Catalytic Reduction of Nitrogen Oxides

1. Technical Field

This invention relates to the catalytic reduction of nitrogen oxides. In particular, this invention relates to the catalytic reduction of noxious nitrogen oxides present in waste gaseous streams by utilizing specially treated microporous molecular sieve compositions as catalysts. This invention provides for the effective elimination of noxious nitrogen oxides as a source of pollution from fossil fuel-fired power generation plants and other industrial plant off-gas streams.

2. Background of the Invention

It is generally recognized that atmospheric pollution is a serious problem existing in the world today. It is also recognized that certain nitrogen oxides contribute significantly to this problem.

There are a least six stable oxides of nitrogen but only nitric oxide (NO) and nitrogen dioxide (NO.sub.2) are troublesome from a pollution standpoint. In common with other major air pollutants, these noxious nitrogen oxides arise chiefly from the production of energy, more specifically by the fixation of atmospheric nitrogen in high-temperature regions of furnaces and internal combustion engines. Another source of these noxious nitrogen oxides are inorganic and organic nitration reactions in chemical process industries. Transportation, industry and electricity generation all contribute to the problem.

Oxides of nitrogen play a dual role in air pollution, first as a pollutant in their own right and second as the initiator of complex photochemical reactions with hydrocarbons. While photochemical smog is the most visible and immediately serious consequence of pollution by these noxious nitrogen oxides, e.g., adverse effects on human health, it is recognized that the presence of these noxious nitrogen oxides in the atmosphere will adversely affect the environment even though no photochemical smog has ever been detected in the particular environment. It is most important, therefore, that noxious nitrogen oxides be removed from exhaust gases emitted from polluting sources such as power plants, nitric acid plants, automobiles and the like.

Various methods have been proposed for removing noxious nitrogen oxides from gas streams and preventing the pollution of the atmosphere with these substances.

U.S. Pat. No. 4,220,632 describes noxious nitrogen oxides in a waste gas stream such as the stack gas from a fossil-fuel-fired power generation plant or other industrial plant off gas stream which are catalytically reduced to elemental nitrogen and/or innocuous nitrogen oxides employing ammonia as a reductant in the presence of a zeolite catalyst in the hydrogen or sodium form having pore openings of about 3 to 10 Angstroms.

U.S. Pat. No. 3,895,094 discloses oxides of nitrogen which are selectively removed from air-polluting exhaust gases from nitric acid manufacturing plants by reaction with a stoichiometric amount of ammonia in the presence of an acid-resistant aluminosilicate molecular sieve composition as catalyst.

U.K. Pat. No. GB 2,039,863 describes a process for the reduction of nitrogen oxides with ammonia, when the nitrogen oxides to be reduced are in a gas mixture containing up to 21% by volume oxygen in which the gas stream to be treated is passed over clinoptilolite predominantly in the hydrogen form, the temperature being treater than 200.degree. C., space velocity being 4000 to 20,000 hr.sup.-1 and the molar ratio of NH.sub.3 to nitrogen oxides being in the range of 0.4 to 2.5.

U.S. Pat. No. 4,473,535 discloses a process for reducing nitric oxide with ammonia in the presence of a copper-exchanged mordenite catalyst at a temperature between about 300.degree. F. and 800.degree. F.

U.S. Pat. No. 4,046,888 relates to a method for selectively reducing nitrogen oxides contained in exhaust gases by using ammonia as a reducing agent and a zeolite catalyst in which the zeolite catalyst is contacted with ammonia in an amount excessive over the stoichiometric amount necessary for reduction of nitrogen oxides in an exhaust gas to thereby activate the zeolite catalyst and then, the amount of ammonia is reduced to a minimum amount necessary for reduction of nitrogen oxides to effect the catalytic reduction.

This invention relates to a method for catalytically reducing one or more nitrogen oxides from a gaseous stream containing one or more nitrogen oxides (NO.sub.x) and optionally one or more sulfur oxides (SO.sub.x) which comprises contacting said gaseous stream and ammonia with a microporous molecular sieve composition at effective reduction conditions in which the amount of ammonia in said method is excessive over the stoichiometric amount necessary for catalytically reducing one or more nitrogen oxides from said gaseous stream, wherein said microporous molecular sieve composition is (i) optionally acid treated with an inorganic or organic acid, (ii) hydrogen forming cation exchanged and (iii) optionally metal cation exchanged, prior to said contacting in said method, and wherein at least a portion of excessive ammonia in said method is oxidized without substantial adverse effect on catalytically reducing one or more nitrogen oxides from said gaseous stream.

As indicated above, this invention relates to a method for catalytically reducing one or more nitrogen oxides from a gaseous stream containing one or more nitrogen oxides and optionally one or more sulfur oxides which comprises contacting said gaseous stream and ammonia with a microporous molecular sieve composition at effective reduction conditions in which the amount of ammonia in said method is excessive over the stoichiometric amount necessary for catalytically reducing one or more nitrogen oxides from said gaseous stream, wherein said microporous molecular sieve composition is (i) optionally acid treated with an inorganic or organic acid, (ii) hydrogen-forming cation exchanged and (iii) optionally metal cation exchanged, prior to said contacting in said method, and wherein at least a portion of excessive ammonia in said method is oxidized without substantial adverse effect on catalytically reducing one or more nitrogen oxides from said gaseous stream.

