BACKGROUND OF THE INVENTION

Natural and synthetic zeolitic crystalline aluminosilicates are useful as catalysts and adsorbents. These alumino- silicates have distinct crystal structures which are deπton- strated by X-ray diffraction. The crystal structure defines cavities and pores which are characteristic of the different species. The adsorptive and catalytic properties of each crystalline aluminosilicate are determined in part by the dimensions of its pores and cavities. Thus, the utility of a particular zeolite in a particular application depends at least partly on its crystal structure.

Because of their unique molecular sieving characteristics, as well as their catalytic properties, crystalline alumino- silicates are especially useful in such applications as gas drying and separation and hydrocarbon conversion. Although many different crystalline aluminosilicates and silicates have been disclosed, there is a continuing need for new zeolites and silicates with desirable properties for gas separation and drying, hydrocarbon and chemical conversions, and other applications.

Crystalline aluminosilicates are usually prepared from aqueous reaction mixtures containing alkali or alkaline earth metal oxides, silica, and alumina. "Nitrogenous zeolites" have been prepared from reaction mixtures con- taining an organic templating agent, usually a nitrogen- containing organic cation. By varying the synthesis conditions and the composition of the reaction mixture, different zeolites can be formed using the same templating agent. Use of N,N,N-trimethyl cyclopentylammonium iodide in

the preparation of Zeolite SSZ-15 molecular sieve is dis- closed in U.S. Patent No. 4,610,854; use of 1-azoniaspiro [4.4] nonyl bromide and N,N,N-trimethyl neopentylammonium iodide in the preparation of a molecular sieve termed " osod" is disclosed in Helv. Chim. Acta (1974); vol. 57, P- 1533 ( . Sieber and . M. Meier); use of quinuclidinium compounds to prepare a zeolite termed "NU-3" is disclosed in European Patent Publication No. 40016; use of l,4-di(l- azoniabicyclo [2.2.2. Joctane) lower alkyl compounds in the preparation of Zeolite SSZ-16 molecular sieve is disclosed in U.S. Patent No. 4,508,837; use of N,N,N-trialkyl-l- adamantamine in the preparation of Zeolite SSZ-13 molecular sieve is disclosed in U.S. Patent No. 4,544,538, and for SSZ-24 in U.S. Patent No. 4,665,110.

Synthetic zeolitic crystalline borosilicates are useful as catalysts. Methods for preparing high silica content zeo- lites that contain framework boron are known and disclosed in U.S. Patent No. 4,269,813. The amount of boron contained in the zeolite usually may be made to vary by incorporating different amounts of borate ion in the zeolite forming solution.

The use of a quaternary ammonium compound in the preparation of a boron-containing zeolite is disclosed in European Patent Application No. 188,913. A method for treating a zeolite containing aluminum and boron with a silicon substi- tution treatment is disclosed in U.S. Patent No. 4,701,313.

The present invention relates to a novel family of stable synthetic crystalline materials characterized as boro- silicates identified as SSZ-33 and having a specified X-ray diffraction pattern, and also to the preparation and use of such materials.

SUMMARY OF THE INVENTION

We have prepared a family of crystalline borosilicate molecular sieves with unique properties, referred to herein as "Zeolite SSZ-33" or simply as "SSZ-33", and have found highly effective methods for preparing SSZ-33. Also, advantageous uses for SSZ-33 have been discovered.

Thus, according to the present invention, a zeolite composition, SSZ-33, is provided.

SSZ-33 has a mole ratio of an oxide selected from silicon oxide, germanium oxide, and mixtures thereof to an oxide selected from boron oxide or mixtures of boron oxide with aluminum oxide, gallium oxide, or iron oxide greater than about 20:1; contains greater than 100 ppm boron and has an X-ray diffraction pattern in accordance with Table 1(a) below.

The SSZ-33 zeolite preferably has a composition, as synthesized and in the anhydrous state, in terms of mole ratios of oxides as follows: (1.0 to 5)Q ₂ 0:(0.1 to 1.0)M ₂ O:W ₂ O ₃ :(greater than 20)YO ₂ wherein M is an alkali metal cation, W is selected from boron, Y is selected from silicon, germanium and mixtures thereof, and Q is a tri- cyclodecane quaternary ammonium ion.

SSZ-33 zeolites preferably have a YO-iW _j Og mole ratio greater than about 20:1 and can be made essentially alumina free. As prepared, the silica:boron oxide ratio is typically in the range of 20:1 to about 100:1. Higher mole ratios can be obtained by treating the zeolite with chelating agents or acids to extract boron from the zeolite

lattice. The silica:boron oxide mole ratio can also be increased by using silicon and carbon halides and other similar compounds.

The boron in the crystalline network may also be replaced by aluminum using the procedures described in U.S. Patent Nos. 4,559,315 and 4,550,092 which are hereby incorporated by reference.

According to one embodiment of the present invention, a method is provided for making SSZ-33 zeolites, comprising preparing an aqueous mixture containing sources of a tricyclodecane quaternary ammonium ion, boron oxide, and an oxide selected from silicon oxide, germanium oxide, and mixtures thereof. The aqueous mixture has a composition, in terms of mole ratios of oxides falling within the following ranges: Y0 ₂ /W ₂ 0 ₃ , 20:1 to about 100:1; Q/Y0 ₂ , 0.05:1 to 0.50:1 (wherein Y is selected from silicon, germanium, and mixtures thereof, W is selected from boron, and Q is a tri- cyclodecane quaternary ammonium ion). The mixture is maintained at a temperature of at least 100°C until the crystals of said zeolite are formed and the crystals are recovered.

A zeolite having the same X-ray diffraction pattern as the SSZ-33 zeolite is described in our application U.S. Serial No. 172,737 entitled "New Zeolite SSZ-26". As synthesized using the method described therein, this zeolite contains primarily silica and alumina. The method for preparing SSZ-26 described in this application cannot be used to make the boron-containing SSZ-33. Additionally, SSZ-33 cannot be prepared by replacing the aluminum with boron in the

synthesized SSZ-26 structure. Successful preparation of the boron-containing SSZ-33 structure requires using a new synthesis method described herein.

SSZ-33 has the same X-ray diffraction pattern as SSZ-26 but SSZ-33 is made using a template described in our application U.S. Serial No. 260,439 entitled "New Zeolite SSZ-31". The template described in SN 260,439 is used to make a new all silicate or aluminosilicate zeolite SSZ-31. This template is a tricyclodecane quaternary ammonium template.

Among other factors, the present invention is based on our finding that a new boron-containing zeolite, SSZ-33, emerges by using boron and a template which was used to prepare SSZ-31. Surprisingly, the x-ray diffraction pattern of SSZ-33 is the same as that of SSZ-26, although SSZ-33 is not made using the original propellane-baεed SSZ-26 template. We have also found that the SSZ-33 zeolite has unexpectedly outstanding hydrocarbon conversion properties, particularly including catalytic cracking properties and reforming properties with high sulfur tolerance.

