenium, rhodium, iridium or mixtures thereof. Amounts of noble metal up to about 1 weight percent are typical with lower amounts, e.g. up to about 0.1 or 0.5 weight percent being preferred.

The NO reduction is suitably conducted by passing the gas containing the oxides of nitrogen over the catalyst at an elevated temperature, typically at least 200°C, and usually within the range of.200 to 600*C. The gas mixture may be mixed with ammonia to promote reduction of the oxides of nitrogen and pre-mixing may be conducted at a temperature of up to about 200 ^β C. The amount of ammonia which is mixed with the gas mixture is typically within the range of 0.75 to 1.25 of the stoichiometric amount, which itself varies according to the ratio of the different oxides of nitrogen in the gas mixture, as shown by the equations: 6NO + 8NH ₃ = 7N + 12H ₂ 0 6N0 + 4NH ₃ = 5N ₂ + 6H ₂ 0 The crystalline catalytic compositions may also be used for the reduction of oxides of nitrogen in gaseous mixtures in the presence of other reducing agents such as carbon or carbon monoxide. Reduction of the oxides of nitrogen in this way is of particular utility in the regeneration of fluid catalytic cracking (FCC) catalysts, since regeneration under appropriate conditions will produce the required concentrations of carbon monoxide which may then be used to reduce the proportion of NO in the regeneration gases in the presence of the catalyst.

Because the present catalytic compositions have been found to be stable, their use as cracking catalysts, e.g. in fluid catalytic cracking processes, with resid feeds will represent an especially favorable mode of utilization. Still further, they may be used in combination with one or more other catalyst components such as, for example, cracking catalysts comprising silica-alumina and/or zeolite Y, e.g. USY. The present catalytic compositions are especially useful for reactions using high molecular weight, high boiling or non-distillable feeds, especially residual feeds, i.e. feeds which are essentially non-distillable

or feeds which have an initial boiling point (5% point) above about 565°C (1050°F) . Residual feeds which may be used with the present catalytic compositions include feeds with API gravities below about 20, usually below 15 and typically from 5 to 10 with Conradsen Carbon Contents (CCR) of at least 1% by weight and more usually at least 5% or more, e.g. 5-10%. In some resid fractions the CCR may be as high as about 20 weight percent or even higher. The aromatic contents of these feeds will be correspondingly high, as may the contents of heteroatoms such as sulfur and nitrogen, as well as metals. Aromatics content of these feeds will usually be at least 50 weight percent and typically much higher, usually at least 70 or 80 weight percent, with the balance being principally naphthenes and heterocyclics. Typical petroleum refinery feeds of this type include atmospheric and vacuum tower resids, asphalts, aromatic extracts from solvent extraction processes, e.g. phenol or furfural extraction, deasphalted oils, slop oils and residual fractions from various processes such as lube production, coking and the like. High boiling fractions with which the present catalytic compositions may be used include gas oils, such as atmospheric gas oils; vacuum gas oils; cycle oils, especially heavy cycle oil; deasphalted oils; solvent extracts, such as bright stock; heavy gas oils, such as coker heavy gas oils; and the like. The present catalytic materials may also be utilized with feeds of non-petroleum origin, for example, synthetic oils produced by coal liquefaction, Fischer-Tropsch waxes and heavy fractions and other similar materials.

The compositions of this invention can also be used as adsorbents and separation vehicles in pharmaceutical and fine chemical applications. For example, porous compositions may be used in the purification of drugs like insulin or be used as solid vehicles for the controlled delivery of drugs. Another

application for use of these porous materials involves waste disposal where the extraordinary pore volumes are exploited. Therefore, at least one component can be partially or substantially totally separated from a mixture of components having differential sorption characteristics with respect to the present porous composition by contacting the mixture with the composition to selectively sorb the one component. Examples of this include contacting a mixture comprising water and at least one hydrocarbon component, whereby the at least one hydrocarbon component is selectively sorbed. Another example includes selective sorption of at least one hydrocarbon component from a mixture comprising same and at least one additional hydrocarbon component.