Copending U.S. patent application Ser. No. (178,912), filed on an even date herewith and commonly assigned, relates to a method for catalytically reducing one or more nitrogen oxides from a gaseous stream containing one or more nitrogen oxides and one or more sulfur oxides which comprises contacting said gaseous stream and ammonia with microporous non-zeolitic molecular sieve composition at effective reduction conditions, wherein said microporous non-zeolitic molecular sieve composition is (i) optionally acid treated with an inorganic or organic acid, (ii) hydrogen-forming cation exchanged and (iii) optionally metal cation exchanged, prior to said contacting in said method.

Copending U.S. patent application Ser. No. (178,978), filed on an even date herewith and commonly assigned, relates to a method for catalytically reducing one or more nitrogen oxides from a gaseous stream containing one or more nitrogen oxides and one or more sulfur oxides which comprises contacting said gaseous stream and ammonia with a multi-dimensional, microporous molecular sieve composition having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of greater than about 6.5 at effective reduction conditions, wherein said multi-dimensional, microporous molecular sieve composition is (i) acid treated with an inorganic or organic acid, (ii) hydrogen-forming cation exchanged and (iii) metal cation exchanged, prior to said contacting in said method.

The basic chemical reactions effected by the method of this invention are believed to be the catalyzed reduction of a nitrogen oxide to free nitrogen with ammonia at reductive reaction temperatures and pressures, and are represented by the following equations:

The exact reactions involved in the method of this invention are dependent on the composition of the gaseous stream and the catalytic bed operating conditions.

The source of the gaseous stream containing the nitrogen oxides, to be reductively removed by the method of this invention, will typically be an industrial flue gas, such as the flue gas from a power generating facility. These flue gases generally comprise, in varying relative amounts, a mixture of oxygen, water vapor, carbon dioxide, sulfur oxides nitrogen oxides and nitrogen.

The amount of ammonia employed should be sufficient to effect complete reduction of the nitrogen oxides to elemental nitrogen and/or nitrous oxide. The amount of ammonia employed in said method is excessive over the stoichiometric amount necessary for catalytically reducing one or more nitrogen oxides from the gaseous stream. The exact amount of ammonia required is determined by the amount of NO.sub.x in the process effluent. Ammonia is added to and mixed with the gaseous stream prior to contact with the molecular sieve catalyst composition. It is preferred that the quantity of ammonia added be sufficient to obtain a mole ratio of ammonia to nitrogen oxide of from about 1.05:1.00 to about 1.50:1.00 or greater.

In addition to effective catalytic reduction of nitrogen oxides in accordance with the method of this invention, any excess ammonia utilized in the catalytic reduction reaction may be oxidized without an adverse effect on nitrogen oxide (NO.sub.x) conversion rates. The basic chemical reactions are believed to be represented by the following equations:

The exact reactions involved are dependent on the catalytic bed operating conditions. Preferably, a substantial portion of excessive ammonia in said method is oxidized without substantial adverse effect on catalytically reducing one or more nitrogen oxides from the gaseous stream. Ammonia emissions can thereby be effectively eliminated or reduced to within permissible limits in accordance with the method of this invention.

The method of this invention further includes the utilization of a microporous molecular sieve composition including mixtures thereof as a catalyst. As described more fully hereinafter, the molecular sieve compositions are acid treated with an inorganic or organic acid, hydrogen-forming cation exchanged and metal cation exchanged, prior to contacting with ammonia and the gaseous stream in the method of this invention. Suitable molecular sieve compositions for use in the method of this invention include the zeolitic, silica or non-zeolitic varieties including mixtures of the same variety or different varieties.

Typical of the molecular sieves of the zeolitic varieties are the chabazite, faujasite, levynite, Linde Type A, gismondine, erionite, sodalite, Linde Type X and Y, analcime, gmelinite, harmotome, levynite, episilbite, heulandite, stilbite, edingtonite, mesolite, natrolite, mordenite, scolecite, thomsonite, brewsterite, laumontite, phillipsite, the ZSM's, e.g., ZSM-5 (U.S. Pat. No. 3,702,886), ZSM-20 (U.S. Pat. No. 3,972,983), ZSM-12 (U.S. Pat. No. 3,832,449), ZSM-34 (U.S. Pat. No. 4,086,186), etc. and Beta (U.S. Pat. No. 3,308,069 and U.S. Re. Pat. No. 28,341), and the like. Typical of suitable zeolitic molecular sieves employable in the practice of this invention are the following:

Zeolites A, AgX, AgY, AlHY, alkylammonium X and Y, BaX, BaY, BeY, Ca-A, Ca-germanic near-faujasite, Ca-HX, Cs-X, Ca-Y, calcium NH.sub.4 Y, CdX, CdY, CeY, CoA, CoX, CoY, CrY, CsX, CsY, Cu-X Cu-Y, diethylammonium Y, ethylammonium Y, Fe-X, Fe-Y, HY, KX, KY, La-X, La-Y, LiA, LiX, LiY, LZ-10, LZ-105, LZ-210, MgNH.sub.4 Y, MgHY, MgNaY, MgNH.sub.4 Y, MgX, MgY, MnX, MnY, Na-A, Na-germanic near faujasite, Na-X, Na-Y, L, KL, NH4-germanic, NH.sub.4 X, NH4Y, activated NH.sub.4 Y, Ni-A, Ni-X, Ni-Y, omega, PdY, rare earth X, rare earth Y, rare earth ammonium Y, RbX, RhY, SrX, SrY, steam stabilized or ultra-stable Y, tetramethylammonium Y, tetraethylammonium Y, triethylammonium Y, X, Y, Y-82, Y-72, ZK-5, Zn-X, Zn-Y, the ZSM's, supra, and the like.