DETAILED DESCRIPTION OF THE INVENTION

SSZ-33 zeolites, as synthesized, have a crystalline structure whose X-ray powder diffraction pattern shows the following characteristic lines:

1

3 4 5 6 7 8 9 0 1

Typical SSZ-33 borosilicate and calcined borosilicate 3 zeolites have the X-ray diffraction pattern of Tables 2 and ⁴ 4 below. 5 ⁶ The X-ray powder diffraction patterns were determined by ' standard techniques. The radiation was the K-alpha/doublet 8 of copper and a scintillation counter spectrometer with a 9 strip-chart pen recorder was used. The peak heights I and 0 the positions, as a function of 2 θ where θ is the Bragg angle, were read from the spectrometer chart. From these 2 measured values, the relative intensities, 100I/I , where I 3 i _ε the intensity of the strongest line or peak, and d, the 4 interplanar spacing in Angstroms corresponding to the 5 recorded lines, can be calculated. 6 ? The X-ray diffraction pattern of Table 1(a) is ° characteristic of SSZ-33 zeolites. The zeolite produced by ' exchanging the metal or other cations present in the zeolite " with various other cations yields substantially the same 1 diffraction pattern although there can be minor shifts in interplanar spacing and minor variations in relative intensity. Minor variations in the diffraction pattern can 4 also result from variations in the organic compound used in

the preparation and from variations in the εilica-to-boron mole ratio from sample to sample. Calcination can also cause minor shifts in the X-ray diffraction pattern. Notwithstanding these minor perturbations, the basic crystal lattice structure remains unchanged.

After calcination, the SSZ-33 zeolites have a crystalline structure whose X-ray powder diffraction pattern shows the characteristic lines as indicated in Table 1(b) below.

SSZ-33 zeolites can be suitably prepared from an aqueous solution containing sources of an alkali metal oxide, a ζ_ tricyclo[5.2.1.0 ' Jdecane quaternary ammonium ion, boron oxides, and an oxide of silicon or germanium, or mixture of the two. The reaction mixture should have a composition in terms of mole ratios falling within the following ranges:

2 6 wherein Q is a (tricyclo[5.2.1.0 ' Jdecane) quaternary ammonium ion, Y is silicon, germanium or both, and W is boron. M is an alkali metal, preferably sodium. The organic compound which acts as a source of the quaternary ammonium ion employed can provide hydroxide ion.

The tricyclodecane quaternary ammonium ion component Q, of the crystallization mixture, is derived from the quaternary ammonium compound. Preferably, the tricyclo[5.2.1.0 ' ]- decane quaternary ammonium ion is derived from a compound of the formula:

wherein each of Y., Y ₂ , and Y, independently is a lower alkyl and most preferably methyl; A is an anion which : not detrimental to the formation of the zeolite.

The quaternary ammonium compounds are prepared by methods known in the art.

By "lower alkyl" is meant alkyl of from about 1 to 3 carbon atoms.

A is an anion which is not detrimental to the formation of the zeolite. Representative of the anions include halogens, such as fluoride, chloride, bromide and iodide, hydroxide, acetate, sulfate, carboxylate. Hydroxide is the most preferred anion. It may be beneficial to ion exchange, for example, the halide for hydroxide ion, thereby reducing or eliminating the alkali metal hydroxide quantity required.

The reaction mixture is prepared using standard zeolitic preparation techniques. Sources of boron for the reaction mixture include borosilicate glasses and other reactive boron oxides. These include borates, boric acid and borate esters. Typical sources of silicon oxide include fumed silica, silicates, silica hydrogel, silicic acid, colloidal silica, tetra-alkyl orthosilicates, and silica hydroxides.

The reaction mixture is maintained at an elevated temperature until the crystals of the zeolite are formed. The temperatures during the hydrothermal crystallization step are typically maintained from about 140°C to about 200°C, preferably from about 150°C to about 170°C and most preferably from about 155°C to about 165°C. The crystallization period is typically greater than 1 day and preferably from about 3 days to about 7 days.

The hydrothermal crystallization is conducted under pressure and usually in an autoclave so that the reaction mixture is subject to autogenous pressure. The reaction mixture can be stirred during crystallization.

Once the zeolite crystals have formed, the solid product is separated from the reaction mixture by standard mechanical separation techniques such as filtration. The crystals are water-washed and then dried, e.g., at 90°C to 150 ^β C from 8 to 24 hours, to obtain the as synthesized, SSZ-33 zeolite crystals. The drying step can be performed at atmospheric or subatmospheric pressures.

During the hydrothermal crystallization step, the SSZ-33 crystals can be allowed to nucleate spontaneously from the reaction mixture. The reaction mixture can also be seeded with SSZ-33 crystals both to direct, and accelerate the crystallization, as well as to minimize the formation of undesired borosilicate contaminants.

The synthetic SSZ-33 zeolites can be used as synthesized or can be thermally treated (calcined). Usually, it is desirable to remove the alkali metal cation by ion exchange and replace it with hydrogen, ammonium, or any desired metal ion. The zeolite can be leached with chelating agents, ^e -9«. EDTA or dilute acid solutions, to increase the silica:boron mole ratio. The zeolite can also be steamed; steaming helps stabilize the crystalline lattice to attack from acids. The zeolite can be used in intimate combination with hydrogenating components, such as tungsten, vanadium, molybdenum, rhenium, nickel, cobalt, chromium, manganese, or a noble metal, such as palladium or platinum, for those applications in which a hydrogenation-dehydrogenation function is desired. Typical replacing cations can include metal cations, e.g., rare earth. Group IIA and Group VIII metals, as well as their mixtures. Of the replacing metallic cations, cations of metals such as rare earth, Mn, Ca, Mg, Zn, Cd, Pt, Pd, Ni, Co, Ti, Al, Sn, Fe, and Co are particularly preferred.

The hydrogen, ammonium, and metal components can be exchanged into the zeolite. The zeolite can also be impregnated with the metals, or, the metals can be physically intimately admixed with the zeolite using standard methods known to the art. And, some metals can be occluded in the crystal lattice by having the desired metals present as ions in the reaction mixture from which, the SSZ-33 zeolite is prepared.

Typical ion exchange techniques involve contacting the synthetic zeolite with a solution containing a salt of the desired replacing cation or cations. Although a wide variety of salts can be employed, chlorides and other halides, nitrates, acetates, and sulfates are particularly preferred. Representative ion exchange techniques are disclosed in a wide variety of patents including U.S. Nos. 3,140,249; 3,140,251; and 3,140,253.

Following contact with the salt solution of the desired replacing cation, the zeolite is typically washed with water and dried at temperatures ranging from 65 ^β C to about 315°C. After washing, the zeolite can be calcined in air or inert gas at temperatures ranging from about 200°C to 820 ^β C for periods of time ranging from 1 to 48 hours, or more, to produce a catalytically active product especially useful in hydrocarbon conversion processes.

Regardless of the cations present in the synthesized form of the zeolite, the spatial arrangement of the atoms which form the basic crystal lattice of the zeolite remains essentially unchanged. The exchange of cations has little, if any, effect on the zeolite lattice structures.

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The SSZ-33 borosilicate and boroaluminosilicate can be formed into a wide variety of physical shapes. Generally speaking, the zeolite can be in the form of a powder, a granule, or a molded product, such as extrudate having particle size sufficient to pass through a 2-meεh (Tyler) screen and be retained on a 400-mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion with an organic binder, the borosilicate and boroaluminosilicate can be extruded before drying, or, dried or partially dried and then extruded. The zeolite can be composited with other materials resistant to the temperatures and other conditions employed in organic conversion processes. Such matrix materials include active and inactive materials and synthetic or naturally occurring zeolites as well as inorganic materials such as clays, silica and metal oxides. The latter may occur naturally or may be in the form of gelatinous precipitates, sols, or gels, including mixtures of silica and metal oxides. Use of an active material in conjunction with the synthetic zeolite, i.e., combined with it, tends to improve the conversion and selectivity of the catalyst in certain organic conversion processes. Inactive materials can suitably serve as diluents to control the amount of conversion in a given process so that products can be obtained economically without using other means for controlling the rate of reaction. Frequently, zeolite materials have been incorporated into naturally occurring clays, e.g., bentonite and kaolin. These materials, i.e., clays, oxides, etc., function, in part, as binders for the catalyst. It is desirable to provide a catalyst having good crush strength, because in petroleum refining the catalyst is often subjected to rough handling. This tends to break the catalyst down into powders which cause problems in processing.