As in the case of many catalysts, it may be desired to incorporate the new crystal composition with another material resistant to the temperatures and other conditions employed in organic conversion processes. Such materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and/or metal oxides such as alumina, titania and/or zirconia. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Use of a material in conjunction with the new crystal, i.e. combined therewith or present during synthesis of the new crystal, which is active, tends to change the conversion and/or selectivity of the catalyst in certain organic conversion processes. Inactive materials suitably serve as diluents to control the amount of conversion in a given process so that products can be obtained economically and orderly without employing other means for controlling the rate of reaction. These materials may be incorporated with naturally occurring clays, e.g. bentonite and kaolin.

to improve the crush strength of the catalyst under commercial operating conditions. Said materials, i.e. clays, oxides, etc., function as binders for the catalyst. It is desirable to provide a.catalyst having good crush strength because in commercial use it is desirable to prevent the catalyst from breaking down into powder-like materials. These clay binders have been employed normally only for the purpose of improving the crush strength of the catalyst. Naturally occurring clays which can be composited with the new crystal include the montmorillonite and kaolin family, which families include the subbentonites , and the kaolins commonly known as Dixie, McNamee, Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. in addition to the foregoing materials, the new crystal can be composited with a porous matrix material such as silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia, silica-alumina-magnesia and silica-magnesia-zirconia.

It may be desirable to provide at least a part of the foregoing matrix materials in colloidal form so as to facilitate extrusion of the bound catalyst components(s) .

The relative proportions of finely divided crystalline material and inorganic oxide matrix vary widely, with the crystal content ranging from 1 to 90 percent by weight and more usually, particularly when the composite is prepared in the form of beads, in the range of 2 to 80 weight percent of the composite.

The invention will now be more particularly described with reference to the following examples and the accompanying drawings, in which:

Figures l, 2, 3, 4, and 5 are X-ray diffraction patterns of the products of Examples 1, 2, 3, 4, and 5. In the examples, whenever sorption data are set forth for comparison of sorptive capacities for water, cyclohexane, benzene and/or n-hexane, they are Equilibrium Adsorption values determined as follows: A weighed sample of the adsorbent, after calcination at about 540°C for at least about 1 hour and other treatment, if necessary, to remove any pore blocking contaminants, is contacted with the desired pure adsorbate vapor in an adsorption chamber. The increase in weight of the adsorbent is calculated as the adsorption capacity of the sample in terms of grams/100 grams adsorbent based on adsorbent weight after calcination at about 540"C. The present composition usually exhibits an equilibrium benzene adsorption capacity at 50 Torr and 25°C of greater than about 10 grams/100 grams, particularly greater than about 17.5 g/100 g, and more particularly greater than about 20 g/100 g.

A preferred way to measure adsorption is to contact the desired pure adsorbate vapor in an adsorption chamber evacuated to less than 1 mm at conditions of 1.6 kPa (12 Torr) of water vapor, 5.3 kPa (40 Torr) of n-hexane or cyclohexane vapor, or 6.7 or 8.0 kPa (50 or 60 Torr) of benzene vapor, at 25 ^β C. The pressure is kept constant (within about + 0.5 mm) by addition of adsorbate vapor controlled by a manostat during the adsorption period. As adsorbate is adsorbed by the new crystal, the decrease in pressure causes the manostat to open a valve which admits more adsorbate vapor to the chamber to restore the above control pressures. Sorption is complete when the pressure change is not sufficient to activate the manostat.

Another way of measuring benzene adsorption is on a suitable thermogravimetric analysis system, such as a computer-controlled 990/951 duPont TGA system. The adsorbent sample is dehydrated (physically sorbed water ⁵ removed) by heating at, for example, about 350 ^β C or 500°C to constant weight in flowing helium. If the sample is in as-synthesized form, e.g. containing organic directing agents, it is calcined at about 540 ^β C in air and held to constant weight instead of ° the previously described 350 ^β C or 500°C treatment.

Benzene adsorption isotherms are measured at 25"C by blending a benzene saturated helium gas stream with a pure helium gas stream in the proper proportions to obtain the desired benzene partial pressure. The value of the adsorption at 6.7 kPa (50 Torr) or 8.0 kPa (60

Torr) of benzene is taken from a plot of the adsorption isotherm.