Molecular sieves of the non zeolitic variety include the silica molecular sieves, such as silicalite as depicted in U.S. Pat. No. 4,061,724.

Other molecular sieves of the non-zeolitic variety include those having an empirical chemical compostion on an anhydrous basis expressed by the formula:

where "Q" represents at least one element present as a framework oxide unit "QO.sub.2.sup.n " with charge "n" where "n" may be -3, -2, -1, 0 or +1; "R" represents at least one organic templating agent present on the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Q.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value from zero to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of QO.sub.2.sup.n, AlO.sub.2.sup.-, PO.sub.2.sup.+, SiO.sub.2, respectively, present as framework oxide units. "Q" is characterized as an element having a mean "T-O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms. "Q" has a cation electronegativity between about 125 kcal/gm atom to about 310 kcal/gm-atom and "Q" is capable of forming stable Q--O--P, Q--O--Al or Q--O--Q bonds in crystalline three dimensional oxide structures having a "Q--O" bond dissociation energy greater than about 59 kcal/gm atom at 298.degree. K.; and said mole fractions being within the limiting compositional values or points as follows:

w is equal to 0 to 98 mole percent;

y is equal to 1 to 99 mole percent;

x is equal to 1 to 99 mole percent; and

z is equal to 0 to 99 mole percent.

The "Q" of the "QAPSO" molecular sieves of formula (I) may be defined as representing at least one element capable of forming a framework tetrahedral oxide and may be one of the elements arsenic, beryllium, boron, chromium, cobalt, gallium, germanium, iron, lithium, magnesium, manganese, titanium, vanadium and zinc. The invention contemplates combinations of the elements as representing Q, and to the extent such combinations are present in the structure of a QAPSO they may be present in molar fractions of the Q component in the range of 1 to 99 percent thereof. It should be noted that formula (I) contemplates the non-existence of Q and Si. In such case, the operative structure is that of aluminophosphate or AlPO.sub.4. Where z has a positive value, then the operative structure is that of silicaluminophosphate or SAPO, discussed below. Thus, the term QAPSO does not perforce represent that the elements Q and Si are present. When Q is a multiplicity of elements, then to the extent the elements present are as herein contemplated, the operative structure is that of the ELAPSO's or ELAPO's or MeAPO's or MeAPSO's, as herein discussed. However, in the contemplation that molecular sieves of the QAPSO variety will be invented in which Q will be another element or elements, then it is the intention to embrace the same as a suitable molecular sieve for the practice of this invention.

Illustrations of QAPSO compositions and structures are the various non zeolitic compositions and structures described hereinbelow.

The term "non-zeolitic molecular sieves" or "NZMS" is defined in the instant invention to include the "SAPO" molecular sieves of U.S. Pat. No. 4,440,871 and U.S. Ser. No. 575,745, filed Jan. 31, 1984, "ELAPSO" molecular sieves as disclosed in U.S. Ser. No. 600,312, filed Apr. 13, 1984, and certain "AlPO.sub.4 ", "MeAPO", "FeAPO", "TAPO" and "ELAPO" molecular sieves, as hereinafter described. Crystalline "AlPO.sub.4 " aluminophosphates are disclosed in U.S. Pat. No. 4,310,440 issued Jan. 12, 1982, and in U.S. Ser. No. 880,559, filed June 30, 1986; crystalline metal aluminophosphates (MeAPOs where "Me" is at least one of Mg, Mn, Co and Zn) are disclosed in U.S. Pat. No. 4,567,029, issued Jan. 28, 1986; crystalline ferroaluminophosphates (FeAPOs) are disclosed in U.S. Pat. No. 4,554,143, issued Nov. 19, 1985; titanium aluminophosphates (TAPOs) are disclosed in U.S. Pat. No. 4,500,651, issued Feb. 19, 1985; certain non-zeolitic molecular sieves ("ELAPO") are disclosed in EPC U.S. patent application No. 85104386.9 (Publication No. 0158976, published Oct. 13, 1985) and 85104388.5 (Publication No. 158349, published Oct. 16, 1985); and ELAPSO molecular sieves are disclosed in copending U.S. Ser. No. 600,312, filed Apr. 13, 1984 (EPC Publication No. 0159624, published Oct. 30, 1985). The aforementioned applications and patents are incorporated herein by reference thereto. The nomenclature employed herein to refer to the members of the aforementioned NZMSs is consistent with that employed in the aforementioned applications or patents. A particular member of a class is generally referred to as a "-n" species wherein "n" is an integer, e.g., SAPO-11, MeAPO-11 and ELAPSO 31. In the following discussion on NZMSs set forth hereinafter the mole fraction of the NZMSs are defined as compositional values which are plotted in phase diagrams in each of the identified patents, published applications or copending applications.