Naturally occurring clays which can be composited with the synthetic zeolites of this invention include the montmorillonite and kaolin families, which families include the sub-bentonites 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. Fibrous clays such as sepiolite and attapulgite can also be used as supports. Such clays can be used in the raw state as originally mined or can be initially subjected to calcination, acid treatment or chemical modification.

In addition to the foregoing materials, the SSZ-33 zeolites can be composited with porous matrix materials and mixturesof matrix materials such as silica, alumina, titania, magnesia, silica:alumina, silica-magnesia, εilica-zirconia, silica-thoria, εilica-beryllia, εilica-titania, titania-zirconia as well as ternary compositions such as εilica-alumina-thoria, εilica-alumina-zirconia, εilica-alumina-magnesia, and silica-magnesia-zirconia. The matrix can be in the form of a cogel.

The SSZ-33 zeolites can also be composited with other zeolites such as synthetic and natural faujasites (e.g., X and Y), erionites, and mordenites. They can also be composited with purely synthetic zeolites such as those of the ZSM εerieε. The combination of zeolites can also be composited in a porous inorganic matrix.

SSZ-33 zeolites are useful in hydrocarbon conversion reactions. Hydrocarbon conversion reactions are chemical and catalytic processes in which carbon-containing compounds are changed to different carbon-containing compounds.

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Exampleε of hydrocarbon converεion reactions include catalytic cracking, hydrocracking, and olefin and aromatics formation reactionε. The catalyεtε are uεeful in other petroleum refining and hydrocarbon converεion reactions such as isomerizing n-paraffins and naphthenes, polymerizing and oligomerizing olefinic or acetylenic compoundε such as isobutylene and butene-1, reforming, alkylating, iεomerizing polyalkyl εubεtituted aromaticε (e.g., ortho xylene), and diεproportionating aromaticε (e.g., toluene) to provide mixtures of benzene, xylenes, and higher methylbenzeneε. The SSZ-33 catalyεtε have high εelectivity, and under hydrocarbon converεion conditionε can provide a high 3 percentage of deεired products relative to total products. 4 5 SSZ-33 zeolites can be used in processing hydrocarbonaceous 6 feedstocks. Hydrocarbonaceous feedstockε contain carbon 7 compoundε and can be from many different εourceε, εuch aε virgin petroleum fractionε, recycle petroleum fractionε, 9 εhale oil, liquefied coal, tar εand oil, and in general, can o ^De any carbon containing fluid εusceptible to zeolitic i catalytic reactions. Depending on the type of procesεing 2 the hydrocarbonaceous feed is to undergo, the feed can 3 contain metals or be free of metals, it can also have high 4 or low nitrogen or sulfur impurities. It can be 5 appreciated, however, that general processing will be more 6 efficient (and the catalyst more active) the lower the 7 metal, nitrogen, and sulfur content of the feedstock. 8 9 Using the SSZ-33 catalyst which contains boron and aluminum 0 framework subεtitution and a hydrogenation promoter, heavy 2 petroleum reεidual feedεtockε, cyclic stocks, and other 2 hydrocracking charge stockε can be hydrocracked at 3 hydrocracking conditions including a temperature in the ₄ range of from 175 ^β C to 485°C, molar ratios of hydrogen to

1 hydrocarbon charge from 1 to 100, a preεsure in the range of 2 from 0.5 to 350 bar, and a liquid hourly space velocity 3 (LHSV) in the range of from 0.1 to 30. 4 5 Hydrocracking catalysts comprising SSZ-33 contain an 6 effective amount of at least one hydrogenation catalyst 7 (component) of the type commonly employed in hydrocracking 8 catalystε. The hydrogenation component iε generally 9 εelected from the group of hydrogenation catalyεtε 0 conεiεting of one or more metalε of Group VIB and Group 1 VIII, including the salts, complexes, and solutionε 2 containing such. The hydrogenation catalyst is preferably 3 εelected from the group of metals, salts, and complexes 4 thereof of the group consiεting of at least one of platinum, 5 palladium, rhodium, iridium, and mixtures thereof or the 6 group consisting of at least one of nickel, molybdenum, 7 cobalt, tungsten, titanium, chromium, and mixtures thereof. 8 Reference to the catalytically active metal or metalε iε 9 intended to encompaεs such metal or metals in the elemental 0 state or in some form such as an oxide, sulfide, halide, i carboxylate, and the like. 2 3 A hydrogenation component is present in the hydrocracking 4 catalyst in an effective amount to provide the hydrogenation 5 function of the hydrocracking catalyst and preferably in the range of from 0.05% to 25% by weight. 7 8 The SSZ-33 catalyst may be employed in conjunction with 9 traditional hydrocracking catalysts, e.g., any aluminosilicate heretofore employed as a component in

31 hydrocracking catalysts. Representative of the zeolitic

32 aluminosilicates disclosed heretofore as employable aε

33 component partε of hydrocracking catalysts are Zeolite Y

-A (including st5__m stabilized, e.g., ultra-stable Y) , Zeolite

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X, Zeolite beta (U.S. Patent No. 3,308,069), Zeolite ZK-20 (U.S. Patent No. 3,445,727), Zeolite ZSM-3 (U.S. Patent No. 3,415,736), faujaεite, LZ-10 (U.K. Patent 2,014,970, June 9, 1982), ZSM-5-type zeolites, e.g., ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35, ZSM-38, ZSM-48, crystalline silicates such as silicalite (U.S. Patent No. 4,061,724), erionite, mordenite, offretite, chabazite, FU-1-type zeolite, NU-type zeolites, LZ-210-type zeolite, and mixtures thereof. Traditional hydrocracking catalystε containing amountε of ^Na 2° less than about one percent by weight are generally preferred. The relative amounts of the SSZ-33 component and traditional hydrocracking component, if any, will depend at least in part, on the εelected hydrocarbon feedstock and on the desired product distribution to be obtained therefrom, but in all instances an effective amount of SSZ-33 is employed.

The hydrocracking catalysts are typically employed with an inorganic o_xide matrix component which may be any of the inorganic oxide matrix components which have been employed heretofore in the formulation of hydrocracking catalysts including: amorphous catalytic inorganic oxides, e.g., catalytically active εilica-aluminaε, clayε, εilicaε, aluminas, εilica-aluminaε, εilica-zirconiaε, silica-magnesiaε, alumina-borias, alumina-titanias, and the like and mixtureε thereof. The traditional hydrocracking catalyεt component (TC) and SSZ-33 may be mixed separately with the matrix component and then mixed or the TC component and SSZ-33 may be mixed and then formed with the matrix component.

SSZ-33 can be used to dewax hydrocarbonaceous feedε by εelectively removing εtraight chain paraffinε. The catalytic dewaxing conditions are dependent in large measure

on the feed used and upon the desired pour point. Generally, the temperature will be between about 200°C and about 475 ^β C, preferably between about 250°C and about 450°C. The pressure is typically between about 15 pεig and about 3000 psig, preferably between about 200 psig and 3000 pεig. The liquid hourly εpace velocity (LHSV) preferably will be from 0.1 to 20, preferably between about 0.2 and about 10.