In the examples, percentages are by weight unless otherwise indicated. EXAMPLE 1

One hundred grams of cetyltrimethylammonium (CTMA) hydroxide solution (prepared by contacting a 29 wt.% N,N,N-trimethyl-l-hexadecanaminium chloride solution with a hydroxide-for-halide exchange resin) was combined with 17.5 grams of tetraethylorthosilicate

(TEOS) with stirring. The stirring was continued for one hour. This mixture was placed in a polypropylene bottle and put into a steam box (~100°C) for 48 hours. The mixture had a composition in terms of moles per mole SiO assuming complete exchange of the surfactant:

0.57 moles of (CTMA) ₂ 0 47 moles of H_0 The mixture ratio of Solvent/(R' 0+M ₂ 0) was 82. The resultant product was filtered, washed, air-dried and calcined (1 hour at 540°C in flowing nitrogen followed by 6 hours in air) . The X-ray diffraction pattern of the calcined product is shown in

Figure 1. A tabulation of the X-ray diffraction peak positions obtained by deconvolution of this pattern for this preparation follows:

Interplanar d-Spacing Relative Intensity d d 32.6 100.0 1.00

28.2 17.4 0.87

21.4 1.7 0.66

20.0 1.3 0.61

17.9 5.1 0.55 17.1 7.1 0.52

16.2 1.9 0.50

15.7 1.4 0.48

The benzene sorption capacity was measured to be approximately 55 wt.%. EXAMPLE 2

One hundred grams of cetyltrimethylammonium (CTMA) hydroxide solution prepared as in Example 1 was combined with 20 grams of tetraethylorthosilicate (TEOS) with stirring at approximately 4 ^β C. The stirring was continued for one hour. This mixture was placed in a polypropylene bottle and put into a steam box ( ^" 100°C) for 48 hours. The mixture had a composition in terms of moles per mole Si0 ₂ assuming complete exchange of the surfactant: 0.59 moles of (CTMA) ₂ 0

41 moles of H ₂ 0 The mixture ratio of solvent/(R* 0+M ₂ 0) was 82. The resultant product was filtered, washed, air- dried and calcined (1 hour at 540 ^β C in flowing nitrogen followed by 6 hours in air) . The X-ray diffraction pattern of the calcined product is shown in Figure 2. A tabulation of the X-ray diffraction peak positions obtained by deconvolution of this pattern for this preparation follows:

The benzene sorption capacity was measured to be approximately 12.1 wt.%.

EXAMPLE 3 One hundred grams of cetyltrimethylammonium (CTMA) hydroxide solution prepared as in Example 1 was combined with 17.5 grams of tetraethylorthosilicate (TEOS) and 2.75 grams of titanium ethoxide with stirring. The stirring was continued for one hour. This mixture was placed in a polypropylene bottle and put into a steam box (~100 ^β C) for 7 days. The mixture had a composition in terms of moles per mole Si0 ₂ assuming complete exchange of the surfactant: 0.57 moles of (CTMA) 0 47 moles of H ₂ 0 0.14 moles of Ti0 ₂ 0.48 moles (CTMA) ₂ 0/mole (Si0 ₂ + Ti0 ₂ )

The mixture ratio of solvent/(R' 0+M ₂ 0) was 82. The resultant product was filtered, washed, air- dried and calcined (1 hour at 540°C in flowing nitrogen followed by 6 hours in air) . The X-ray diffraction pattern of the calcined product is shown in Figure 3. A tabulation of the X-ray diffraction peak positions obtained by deconvolution of this pattern for this preparation follows:

° The benzene sorption capacity was measured to be approximately 32 wt.%.

The elemental analyses of the products of Examples 1, 2 and 3 are included in the following tabulation: ELEMENTAL ANALYSES, WT.% Ti Al Si Ash. 1000"C

0.039 11.73 25.89 0.075 16.86 37.13 2.18 — 14.56 32.35 EXAMPLE 4 One hundred grams of cetyltrimethylammonium (CTMA) hydroxide solution prepared as in Example 1 was combined with 30 grams of tetraethylorthosilicate (TEOS) with stirring. The stirring was continued for one hour. An 11.2 gram quantity of IN NaOH solution was then added. This mixture was placed in a polypropylene bottle and put into a steam box (~100°C) for 48 hours. The mixture had a composition in terms of moles per mole Si0 ₂ assuming complete exchange of the surfactant: o.33 moles of (CTMA) ₂ 0