"ELAPSO" molecular sieves are described in copending U.S. Ser. No. 600,312, filed Apr. 13, 1984, (EPC Publication No. 0159,624, published Oct. 30, 1985, incorporated herein by reference) as crystalline molecular sieves having three dimensional microporous framework structures of ELO.sub.2, AlO.sub.2, PO.sub.2, SiO.sub.2 oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (EL.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of from zero to about 0.3; "EL" represents at least one element capable of forming a three dimensional oxide framework, "EL" being characterized as an element having a mean "T--O" distance in tetrahedral oxide structures between about 1.51 Angstroms and about 2.06 Angstroms, "EL" having a cation electronegativity between about 125 Kcal/g-atom to about 310 Kcal/gm atom and "EL" being capable of forming stable M--O--P, M--O--Al or M--O--M bonds in crystalline three dimensional oxide structures having a "M--O" bond dissociation energy greater than about 59 kcal/g-atom at 298.degree. K.; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus and silicon, respectively, present as framework oxides, said mole fractions being within the limiting compositional values or points as follows:

where "p" is an integer corresponding to the number of elements "El" in the (El.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 constituent.

The "ELAPSO" molecular sieves are also described as crystalline molecular sieves having three dimensional microporous framework structures of ELO.sub.2, AlO.sub.2, SiO.sub.2 and PO.sub.2 tetrahedral oxide units and having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (EL.sub.w Al.sub.w P.sub.y Si.sub.z)O.sub.2 and has a value of from zero to a about 0.3; "EL" represents at least one element capable of forming a framework tetrahedral oxide and is selected from the group consisting of arsenic, beryllium, boron, chromium, cobalt, gallium, germanium, iron, lithium, magnesium, manganese, titanium and zinc; and "w", "x", "y" and "z" represent the mole fractions of "EL", aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides, said mole fractions being within the limiting compositional values or points as follows:

where "p" is as above defined.

The "ELAPSO" molecular sieves include numerous species which are intended herein to be within the scope of the term "non zeolitic molecular sieves" such being disclosed in the following copending and commonly assigned applications, incorporated herein by reference thereto [(A) following a serial number indicates that the application is abandoned, while (CIP) following a serial number indicates that the application is a continuation in part of the immediately preceding application and (C) indicates that the application is a continuation of the immediately preceding application]:

The disclosures of the patents listed in the foregoing table are herein incorporated by reference.

As already mentioned, the TiAPSO molecular sieves are described in U.S. Pat. No. 4,684,617 (incorporated herein by reference); these TiAPSO molecular sieves are also described in U.S. Ser. No. 049,274, filed May 13, 1987.

The MgAPSO molecular sieves of U.S. Ser. No. 600,180, filed Apr. 13, 1984 have three-dimensional microporous framework structures of MgO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral oxide units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

mR: (Mg.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of Mg.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value from zero (0) to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of magnesium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides and each preferably has a value of at least 0.01. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the MgAPSO molecular sieves the values "w", "x", "y" and "z" in the above formula are within the limiting compositional values or points as follows:

MgAPSO composition are generally synthesized by hydrothermal crystallization for an effective time at effective pressures and temperatures from a reaction mixture containing reactive sources of magnesium, silicon, aluminum and phosphorus, an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and may be an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C. until crystals of the MgAPSO product are obtained, usually a period of from several hours to several weeks. Generally, the crystallization period will be from about 2 hours to about 30 days with it typically being from about 4 hours to about 20 days for obtaining MgAPSO crystals. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the MgAPSO compositions, it is preferred to employ reaction mixture compositions expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and can have a value within the range of from zero (0) to about 6 and is more preferably an effective amount greater than zero to about 6; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "w", "x", "y"and "z" represent the mole fractions of magnesium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w","x","y"and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing magnesium, aluminum, phosphorus and silicon as framework tetrahedral oxides are prepared as follows:

MgAPSO compositions are prepared using numerous reagents. Typical reagents which may be employed to prepare MgAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea for hydrated pseudoboehmite;

(c) LUDOX LS: Trademark of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) Mg(Ac).sub.2 : magnesium acetate tetrahydrate, Mg(C.sub.2 H.sub.3).sub.2.4H.sub.2 O;

(e) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid in water;

(f) TBAOH: tetrabutylammonium hydroxide (40 wt. % in water);

(g) Pr.sub.2 NH: di-n-propylamine;

(h) Pr.sub.3 NH: tri-n-propylamine;

(i) Quin: Quinuclidine;

(j) MQuin: Methyl Quinuclidine hydroxide, (17.9%) in water);

(k) C-hex: cyclohexylamine;

(l) TEAOH: tetraethylammonium hydroxide (40 wt. % in water);

(m) DEEA: Diethylethanolamine;

(n) i-Pr.sub.2 NH: di-isopropylamine;

(o) TEABr: tetraethylammonium bromide; and

(p) TPAOH: tetrapropylammonium hydroxide (40 wt. % in water).