Hydrogen iε preferably present in the reaction zone during the catalytic dewaxing process. The hydrogen to feed ratio is typically between about 500 and about 30,000 SCF/bbl (standard cubic feet per barrel), preferably about 1,000 to about 20,000 SCF/bbl. Generally, hydrogen will be separated from the product and recycled to the reaction zone. Typical feedstocks include light gas-oil, heavy gas-oilε, and reduced crudes boiling about 350°F.

The SSZ-33 hydrodewaxing catalyst may optionally contain a hydrogenation component of the type commonly employed in dewaxing catalyεtε. The hydrogenation component may be εelected from the group of hydrogenation catalyεtε conεiεting of one or more metalε of Group VIB and Group VIII, including the εaltε, complexes and solutionε containing εuch metals. The preferred hydrogenation catalyst is at least one of the group of metals, saltε, and complexeε selected from the group consiεting of at leaεt one of platinum, palladium, rhodium, iridium, and mixtures thereof or at least one from the group conεiεting of nickel, molybdenum, cobalt, tungsten, titanium, chromium, and mixtures thereof. Reference to the catalytically active metal or metals is intended to encompass εuch metal or metals in the elemental state or in some form such as an oxide, εulfide, halide, carboxylate, and the like.

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The hydrogenation component of the hydrodewaxing catalyεt iε preεent in an effective amount to provide an effective hydrodewaxing catalyεt preferably in the range of from about 0.05 to 5% by weight.

SSZ-33 can be uεed aε a reforming catalyεt to convert εtraight run naphthaε and similar mixtures to highly aromatic mixtures. Thus, normal and slightly branched chained hydrocarbons, preferably having a boiling range above about 40°C and lesε than about 200°C, can be converted to productε having a substantial aromatics content by contacting the hydrocarbon feed with the zeolite at a temperature in the range of from about 400°C to 600°C, preferably 480 ^β C-550°C at pressures ranging from atmospheric to 20 atmospheres, and LHSV ranging from 0.1 to 15. The hydrogen to hydrocarbon ratio will range between 1 and 10. (B)SSZ-24 can be used in a fixed, fluid, or moving bed reformer.

The reforming catalyst preferably contains a Group VIII metal compound to have sufficient activity for commercial use. By Group VIII metal compound as uεed herein is meant the metal itself or a compound thereof. The Group VIII noble metals and their compounds, platinum, palladium, and iridium, or combinations thereof can be used. The most preferred metal iε platinum. The amount of Group VIII metal preεent in the converεion catalyεt εhould be within the normal range of use in reforming catalystε, from about 0.05 to 2.0 wt. percent, preferably 0.2 to 0.8 wt. percent. In addition, the catalyεt can alεo contain a second Group VII metal. Eεpecially preferred is rhenium.

The zeolite/Group VIII metal catalyst can be used without a binder or matrix. The preferred inorganic matrix, where one is used, is a silica-based binder such as Cab-O-Sil or Ludox. Other matrices such as alumina, magnesia and titania can be used. The preferred inorganic matrix is nonacidic.

It is critical to the εelective production of_ axomatics in useful quantities that the converεion catalyεt be subεtantially free of acidity, for example, by poiεoning the zeolite with a basic metal, e.g., alkali metal, compound. The zeolite is usually prepared from mixtures containing alkali metal hydroxides and thus, have alkali metal contents of about 1-2 wt. %. These high levels of alkali metal, usually sodium or potassium, are unacceptable for most other catalytic applications because they greatly deactivate the catalyst for cracking reactionε by reducing catalyεt acidity. Therefore, the alkali metal iε removed to low levels by ion exchange with hydrogen or ammonium ions. By alkali metal compound as used herein iε meant elemental or ionic alkali metals or their basic compounds. Surprisingly, unless the zeolite itself is substantially free of acidity, the alkali metal iε required in the preεent process to reduce acidity and improve aromatics production.

The amount of alkali metal neceεsary to render the zeolite substantially free of acidity can be calculated using standard techniques based on the aluminum, gallium or iron content of the zeolite. If a zeolite free of alkali metal is the starting material, alkali metal ions can be ion exchanged into the zeolite to εubstantially eliminate the acidity of the zeolite. An alkali metal content of about 100%, or greater, of the acid sites calculated on a molar basis is sufficient.

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Where the basic metal content is less than 100% of the acid sites on a molar basiε, the teεt described in U.S. Patent No. 4,347,394 which patent is incorporated totally herein by reference, can be uεed to determine if the zeolite is εubεtantially free of acidity.

The preferred alkali metals are sodium, potassium, and cesium as well as other Groups IA and IIA metals. The zeolite itself can be substantially free of acidity only at very high silica:alumina mole ratioε; by "zeolite conεiεting eεsentially of silica" is meant a zeolite which is substantially free of acidity without base poisoning.

We have also found that SSZ-33 is advantageously used to catalytically crack hydrocarbon feedstocks in the absence of hydrogen. Preferred conditions involve a fluidized catalytic cracking procesε which consists of contacting a hydrocarbon feedstock with a catalyst in a reaction zone in the absence of added hydrogen at average catalyst temperatures ranging from 800°F to 1500 ^β F, separating the catalyst from the product effluent, introducing the catalyst into a steam-stripping zone, and subsequently into a regeneration zone in the presence of steam and free oxygen containing gas where reaction coke deposited on the catalyst is burned off at elevated temperatures ranging from 1000°F to 1550 ^β F, and then recycling the reactivated catalyst to the reaction zone.

For this purpoεe, the SSZ-33 can be employed in conjunction with traditional cracking catalystε either as an incorporated conεtituent component or aε a εeparate additive particle.

The catalyst may be employed in conjunction with traditional cracking catalysts, comprising any aluminosilicate heretofore employed aε a component in cracking catalysts. Representative of the zeolitic aluminosilicateε disclosed heretofore as employable as component parts of cracking catalystε are Zeolite Y (including εteam stabilized Y, rare earth Y, chemically modified Y, ultra-stable Y or combinations thereof), Zeolite X, Zeolite beta (U.S. Patent No. 3,308,069), Zeolite ZK-20 (U.S. Patent No. 3,445,727), Zeolite ZSM-3 (U.S. Patent No. 3,415,736), faujasite, LZ-10 (U.K. Patent 2,014,970, June 9, 1982), ZSM-5-Type Zeolites, e.g., ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35, ZSM-38, ZSM-48, cryεtalline silicates such as silicalite (U.S. Patent No. 4,061,724), erionite, mordenite, offretite, chabazite, FU-1-type zeolite, NU-type zeolite, LZY-210 type zeolite or other dealuminated zeolite of 24.5A unit cell size or lower, or zeolite grown "in-situ" in matrix materials (U.S. Patent Nos. 3,647,718 and 4,493,902), and the mixtures thereof. The term "zeolite" as used herein contemplates not only aluminosilicates but substances in which the aluminum is replaced by gallium or boron and substances in which silicon is replaced by germanium. Other representative acidic aluminosilicates also deemed employable aε component partε are amorphouε εilica-alumina catalyεtε, εynthetic mica-montmorillonite catalysts (as defined in U.S. Patent ^No « 3,252,889), crosε-linked or pillared clays (as defined in U.S. Patent Nos. 4,176,090; 4,248,739; 4,238,364 and 4,216,188), and acid activated clayε — bentonite, hectorite, saponite.

