Ultrastable hexagonal, cubic and wormhole aluminosilicate mesostructures

• US 6,706,169 B2
• Filed: 04/23/2002
• Issued: 03/16/2004
• Est. Priority Date: 05/25/2000
• Status: Expired due to Fees

• Current Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Original Assignee: The Board of Trustees of Michigan State University (Michigan State University)
• Inventors: Liu, Yu, Zhang, Wenzhong, Pinnavaia, Thomas J.
• Primary Examiner(s): SAMPLE, DAVID R
• Application Number:
  US10/128,093
• Publication Number:
  US 20020187098A1
• Time in Patent Office: 693 Days
• Field of Search: 208/120.01, 208/122
• US Class Current: 208/120.01
• CPC Class Codes: B01J 2229/36 Steaming
• CPC Class Codes: B01J 2229/62 in or on other molecular sieves
• CPC Class Codes: B01J 29/005 Mixtures of molecular sieves comprising at least one molecular sieve which is not an aluminosilicate zeolite, e.g. from groups B01J29/03 - B01J29/049 or B01J29/82 - B01J29/89
• CPC Class Codes: B01J 29/0308 Mesoporous materials not having base exchange properties, e.g. Si-MCM-41
• CPC Class Codes: B01J 29/041 Mesoporous materials having base exchange properties, e.g. Si/Al-MCM-41
• CPC Class Codes: B01J 29/084 Y-type faujasite
• CPC Class Codes: B01J 29/40 of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
• CPC Class Codes: B01J 29/7007 Zeolite Beta
• CPC Class Codes: C01B 33/38 Layered base-exchange silicates, e.g. clays, micas or alkali metal silicates of kenyaite or magadiite type activation of naturally occurring clays B01J20/12; pillared layered base-exchange silicates B01J29/049
• CPC Class Codes: C01B 39/04 using at least one organic template directing agent, e.g. an ionic quaternary ammonium compound or an aminated compound
• CPC Class Codes: C01B 39/48 using at least one organic template directing agent
• CPC Class Codes: C10G 11/05 Crystalline alumino-silicates, e.g. molecular sieves
• CPC Class Codes: C10G 47/16 Crystalline alumino-silicate carriers

Abstract

Mesoporous hexagonal, cubic or wormhole aluminosilicates derived from zeolite seeds using an ionic structure directing agent are described. The aluminum in the structures is stable so that the framework of the structures does not collapse when heated in the presence of water or water vapor (steam). The steam stable aluminosilicates can be used as acid catalysts for hydrocarbon conversions, including the fluidized bed catalytic cracking and the hydrocracking of petroleum oils, and other cracking of organic compounds.

Claims

1. A method for catalytic cracking or hydrocracking of an organic molecule into lower molecular weight components, which comprises:

(a) providing in a reactor a catalytic cracking catalyst which comprises;

a mesoporous aluminosilicate-carbon composition which comprises;

a framework of tetrahedral linked SiO₄ and AlO₄ units, the framework defining mesopores having an Si to Al molar ratio of between about 1000 to 1 and 1 to 1 and between 0.01 and 10 wt % carbon embedded in the mesopores, and having at least one X-ray diffraction peak corresponding to a basal spacing between about 3.0 and 15.0 nm, wherein the tetrahedral AlO₄ units in the framework exhibit a ²⁷Al MAS-NMR resonance with a chemical shift between about 57 and 65 ppm relative to a 1.0 M aluminum nitrate solution as an external chemical shift reference, wherein a BET surface area is between 400 and 1300 m² per gram, wherein an average pore size of the framework is between about 2.0 and 10.0 nm, and wherein a pore volume of the framework is between about 0.1 and 1.9 cm³ per gram; and

a binder for the aluminosilicate-carbon composition; and

(b) introducing the organic molecule onto the catalyst at temperatures and pressures which cause cracking of the organic molecule into the lower molecular weight components.

2. A method for catalytic cracking or hydrocracking of an organic molecule into lower molecular weight components, which comprises:

(a) providing in a reactor a catalytic cracking catalyst which comprises;

a mesoporous aluminosilicate composition which comprises a framework of linked tetrahedral SiO₄ and AlO₄ units, the framework defining mesopores having an Si to Al molar ratio of between about 1000 to 1 and 1 to 1, and having at least one X-ray diffraction peak corresponding to a basal spacing between about 3.0 and 15.0 nm, wherein the tetrahedral AlO₄ units in the framework exhibit a ²⁷Al MAS-NMR resonance with a chemical shift between about 57 and 65 ppm relative to a 1.0 M aluminum nitrate solution as an external chemical shift reference, wherein a BET surface area is between 400 and 1300 m² per gram, wherein an average pore size of the framework is between about 2.0 and 10.0 nm, and wherein a pore volume of the framework is between about 0.1 and 1.9 cm³ per gram; and

a binder for the aluminosilicate composition; and

(b) introducing the organic molecule onto the catalyst at temperatures and pressures which cause cracking of the organic molecule into the lower molecular weight components.