The MgAPSO compositions may be prepared by preparing reaction mixtures having a molar composition expressed as:

wherein e, f, g, h, i and j represent the moles of template R, magnesium (expressed as the oxide), SiO.sub.2,Al.sub.2 O.sub.3, P.sub.2 O.sub.5 (H.sub.3 PO.sub.4 expressed as P.sub.2 O.sub.5) and H.sub.2 O, respectively.

The reaction mixtures may be prepared by the following representative procedures, designated hereinafter as Methods A, B and C.

The reaction mixture is prepared by mixing round aluminum source (alipro or CATAPAL) with the H.sub.3 PO.sub.4 and water on a gradual basis with occasional cooling with an ice bath. The resulting mixture is blended until a homogeneous mixture is observed. When the aluminum source is CATAPAL the water and H.sub.3 PO.sub.4 are first mixed with the CATAPAL added thereto. The magnesium acetate is dissolved in a portion of the water and is then added followed by addition of the LUDOX LS. The combined mixture is blended until a homogeneous mixture is observed. The organic templating agent is added to this mixture and blended until a homogeneous mixture is observed. The resulting mixture (final reaction mixture) is placed in a lined (polytetrafluoro ethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for an effective time. Alternatively, if the digestion temperature is 100.degree. C. the final reaction mixture is placed in a lined (polytetrafluoroethylene) screw top bottle for a time. Digestions are typically carried out under autogenous pressure. The products are removed from the reaction vessel, cooled and evaluated as set forth hereinafter.

When method B is employed the organic templating agent is di n-propylamine. The aluminum source, silicon source and one-half of the water are first mixed and blended until a homogeneous mixture is observed. A second solution was prepared by mixing the remaining water, the H.sub.3 PO.sub.4 and the magnesium acetate. This solution is then added to the above mixture. The magnesium acetate and H.sub.3 PO.sub.4 solution is then added to the above mixture and blended until a homogeneous mixture is observed. The organic templating agent(s) is/are then added and the resulting reaction mixture digested and product recovered as in Method A.

Method C is carried out by mixing aluminum isopropoxide, LUDOX LS and water in a blender or by mixing water and aluminum iso propoxide in a blender followed by addition of the LUDOX LS. H.sub.3 PO.sub.4 and magnesium acetate are then added to the resulting mixture. The organic templating agent is then added to the resulting mixture and digested and product recovered as in Method A.

As already mentioned, the MnAPSO molecular sieves are described in U.S. Pat. No. 4,686,092 issued Aug. 11, 1987 (incorporated herein by reference).

The CoAPSO molecular sieves of U.S. Ser. No. 600,174, filed Apr. 13, 1984 have three-dimensional microporous framework structures of CoO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Co.sub.w Al.sub.w P.sub.y Si.sub.z)O.sub.2 and has a value of from zero to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of cobalt, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides, where the mole fractions "w", "x", "y" and "z" are each at least 0.01 and are generally defined, as being within the limiting compositional values or points as follows:

In a preferred subclass of the CoAPSO molecular sieves the values of "w", "x", "y" and "z" in the above formula are within the limiting compositional values or points as follows:

CoAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of cobalt, silicon, aluminum and phosphorus, an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and optionally an alkali metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at an effective temperature which is generally between 50.degree. C. and 250.degree. C. and preferably between 100.degree. C. and 200.degree. C. until crystals of the CoAPSO product are obtained, usually for an effective time of from several hours to several weeks. Generally the effective crystallization time will be from about 2 hours to about 30 days and typically from about 4 hours to about 20 days. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the CoAPSO, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing cobalt, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

CoAPSO compositions may be prepared using numerous reagents. Reagents which may be employed to prepare CoAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for pseudoboehmite;

(c) LUDOX LS: Trademark of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) Co(Ac).sub.2 : cobalt acetate, CO(C.sub.2 H.sub.3 O.sub.2).sub.2.4H.sub.2 O;

(e) CoSO.sub.4 : cobalt sulfate, (CoSO.sub.4.7H.sub.2 O);

(f) H.sub.3 PO.sub.4 : 85 weight percent phosphoric acid in water;

(g) TBAOH: tetrabutylammonium hydroxide (25 wt % in methanol);

(h) Pr.sub.2 NH: di-n propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH):

(l) C-hex: cyclohexylamine;

(m) TEAOH: tetraethylammonium hydroxide (40 wt. % in water);

(n) DEEA: diethanolamine;

(o) TPAOH: tetrapropylammonium hydroxide (40 wt. % in water); and

(p) TMAOH: tetramethylammonium hydroxide (40 wt. % in water).

CoAPSO compositions may be prepared by preparing reaction mixtures having a molar composition expressed as:

wherein e, f, h, i, g, and j represent the moles of template R, cobalt (expressed as the oxide), Al.sub.2 O.sub.3, P.sub.2 O.sub.5 (H.sub.3 PO.sub.4 expressed as P.sub.2 O.sub.5), SiO.sub.2 and H.sub.2 O, respectively.