Traditional cracking catalysts containing amounts of Na-0 less than about one percent by weight are generally preferred. The relative amountε of the SSZ-33 component and traditional cracking component (TC), if any, will depend at

least in part, on the εelected hydrocarbon feedεtock and on the desired product distribution to be obtained therefrom, but in all inεtanceε, an effective amount of SSZ-33 iε employed. When a TC component iε employed, the relative weight ratio of the TC to the SSZ-33 iε generally between about 1:10 and about 500:1, deεirably between about 1:10 and about 200:1, preferably between about 1:2 and about 50:1, and moεt preferably iε between about 1:1 and about 20:1.

The cracking catalyεtε are typically employed with an inorganic oxide matrix component which may be any of the inorganic oxide matrix components which have been employed heretofore in the formulation of FCC catalysts including: amorphous catalytic inorganic oxideε, e.g., catalytically active εilica-aluminaε, clays, synthetic or acid activated clays, silicaε, aluminas, silica-aluminas, silica-zirconiaε, εilica-magneεiaε, alumina-borias, alumina-titanias, pillared or crosε-linked clayε, and the like and mixtureε thereof. The TC component and SSZ-33 may be mixed εeparately with their matrix component and then mixed together or the TC component and SSZ-33 may be mixed together and then formed with the matrix component.

The mixture of a traditional cracking catalyεt and SSZ-33 may be carried out in any manner which reεultε in the coincident preεence of εuch in contact with the crude oil feedεtock under catalytic cracking conditionε. For example, a catalyεt may be employed containing traditional cracking catalyεt component and SSZ-33 in εingle catalyεt particleε or SSZ-33 with or without a matrix component may be added as a discrete component to a traditional cracking catalyst provided its particle has appropriate denεity and particle εize distribution.

SSZ-33 can also be used to oligomerize straight and branched chain olefins having from about 2-21 and preferably 2-5 carbon atoms. The oligomers which are the products of the procesε are medium to heavy olefinε which are uεeful for both fuelε, i.e., gaεoline or a gasoline blending stock and chemicals.

The oligomerization procesε comprises contacting the olefin feedstock in the gaseouε εtate phaεe with SSZ-33 at a temperature of from about 450°F to about 1200°F, a WHSV of from about 0.2 to about 50 and a hydrocarbon partial preεεure of from about 0.1 to about 50 atmoεphereε.

Alεo, temperatures below about 450 ^β F may be used to oligomerize the feedstock, when the feedεtock iε in the liquid phaεe when contacting the zeolite catalyst. Thus, when the olefin feedstock contacts the zeolite catalyst in the liquid phaεe, temperatures of from about 50 ^β F to about 450°F, and preferably from 80-400°F may be used and a WHSV of from about 0.05 to 20 and preferably 0.1 to 10. It will be appreciated that the pressures employed must be sufficient to maintain the εyεtem in the liquid phase. As is known in the art, the preεsure will be a function of the number of carbon atoms of the feed olefin and the temperature. Suitable presεureε include from about 0 pεig to about 3000 pεig.

The zeolite uεed in the oligomerization proceεs can have the original cations asεociated therewith replaced by a wide variety of other cationε according to techniqueε well known in the art. Typical cations would include hydrogen, ammonium, and metal cations including mixtures of the same. Of the replacing metallic cations, particular preference is given to cations of metals such as rare earth metals,

manganeεe, calcium, aε well aε metalε of Group II of the Periodic Table, e.g., zinc, and Group VIII of the Periodic Table, e.g., nicfkel. One of the prime requisites is that the zeolite have a fairly low aromatization activity, i.e., in which the amount of aromatics produced is not more than about 20 percent by weight. This is accompliεhed by uεing a zeolite with controlled acid activity [alpha value] of from about 0.1 to abo-ut 120, preferably from about 0.1 to about 100, aε measured by its ability to crack n-hexane.

Alpha values are defined by a εtandard teεt known in the art, e.g., as shown in U.S. Patent No. 3,960,978 which iε incorporated herein by reference. If required, such zeolites be obtained by steaming, by use in a converεion proceεε or by any other method which may occur to one εkilled in thiε art.

SSZ-33 can be uεed to convert light gaε C ₂ -C _β paraffinε and/or olefinε to higher molecular weight hydrocarbonε including aromatic compoundε. Operating temperatures of 100-700°C, operating presεureε of 0-1000 pεig and space velocitieε of 0.5-40 hr ^~ WHSV can be uεed to convert the ^C 2~ ^C ₆ paraffin and/or olefinε to aromatic compoundε. Preferably, the zeolite will contain a catalyεt metal or metal oxide wherein εaid metal iε εelected from the group conεiεting of Group IB, IIB, VIII, and IIIA of the Periodic Table, and moεt preferably, gallium or zinc and in the range °f from about 0.05-5 percent by weight.

SSZ-33 can be uεed to condenεe lower aliphatic alcoholε having 1-10 carbon atomε to a gaεoline boiling point hydrocarbon product comprising mixed aliphatic and aromatic hydrocarbon. Preferred condensation reaction conditions using SSZ-33 as the condensation catalyεt include a

temperature of about 500 to 1000°F, a presεure of about 0.5 to 1000 pεig and a εpace velocity of about 0.5 to 50 WHSV. U.S. Patent No. 3,984,107 deεcribeε the condenεation process conditions in more detail. The disclosure of U.S. Patent No. 3,984,107 is incorporated herein by reference.

The SSZ-33 catalyst may be in the hydrogen form or may be base exchanged or impregnated to contain amonium or a metal cation complement, preferably in the range of from about 0.05 to 5 percent by weight. The metal cations that may be present include any of the metals of the Groups I-VIII of the Periodic Table. However, in the case of Group IA metalε, the cation content should in no case be so large as to effectively inactivate the catalyst.

The SSZ-33 catalyεt is highly active and highly selective for isomerizing C ₄ to C, hydrocarbonε. The activity meanε that the catalyεt can operate at relatively low temperatureε which thermodynamically favors highly branched paraffins. Consequently, the catalyst can produce a high octane product. The high selectivity means that a relatively high liquid yield can be achieved when the catalyst is run at a high octane.

The iεomerization proceεs comprises contacting the isomerization catalyst with a hydrocarbon feed under isomerization conditions. The feed is preferably a light εtraight run fraction, boiling within the range of 30-250°F and preferably from 60-200 ^β F. Preferably, the hydrocarbon feed for the proceεε compriεeε a εubεtantial amount of C . to C- normal and εlightly branched low octane hydrocarbonε, more preferably C _ς and C _g hydrocarbons.

The preεsure in the procesε iε preferably between 50-1000 psig, more preferably between 100-500 psig. The LHSV iε preferably between about 1 to about 10 with a value in the range of about 1 to about 4 being more preferred. It iε alεo preferable to carry out the iεomerization reaction in the preεence of hydrogen. Preferably, hydrogen iε added to give a hydrogen to hydrocarbon ratio (H ₂ /HC) of between 0.5 and 10 H ₂ /HC, more preferably between 1 and 8 H ₂ /HC. The temperature iε preferably between about 200 ^β F and about 1000 ^β F, more preferably between 400-600 ^β F. As is well known to thoεe εkilled in the iεomerization art, the initial εelection of the temperature within this broad range is made primarily aε a function of the deεired converεion level considering the characteristicε of the feed ^" and of the catalyεt. Thereafter, to provide a relatively conεtant value for converεion, the temperature may have to be slowly increased during the run to compensate for any deactivation that occurs.