0.025 moles of Na ₂ 0 32 moles of H O The mixture ratio of solvent/(R' 0+M ₂ 0) was 90. The resultant product was filtered, washed, air- dried and calcined (1 hour at 540"C in flowing nitrogen followed by 6 hours in air) . The benzene sorption capacity was measured to be approximately 37 wt.%. The

X-ray diffraction pattern of the calcined product is shown in Figure 4. A tabulation of the X-ray diffraction peak positions obtained by deconvolution of this pattern for this preparation follows: ⁵ Interplanar d-Spacinq Relative Intensity d /d. 32.3 100.0 1.00

28.2 16 0.87

21.3 1 0.66 20.1 1 0.62 ° 17.7 13 0.55

17.0 8 0.53

16.5 3 0.51

16.0 7 0.50

EXAMPLE 5 5 One hundred grams of cetyltrimethylammonium (CTMA) hydroxide solution prepared as in Example 1 was combined with 30 grams of tetraethylorthosilicate (TEOS) with stirring. The stirring was continued for one hour. A 2.3 gram quantity of a 25 wt.% aqueous solution of tetramethy1ammonium hydroxide was then added. This mixture was placed in a polypropylene bottle and put into a steam box (~100°C) for 48 hours. The mixture had a composition in terms of moles per mole Si0 ₂ assuming complete exchange of the surfactant: 0.33 moles of (CTMA) ₂ 0

0.025 moles of (TMA) ₂ 0 28 moles of H ₂ 0 The mixture ratio of solvent/(R' 0+M ₂ 0) was 84.8. The resultant product was filtered, washed, air- dried and calcined (1 hour at 540"C in flowing nitrogen followed by 6 hours in air) . The benzene sorption capacity was measured to be approximately 35 wt.%. The X-ray diffraction pattern of the calcined product is shown in Figure 5. A tabulation of the X-ray diffraction peak positions obtained by deconvolution of this pattern for this preparation follows:

013 _-2 _Λ 6_-

EXAMPLE 6 fA.

Argon Physisorp ion For Pore Systems Up to About 60 Angstroms Diameter

To determine the pore diameters of the products of Examples 1 to 5, 0.2 gram samples of the products were placed in glass sample tubes and attached to a physisorption apparatus as described in U.S. Patent No. 4,762,010.

The samples were heated to 300°C for 3 hours in vacuo to remove adsorbed water. Thereafter, the samples were cooled to 87°K by immersion of the sample tubes in liquid argon. Metered amounts of gaseous argon were then admitted to the samples in stepwise manner as described in U.S. Patent No. 4,762,010, column 20. From the amount of argon admitted to the samples and the amount of argon left in the gas space above the samples, the amount of argon adsorbed can be calculated. For this calculation, the ideal gas law and the calibrated sample volumes were used. (See also S.J. Gregg et al.. Adsorption, Surface Area and Porosity, 2nd ed. , Academic Press, (1982)). In each instance, a graph of the amount adsorbed versus the relative pressure above the sample, at equilibrium, constitutes the adsorption isotherm. It is common to use relative pressures which are obtained by forming the ratio of the equilibrium pressure and the vapor pressure P of the adsorbate at the temperature where the isotherm is measured. Sufficiently small amounts of argon were admitted in each step to generate 168 data points in the relative pressure range from 0 to 0.6. At least about 100 points are required to define the isotherm with sufficient detail.

The step (inflection) in the isotherm indicates filling of a pore system. The size of the step indicates the amount adsorbed, whereas the position of the step in terms of P/P reflects the size of the pores in which the adsorption takes place. Larger pores are filled at higher P/P _Q . In order to better locate the position of the step in the isotherm, the derivative with respect to log (P/P ) is formed. This

0.2446, L = d + 0.19, and D = 0.57.

This formula is derived from the method of Horvath and Kawazoe (G. Horvath et al., J. Chem. Eng. Japan 16 (6) 470(1983)). The constants required for the implementation of this formula were determined from a measured isotherm of A1PO.-5 and its known pore size. This method is particularly useful for microporous materials having pores of up to about 60 Angstroms in diameter.

The results of this procedure for the samples from Examples 1 through 5 are tabulated below.

Example Pore Diameter, Angstroms

1 28

2 29

3 30

4 29