The reaction mixtures are prepared by forming a starting reaction mixture comprising the H.sub.3 PO.sub.4 and one-half of the water. This mixture is stirred and the aluminum source (Alipro or CATAPAL) added. The resulting mixture is blended until a homogeneous mixture is observed. The LUDOX-LS is then added to the resulting mixture and the new mixture blended until a homogeneous mixture is observed. The cobalt source (e.g., Co(Ac).sub.2, Co(SO.sub.4) or mixtures thereof) is dissolved in the remaining water and combined with the first mixture. The combined mixture is blended until a homogeneous mixture is observed. The organic templating agent is added to this mixture and blended for about two to four minutes until a homogeneous mixture is observed. The resulting mixture (final reaction mixture) is placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C., 200.degree. C. or 225.degree. C.) for a time. Digestions are typically carried out at the autogenous pressure. The products are removed from the reaction vessel and cooled.

The ZnAPSO molecular sieves of U.S. Ser. No. 600,170, filed Apr. 13, 1984 comprise framework structures of ZnO.sub.2 -2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Zn.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3; and "w", "x", "y" and "z" represent the mole fractions of zinc, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides and each has a value of at least 0.01. The mole fractions "w", "x", "y" and "z" are generally defined being within the limiting compositional values or points as follows:

In a preferred subclass of ZnAPSO molecular sieves the values "w","x","y"and "z" in the above formula are within the limiting compositional values or points as follows:

ZnAPSO compositions are generally synthesized by hydrothermal crystallization at effective process conditions from a reaction mixture containing active sources of zinc, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element or Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure, at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C. until crystals of the ZnAPSO product are obtained, usually a period of from several hours to several weeks. Generally the effective crystallization period is from about 2 hours to about 30 days with typical periods of from about 4 hours to about 20 days being employed to obtain ZnAPSO products. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the ZnAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "b" has a value of from zero (0) to about 500, more preferably between about 2 and about 300; and "w", "x", "y" and "z" represent the mole fractions of zinc, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01. In a preferred embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y"and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y"and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing zinc, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

ZnAPSO compositions are typically prepared numerous reagents. Reagents which may be employed to prepare ZnAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) LUDOX LS: LUDOX LS is the trade name of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(c) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) ZnAc: Zinc Acetate, Zn(C.sub.2 H.sub.3 O.sub.2).sub.2. 4H.sub.2 O;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) TMAOH: Tetramethylammonium hydroxide pentahydrate, (CH.sub.3).sub.4 NOH.5H.sub.2 O;

(i) TPAOH: 40 weight percent aqueous solution of tetrapropylammonium hydroxide, (C.sub.3 H.sub.7).sub.4 NOH;

(j) Pr.sub.2 NH: Di-n-propylamine, C.sub.3 H.sub.7).sub.2 NH;

(k) Pr.sub.3 N: Tri n propylamine, (C.sub.3 H.sub.7).sub.3 N;

(l) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(m) C-hex: cyclohexylamine; and

(n) DEEA: diethylethanolamine, (C.sub.2 H.sub.5).sub.2 NC.sub.2 H.sub.5 OH.

ZnAPSO compositions are typically prepared by forming reaction mixtures having a molar composition expressed as:

wherein e, f, g, h, i and j represent the moles of template R, zinc (expressed as the oxide), Al.sub.2 O.sub.3, P.sub.2 O.sub.5 (H.sub.3 PO.sub.4 expressed as P.sub.2 O.sub.5), SiO.sub.2 and H.sub.2 O respectively.

The reaction mixtures are generally prepared by forming a starting reaction mixture comprising the H.sub.3 PO.sub.4 and a portion of the water. This mixture is stirred and the aluminum source added. The resulting mixture is blended until a homogeneous mixture is observed. The LUDOX LS is then added to the resulting mixture and the new mixture blended until a homogeneous mixture is observed. The zinc source (zinc acetate) is dissolved in the remaining water and combined with the first mixture. The combined mixture is blended until a homogeneous mixture is observed. The organic templating agent is added to this mixture and blended for about two to four minutes until a homogeneous mixture is observed. The resulting mixture (final reaction mixture) is placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at an effective temperature for an effective time. Digestions are typically carried out under autogenous pressure. The products are removed from the reaction vessel and cooled.

As already mentioned, the FeAPSO molecular sieves are described in U.S. Pat. No. 4,683,217 (incorporated herein by reference).

The QuinAPSO quinary molecular sieves of U.S. Ser. Nos. 600,168 and 600,181, both filed Apr. 13, 1984, have three-dimensional microporous framework structures of MO.sub.2.sup.n, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units, where "n" is -3, -2, -1, or +1, and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (M.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of from zero (0) to about 0.3; M represents at least two elements selected from the group consisting of arsenic, beryllium, boron, chromium, cobalt, gallium, germanium, iron, lithium, magnesium, manganese, titanium, vanadium and zinc; and "w", "x", "y" and "z" represent the mole fractions of M, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. Preferably, M represents the combination of cobalt and manganese. The mole fractions "w", "x", "y", and "z" are generally defined as being within the limiting compositional values or points as follows:

Preferably the mole fractions w, x, y and z will fall within the limiting compositional values or points as follows:

QuinAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of the elements M, aluminum, phosphorus and silicon and preferably an organic templating agent, i.e., structure directing, agent. The structure-directing agents are preferably a compound of an element of Group VA of the Periodic Table, and may be an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure and at typical effective temperatures between 50.degree. C. and 250.degree. C., preferably between 100.degree. C. and 200.degree. C., until crystals of the QuinAPSO product are obtained, usually over a period of from several hours to several weeks. Typical effective crystallization times are from about 2 hours to 30 days with from about 4 hours to about 20 days being generally employed to obtain QuinAPSO products. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the QuinAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

aR: (M.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 : bH.sub.2 O

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "w", "x", "y" and "z" represent the mole fractions of elements M, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. QuinAPSO compositions were prepared using numerous regents; the appropriate sources of the various elements M are the same as those used in the preparation of the various APO and APSO molecular sieves containing the same elements, as described in detail above and below.