A low sulfur feed is especially preferred in the iεomerization procesε. The feed preferably containε less than 10 ppm, more preferably lesε than 1 ppm, and moεt preferably leεε than 0.1 ppm εulfur. In the caεe of a feed which iε not already low in εulfur, acceptable levels can be reached by hydrogenating the feed in a presaturation zone with a hydrogenating catalyεt which iε reεiεtant to εulfur poiεoning. An example of a εuitable catalyst for this hydrodeεulfurization proceεε iε an alumina-containing εupport and a minor catalytic proportion of molybdenum oxide, cobalt oxide and/or nickel oxide. A platinum on alumina hydrogenating catalyεt can also work. In which caεe, a sulfur εorber is preferably placed downstream of the hydrogenating catalyst, but upstream of the present iεomerization catalyst. Examples of εulfur εorberε are

alkali or alkaline earth metals on porous refractory inorganic oxides, zinc, etc. Hydrodesulfurization is typically conducted at 315-455°C, at 200-2000 pεig, and at a LHSV of 1-5.

I iε preferable to limit the nitrogen level and the water content of the feed. Catalyεtε and processes which are εuitable for theεe purposes are known to those skilled in the art.

After a period of operation, the catalyst can become deactivated by coke. Coke can be removed by contacting the catalyst with an oxygen-containing gas at an elevated temperature.

The iεomerization catalyεt preferably contains a Group VIII metal compound to have sufficient activity for commercial use. By Group VIII metal compound as used herein is meant the metal itself or a compound thereof. The Group VIII noble metals and their compoundε, platinum, palladium, and iridium, or combinationε thereof can be uεed. Rhenium and tin may alεo be uεed in conjunction with the noble metal. The moεt preferred metal iε platinum. The amount of Group VIII metal preεent in the converεion catalyεt εhould be within the normal range of uεe in iεomerizing catalysts, from about 0.05-2.0 wt. %.

SSZ-33 can be uεed in a process for the alkylation or transalkylation of an aromatic hydrocarbon. The proceεs compriseε contacting the aromatic hydrocarbon with a C- to C ₂₀ olefin alkylating agent or a polyalkyl aromatic hydrocarbon tranεalkylating agent, under at leaεt partial liquid phaεe conditions, and in the presence of a catalyst comprising SSZ-33.

For high catalytic activity, the SSZ-33 zeolite εhould be predominantly in itε hydrogen ion form. Generally, the zeolite iε converted to itε hydrogen form by ammonium exchange followed by calcination. If the zeolite iε εyntheεized with a high enough ratio of organonitrogen cation to εodium ion, calcination alone may be sufficient. It is preferred- tha-t alter calcination-, at- least 80% of the cation sites are occupied by hydrogen ions and/or rare earth ions.

The pure SSZ-33 zeolite may be uεed as a catalyεt, but generally, it iε preferred to mix the zeolite powder with an inorganic oxide binder εuch aε alumina, εilica, εilica/alumina, or naturally occurring clayε and form the mixture into tabletε or extrudateε. The final catalyεt may contain from 1-99 wt. % SSZ-33 zeolite. Uεually the zeolite content will range form 10-90 wt. %, and more typically from 60-80 wt. %. The preferred inorganic binder iε alumina. The mixture may be formed into tablets or extrudates having the deεired εhape by methodε well known in the art.

Exampleε of εuitable aromatic hydrocarbon feedstocks which may be alkylated or transalkylated by the proceεε of the invention include aromatic compoundε εuch aε benzene, toluene, and xylene. The preferred aromatic hydrocarbon is benzene. Mixtures of aromatic hydrocarbonε may alεo be employed.

Suitable olefinε for the alkylation of the aromatic hydrocarbon are thoεe containing 2-20 carbon atoms, such as ethylene, propylene, butene-1, tranεbutene-2, and ciε-butene-2, and higher olefins, or mixtures thereof. The preferred olefin iε propylene. Theεe olefinε may be preεent in admixture with the corresponding C ₂ to C _2Q paraffins, but

it is preferable to remove any dienes, acetylenes, sulfur compoundε or nitrogen compoundε which may be preεent in the olefin feedεtock stream to prevent rapid catalyst deactivation.

When transalkylation iε deεired, the tranεalkylating agent iε a polyalkyl aromatic hydrocarbon containing two or more alkyl groupε that each may have from two to about four carbon atomε. For example, εuitable polyalkyl aromatic hydrocarbonε include di-, tri-, and tetra-alkyl aromatic hydrocarbonε, εuch aε diethylbenzene, triethylbenzene, diethylmethylbenzene (diethyl-toluene) , di-iεopropylbenzene, di-iεopropyltoluene, dibutylbenzene, and the like. Preferred polyalkyl aromatic hydrocarbonε are the dialkyl benzenes. A particularly preferred polyalkyl aromatic hydrocarbon iε di-iεopropylbenzene.

Reaction productε which may be obtained include ethylbenzene from the reaction of benzene with either ethylene or polyethylbenzeneε, cumene from the reaction of benzene with propylene or polyiεopropylbenzenes, ethyltoluene from the reaction of toluene with ethylene or polyethyltoluenes, cymeneε from the reaction of toluene with propylene or polyiεopropyltolueneε, and εecbutylbenzene from the reaction of benzene and n-buteneε or polybutylbenzeneε. The production of cumene from the alkylation of benzene with propylene or the tranεalkylation of benzene with di-iεopropylbenzene iε eεpecially preferred.

When alkylation iε the proceεε conducted, reaction conditionε are aε follows. The aromatic hydrocarbon feed εhould be preεent in εtoichiometric exceεs. It is preferred that molar ratio of aromatics to olefinε be greater than four-to-one to prevent rapid catalyst fouling. The reaction

30

temperature may range from 100-600 ^β F, preferably, 250-450 ^β F. The reaction preεεure should be εufficient to maintain at least a partial liquid phase in order to retard catalyεt fouling. This is typically 50-1000 psig depending on the feedεtock and reaction temperature. Contact time may range from 10 εecondε to 10 hourε, but iε uεually from five minuteε to an hour. The WHSV in termε of gramε (poundε) of aromatic hydrocarbon and olefin per gram (pound) of catalyεt per hour, is generally within the range of about 0.5 to 50.

When transalkylation iε the proceεε conducted, the molar ratio of aromatic hydrocarbon will generally range from about 1:1 to 25:1, and preferably from about 2:1 to 20:1. The reaction temperature may range from about 100-600°F, but it iε preferably about 250-450°F. The reaction preεεure should be εufficient to maintain at leaεt a partial liquid phaεe, typically in the range of about 50-1000 pεig, preferably 300-600 psig. The WHSV will range from about 0.1-10.

The conversion of hydrocarbonaceouε feedε can take place in any convenient mode, for example, in fluidized bed, moving bed, or fixed bed reactors depending on the types of proceεε deεired. The formulation of the catalyεt particleε will vary depending on the converεion proceεε and method of operation.

Other reactionε which can be performed uεing the catalyst of this invention containing a metal, e.g., platinum, include hydrogenation-dehydrogenation reactions, denitrogenation, and desulfurization reactionε.

Some hydrocarbon conversionε can be carried out on SSZ-33 zeoliteε utilizing the large pore εhape-εelective behavior. For example, the substituted SSZ-33 zeolite may be uεed in preparing cumene or other alkylbenzeneε in processes utilizing propylene to alkylate aromatics.