Reagents which may be employed to prepare QuinAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) LUDOX-LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent of Na.sub.2 O;

(c) H.sub.3 PO.sub.4 : 85 weight percent phosphoric acid;

(d) MnAc: Manganese acetate, Mn(C.sub.2 H.sub.3 O.sub.2).sub.2.4H.sub.2 O (for QuinAPSOs containing manganese);

(e) CoAc: Cobalt Acetate, Co(C.sub.2 H.sub.3 O.sub.2).sub.2.4H.sub.2 O (for QuinAPSOs containing cobalt);

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide; and

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH.

QuinAPSOs may be prepared by forming a starting reaction mixture by adding H.sub.3 PO.sub.4 and one-half of the quantity of water. To this mixture aluminum isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture a silica (e.g., LUDOX-LS) is added and the resulting mixture blended (about 2 minutes) until a homogeneous mixture is observed. A second mixture is prepared using manganese acetate (or a appropriate source of another element M) and one-half of the remaining water. A third mixture is prepared using cobalt acetate (or a appropriate source of another element M) and one-half of the remaining water. The three mixtures are admixed and the resulting mixture blended until a homogeneous mixture is observed. The organic templating agent is then added to the resulting mixture and the resulting mixture blended until a homogeneous mixture is observed, i.e., about 2 to 4 minutes. The pH of the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at an effective temperature for an effective time. Digestions are typically carried out under autogeneous pressure.

The CoMnMgAPSO senary molecular sieves of U.S. Ser. No. 600,182, filed Apr. 13, 1984, and of U.S. Ser. No. 057,648 filed June 9, 1987, have three dimensional microporous framework structures of CoO.sub.2.sup.-2, MnO.sub.2.sup.-2, MgO.sub.2.sup.-2, AlO.sub.2, PO.sub.2 and SiO.sub.2 tetrahedral oxide units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Co.sub.t Mn.sub.u Mg.sub.v Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of from zero (0) to about 0.3; "t", "u", "v", "x", "y" and "z" represent the mole fractions of cobalt, manganese, magnesium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides and each has a value of at least 0.01. The mole fractions "w", "x", "y" and "z", where "w" is the sum of "t"+"u"+"v", are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the CoMnMgAPSO molecular sieves the values of "w", "x", "y" and "z" in the above formula are within the limiting compositional values or points as follows:

CoMnMgAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of cobalt, manganese, magnesium, aluminum, phosphorus and silicon, and preferably an organic templating agent, i.e., structure-directing agent. The structure-directing agents are preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C., until crystals of the CoMnMgAPSO product are obtained, usually over a period of from several hours to several weeks. Typical crystallization times are from about 2 hours to about 30 days with from about 4 hours to about 20 days generally being employed to obtain CoMnMgAPSO products. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the CoMnMgAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6 and more preferably from greater than zero to about 2; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "t", "u", "v", "x", "y", and "z" represent the mole fractions of cobalt, manganese, magnesium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In a preferred embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z", where "w" is the sum of "t"+"u"+"v", are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "t", "u", "v", "x", "y" and "z" such that (t+u+v+x+y+z)=1.00 mole. Molecular sieves containing cobalt, manganese, magnesium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

CoMnMgAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare CoMnMgAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) LUDOX-LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O ;

(c) H.sub.3 PO.sub.4 : aqueous solution which is 85 weight percent phosphoric acid;

(d) MnAc: Manganese acetate, Mn(C.sub.2 H.sub.3 O.sub.2).sub.2 .multidot.4H.sub.2 O;

(e) CoAc: Cobalt Acetate, Co(C.sub.2 H.sub.3 O.sub.2).sub.2 .multidot.4H.sub.2 O;

(f) MgAc: Magnesium Acetate Mg(C.sub.2 H.sub.3 O.sub.2).multidot.4H.sub.2 O;

(g) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide; and

(h) Pr.sub.2 NH: di n-propylamine, (C.sub.3 H.sub.7).sub.2 NH.

CoMnMgAPSOs may be prepared by forming a starting reaction mixture by adding H.sub.3 PO.sub.4 and one half of the quantity of water. To this mixture an aluminum isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture a silica (e.g., LUDOX-LS) is added and the resulting mixture blended (about 2 minutes) until a homogeneous mixture is observed.