SSZ-33 can be uεed in hydrocarbon converεion reactions with active or inactive εupportε, with organic or inorganic binders, and with and without added metals. Theεe reactionε are well known to the art, as are the reaction conditions.

SSZ-33 can also be used aε an adεorbent, as a filler in paper, paint, and toothpastes, and as a water-softening agent in detergentε.

The following exampleε illuεtrate the preparation of SSZ-33.

EXAMPLES

Example 1

Preparation of N,N,N-Trimethyl-8-Ammonium Tricyclo[5.2.1.0 2'6]decane Hydroxide (Template )

Five grams of 8-keto-tricyclo[5.2.1.0 2'6]decane (Aldrich Chemical Company) was mixed with 2.63 g of formic acid (88%) and 4.5 g of dimethyl formamide. The mixture was then heated in a preεεure veεεel for 16 hourε at 190°C Care εhould be taken to anticipate the increaεe in pressure the reaction experiences due to C0 ₂ evolution. The reaction was conveniently carried out in a Parr 4748 reactor with Teflon liner. The workup consists of extracting N,N dimethyl-8-amino tricyclo[5.2.1.0 2'6Jdecane from a basic (pH=12) aqueous solution with diethyl ether. The various

extractε were dried with Na ₂ S0 ₄ , the solvent removed, and the product taken up in ethyl acetate. An exceεε of methyl iodide waε added to a cooled εolution which was then εtirred at room temperature for εeveral dayε. The cryεtalε were collected and waεhed with diethyl ether to give N,N,N Trimethyl-8-ammonium tricyclo[5.2.1.0 2'6]decane iodide. The product haε a melting point of 270-72°C and the elemental analyεeε and NMR are conεiεtent with the known εtructure. The vacuum-dried iodide εalt waε then ion-exchanged with ion-exchange reεin AG 1X8 (in molar exceεε) to the hydroxide form. The exchange waε performed over a column or more preferably, by overnight stirring of the resin beads and the iodide salt in an aqueous solution designed to give about a 0.5 molar εolution of the organic hydroxide.

Example 2

3.62 g of a 0.62 M εolution of the template from Example 1 is diluted with 8.36 mL H ₂ 0. 0.08 g of NaOH(solid) and 0.06 9 °f Na ₂ B ₄ 0 ₇ "18H ₂ 0 are disεolved in thiε εolution and then 0.90 g of Cab-O-Sil are blended in laεt. The reaction mixture iε heated in a Parr 4745 reactor at 160°C and rotated at 30 rpm on a εpit in a Blue M oven over a εix-day period. The εolid component of the reaction iε filtered, waεhed repeatedly, dried at 115°C, and analyzed by X-ray diffraction. The product iε identified aε SSZ-33. The pattern iε tabulated in Table 2.

Example 3

The same experiment iε εet up as in Example 2 except the boron content is increased by adding 0.105 g of Na ₂ B ₄ 0 ₇ ^* 18H ₂ 0. This produceε a Si0 ₂ /B ₂ 0 ₃ ratio of 30 in thiε experiment aε compared with a value of 50 in Example 2.

The experiment is run under analogous conditions although this time the crystallization is not complete in 6 days, requiring a total of 10 days. The product iε SSZ-33 by XRD with a εmall amount of Kenyaiite-like impurity.

Example 4

Forty-eight gramε of 0.69 M solution of the template from Example 1 is mixed with 132 g of H ₂ 0, 1.35 g of NaOH(solid), and 0.96 g of Na ₂ B ₄ 0 ₇ ^* 18H ₂ 0. 13.5 g of Cab-O-Sil iε blended in laεt and the reaction iε run in a Parr 300-cc stirred autoclave for six days at 160°C and stirred at 50 rpm. The product is well-crystallized SSZ-33.

TABLE 2

2 θ d/n Int.

7.86 11.25 90 8.36 10.58 2 14.21 6.23 13 15.76 5.62 7 16.77 5.29 10 20.48 4.336 100 21.47 4.139 40 22.03 4.035 90 23.18 3.837 64 25.26 3.526 13 26.83 3.323 40 28.65 3.116 12 29.18 3.060 10 30.62 2.920 8

Example 5

Another run is made on twice the εcale uεed in Example 4 and utilizing an autoclave of 600-cc capacity. The product waε once again a well-cryεtallized sample of SSZ-33 and the X-ray diffraction data is given in Table 3.

TABLE 3

2 θ 100 x I/Io

15.72

16.74 8 20.49 100

21.49 33

22.04 83

22.98 25 Sh 23.16 50 25.28 12 25.47 5 Sh 26.61 18

26.87 38 28.67 15

29.20 8 30.63 7

31.84 7

32.30 5 33.47 7 33.91 2 35.76 5

35

TABLE 3 (Cont.)

2 θ d/n Int. 100 x I/I

36.15 2.485 3 5 36.58 2.456 3 5 37.21 2.416 5 8 37.52 2.397 2 3

Example 6

The product of Example 5 was calcined as follows. The sample was heated in a muffle furnace from room temperature ⁴ up to 540 ^β C at a steadily increasing rate over a seven-hour period. The sample waε maintained at 540°C for four more " hours and then taken up to 600°C for an additional four 7 hours. Nitrogen was paεεed over the zeolite at a rate of 20 εtandard cubic feed per minute during heating. The calcined ⁹ product had the X-ray diffraction lineε indicated in Table 4 ⁰ below. 1 2 TABLE 4 3 2 θ 5 6

7.81 7 8.33 8 13.28 9 14.18 0 15.71 1 16.73 2 20.43 3 20.76 4 21.44

2 θ

22.02 23.00 23.18 23.67 25.27 25.46 26.57 26.80 28.68

29.18 30.66

31.81 32.31

36.60 37.21 37.60

Ion-exchange of the calcined material from Example 6 waε carried out uεing NH.NO, to convert the zeoliteε from Na form to NH. and then eventually H form. Typically the εame maεε of NH.NO, aε zeolite was slurried into H ₂ 0 at ratio of 50/1 H ₂ 0/zeolite. The exchange solution was heated at 100°C for two hours and then filtered. Thiε proceεε waε repeated four timeε. Finally, after the laεt exchange, the zeolite

was washed several times with H ₂ 0 and dried. A repeat calcination as in Example 5 was carried out, but without the final treatment at 600°C. This produces the H form of the zeolites. The surface area for this material was 520 m /g. The micro pore volume was 0.21 cc/g as determined by BET method with N- as abεorbate.

Example 8

Conεtraint Index Determination

0.50 g of the hydrogen form of the zeolite of Example 4 (after treatment according to Exampleε 6 and 7 waε packed into a 3/8-in. εtainless εteel tube with alundum on both εides of the zeolite bed. A Lindburg furnace was used to heat the reactor tube. Helium waε introduced into the reactor tube at 10 cc/minute and atmoεpheric pressure. The reactor was take to 250 ^β F for 40 minutes and then raised to 800°F. Once temperature equilibration was achieved, a 50/50, w/w feed of n-hexane, and 3-methylpentane waε introduced into the reactor at a rate of 0.62 cc/hour. Feed delivery waε made via syringe pump. Direct sampling onto a gas chromatograph was begun after 10 minutes of feed introduction. Conεtraint Index values were calculated from gaε chromatographic data uεing methods known in the art.

Temp.

800

Example 9

SSZ-33 was prepared as in Example 4 and treated aε in Exampleε 6 and 7. The zeolite iε refluxed overnight with Al(N0 ₃ ) ₃ ^* 9H ₂ 0 with the latter being one-half the maεε of the zeolite and uεing the εame dilution as in the ion-exchange of Example 7. The product is filtered, washed, and calcined to 540 ^β C. After pelletizing the zeolite powder and retaining the 20-40 mesh fraction from breaking up the pellet, the catalyεt iε teεted aε in Example 8. Data for the reaction is given in Table 5 along with a variety of catalyεtε made from analogous treatments with other metal salts.

TABLE 5

Constraint Index Determination For Metal-Treated SSZ-33

Example Metal Constraint Conversion, % Temp. , No. Salt Index (10 Min. ) °F

8 None 0 800

9 AI(NΌ ₃ ) ₃ 62 800 10 Ga(N0 ₃ ) ₃ 55 800 11 Cr(N0 ₃ ) ₃ 1 800 12 Fe(N0 ₃ ) ₃ 1 800 13 Zn(AC) ₂ 5 800

The zinc version of SSZ-33 waε evaluated aε a reforming catalyεt. 19 gmε of SZ-33 zeolite waε ion-exchanged with 4.5 gms of Zn(AC) ₂ ^* 2H ₂ 0 and then washed, dried, and calcined

to 540°C. The zeolite powder was impregnated with Pt(NH ₃ ) ₄ ^* 2N0 ₃ to give 0.8 wt. % Pt. The material was calcined up to 550°F in air and maintained at this temperature for three hours. The powder was pelletized on a Carver press at 1000 psi and broken and meshed to 24-40.

The catalyst was evaluated at 900°F in hydrogen under the following conditions:

The feed was an iC, mixture (Philips Petroleum Company).

The catalyεt is very stable and data averaged over 20-63 hours iε given in Table 6.

TABLE 6

Feed

Converεion, % Toluene 0.52 C _c -Cg Octane 63.7 Aromatization

Selectivity Toluene in C ₅ +

Aromaticε, % Aromaticε in C ₅ +

Product, %

Example 15

A reaction iε εet up and run aε in Example 2 except that an equivalent amount of εilica derived from Ludox AS-30 sol replaces Cabosil M5. The product is once again SZ-33 with just a trace of Quartz.

Example 16

A product waε prepared aε in Example 15 followed by treatmentε given in Exampleε 6 and 7. Next, the catalyst was ion-exchanged with an aqueous εolution of Pd (NH ₃ ) ₄ ^* 2N0 ₃ (pH adjuεted to 10 with NH ₄ OH) to give a maximum of 0.5 wt. % loading of palladium. The catalyεt waε then calcined εlowly, up to 900 ^β F in air and held there for three hourε. Table 7 giveε run conditionε and product data for the hydrocracking of n-hexadecane. The catalyεt iε quite stable at the temperatures given.

TABLE 7

655 5 1.55

1200 99.8

22.4

77.7

9.3 22.4

The data showε that the catalyεt haε good iεomerization selectivity.

i Example 17 2 3 The hydrogen form of SSZ-33 can be used in typical fluidized 4 catalytic cracking. For such purposes, the catalyst 5 prepared aε in Exampleε 17, 18, 19 and 20 was tested in a 6 micro-activity teεt (MAT) with εubεequent gaε 7 chromatographic analyεis of the liquid produc_t_to_ determine. 8 calculated octanes. MAT testing waε conducted at 32 WHSV, 9 3 cat/oil ratio, 960 ^β F initial cat temperature and with a 0 total catalyεt charge of 4 gmε. The FCC catalytic octane 1 additive formulated for Exampleε 17, 18, 19 and 20 contained 2 25% by weight SSZ-33, 31.5% Kaolin, and a 43.5% εilica/- 3 alumina matrix. MAT tests were run with fresh FCC catalytic 4 octane additive as well as with the additive steamed at 5 1350°F for five hours. The catalyst inventory contained 90% 6 by weight of a rare earth equilibrium catalyst plus either 7 the steamed or fresh FCC catalytic octane additive. The reference uεed in the MAT for both the fresh and steamed MAT

19 cases iε inventory containing 100% rare earth equilibrium

20 catalyεt. Table 8 shows inspection of the feed and i reεulting converεions and computed octaneε.

22 23 TABLE 8 24 25 MAT Teεt for SSZ-33 Zeolite 26

(Cont. )

240°C 342 ^β C 373 ^β C 424°C 467 ^β C 516°C 592 ^β C 623°C 680 ^β C

90% Reference Catal st Plus

1.0 1.4 1.2 1.0 1.4 1.2

Example 18

The hydrogen form of SSZ-33 can be used in catalytic cracking. The catalyst as prepared in Exampleε 17, 18, 19 and 20 was teεted in fixed fluidized cyclic teεtε. The teεtε were run on freεh additive and on additive steamed at 1350°F for five hours. Fixed fluidized cyclic testing was conducted at 7 cat/oil ratio, with a 1100°F initial catalyst temperature. A εubεequent gaε chromatographic analyεis of the liquid product was made to determine calculated octanes. The same rare earth equilibrium catalyst used in Example 17 was uεed in thiε example for the reference catalyεt; a 10% FCC catalytic octane additive level waε alεo uεed in thiε example. Feed propertieε were the εame aε in Example 17.

Table 9 εhows the computed research octane number and the computed motor octane number.

TABLE 9

Fixed Fluidized Cyclic Teεt

90% Reference Catalyεt, Plus Reference Freεh Steamed Catalyεt Additive Additive

C ₅ -250 RON 87.0 88.9 87.8 MON 76.7 77.2 76.8

C ₅ -340

RON 85.3 86.9 86.0 MON 75.5 76.2 /5.o

Example 19

The hydrogen form of SSZ-33 can be added to the FCC inventory. Aε demonεtrated by the fixed fluidized cycling teεt reεults on Table 11, the octane enhancement for a SSZ-33-derived additive does not εeem to be adversely affected by the presence of high nitrogen in the feedstream. The teεtε were run with the catalyεt inventory containing 10% by weight freεh SSZ-33 FCC catalytic octane additive and 90% εteamed rare earth FCC cracking catalyεt. The SSZ-33 FCC catalytic octane additive iε deεcribed in Example 17 and fixed fluidized cyclic teεting conditions are described in Example 18. High and low nitrogen feedstreamε were uεed to demonεtrate the effectiveneεε of SSZ-33. Feed propertieε of the high and low nitrogen feedεtreamε are given in Table 10. Reference fixed fluidized cyclic teεtε doeε not contain an SSZ-33 additive. Increment octane enhancement due to the preεence of SSZ-33 was observed irrespective of nitrogen level.

TABLE 10

Low Nitrogen High Nitrogen Feed Feed

Example 20

The hydrogen form of SSZ-33 can be uεed in typical fluidized catalytic cracking. For εuch purpoεeε, the FCC catalytic octane additive detailed in Example 17 waε teεted with a non-rare earth FCC catalyεt to demonεtrate that SSZ-33 baεed catalytic octane additiveε can be uεed with both rare earth and non-rare earth FCC catalyεtε. The SSZ-33 FCC catalytic octane additive iε detailed in Example 17 while fixed fluidized cyclic teεting conditionε are deεcribed in Example 18. Reference doeε not contain any FCC catalytic octane additive; low nitrogen feed of Example 19 iε uεed as the test feed. Table 12 εhowε calculated liquid product reεearch and motor octaneε.

TABLE 12

90% Reference ^' Catalyεt, Pluε Reference Catalyεt Freεh Catalyεt

90.8 91.2 77.3 77.8

RON 88.1 89.9

MON 76.4 78.0