Three additional mixtures are prepared using cobalt acetate, magnesium acetate and manganese acetate using one third of the remainder of the water for each mixture. The four mixtures are then admixed and the resulting mixture blended until a homogeneous mixture is observed. An organic templating agent is then added to the resulting mixture and the resulting mixture blended until a homogeneous mixture is observed, i.e., about 2 to 4 minutes. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature for a time. Digestions are typically carried out under autogenous pressure

The SenAPSO molecular sieves of U.S. Ser. No. 600,183, filed Apr. 13, 1984 have three-dimensional microporous framework structures of MO.sub.2.sup.n,AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral oxide units, where "n" is -3, -2, -1, 0 or +1, and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (M.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2, and has a value of from zero to about 0.3; "M" represents three elements selected from the group consisting of arsenic, beryllium, boron, chromium, cobalt, gallium, germanium, iron, lithium, magnesium, manganese, titanium, vanadium and zinc; "n" may have the aforementioned values depending upon the oxidation state of "M"; and "w", "x", "y" and "z" represent the mole fractions of elements "M", aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows, wherein "w" denotes the combined mole fractions of the three elements "M" such that "w"="w.sub.1 "+"w.sub.2 "+"w.sub.3 " and each element "M" has a mole fraction of at least 0.01:

In a preferred subclass of the SenAPSO molecular sieves the values of "w", "x", "y" and "z" in the above formula are within the limiting compositional values or points as follows:

SenAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of elements "M", aluminum, phosphorus and silicon, and preferably an organic templating, i.e., structure-directing, agent. The structure directing agents are preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C., until crystals of the SenAPSO product are obtained, usually over a period of from several hours to several weeks. Typical crystallization times are from about 2 hours to about 30 days with from about 4 hours to about 20 days generally being employed to obtain SenAPSO products. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the SenAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6 and more preferably from greater than zero to about 2; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "w", "x", "y", and "z" represent the mole fractions of elements "M", aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01, with the proviso that each "M" is present in a mole fraction of at least 0 01.

In a preferred embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y"and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. The SenAPSO molecular sieves are prepared by preparative techniques, and using sources of the elements "M" similar to those described for the other APSO molecular sieves described above and below.

The AsAPSO molecular sieves of U.S. Ser. Nos. 599,808, filed Apr. b 13, 1984, and 845,484 filed Mar. 31, 1986 have a framework structure of AsO.sub.2.sup.n, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (As.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements arsenic, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the AsAPSO molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the AsAPSO molecular sieves, the values of w, x, y and z are as follows:

AsAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of arsenic, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the AsAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 12 hours to about 10 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the AsAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 1.0; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 60; and "w", "x", "y" and "z" represent the mole fractions of arsenic, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 1 to about 2 total moles of silicon and arsenic, and from about 1 to about 2 moles of aluminum,.per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing arsenic, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

AsAPSO compositions may be prepared by numerous reagents. Reagents which may be employed to prepare AsAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX-LS: LUDOX LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) As.sub.2 O.sub.5, arsenic (V) oxide;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2 diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

AsAPSOs may be prepared by forming a starting reaction mixture by dissolving the arsenic (V) oxide and the H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum isopropoxide or CATAPAL is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture the templating agent and then the silica is added and the resulting mixture blended until a homogeneous mixture is observed. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The BAPSO molecular sieves of U.S. Ser. Nos. 600,177, filed Apr. 13, 1984, and 845,255 filed Mar. 28, 1986 have a framework structure of BO.sub.2.sup.-, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (B.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3 but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements boron, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the BAPSO molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the BAPSO molecular sieves, the values of w, x, y and z are as follows:

BAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of boron, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the BAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the BAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and "w", "x", "y" and "z" represent the mole fractions of boron, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 1.0 to about 2 total moles of silicon and boron, and from about 0.75 to about 1.25 moles of aluminum, per mole of phosphorus. In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing boron, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

BAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare BAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX-LS: LUDOX LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) H.sub.3 BO.sub.3 : boric acid, and trialkyl borates;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C-hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2-diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

BAPSOs may be prepared by forming a starting reaction mixture by dissolving aluminum isopropoxide in an alcohol such as isopropanol, adding the H.sub.3 PO.sub.4 and recovering the solid which precipitates. This solid is then added to water, and trialkylborate (for example trimethyl borate) added, followed by silica and the templating agent. This mixture is then blended until a homogeneous mixture is observed. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The BeAPSO molecular sieves of U.S. Ser. Nos. 600,176, filed Apr. 13, 1984, and 841,752 filed Mar. 20, 1986 have a framework structure of BeO.sub.2.sup.-2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Be.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements beryllium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the BeAPSO molecular sieves, the values of w, x, y and z are as follows:

BeAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of beryllium, silicon, aluminum and phosphorus, preferrably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the BeAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, have been observed, with from 1 to 10 days being preferred. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the BeAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 to about 300, most preferably not greater than about 20; and "w", "x", "y" and "z" represent the mole fractions of beryllium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing beryllium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

BeAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare BeAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX-LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) beryllium sulfate, BeSO.sub.4 ;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (Cj.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C-hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2 diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

BeAPSOs may be prepared by forming a starting solution by mixing H.sub.3 PO.sub.4 in at least part of the water. To this solution is added beryllium sulfate (or another beryllium salt) and the resultant mixture stirred until a homogeneous solution is obtained. To this solution may be added successively the aluminum oxide, the silica and the templating agent, with the mixture being stirred between each addition until it is homogeneous. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The CAPSO molecular sieves of U.S. Ser. Nos. 599,830, filed Apr. 13, 1984, and 852,174 filed Apr. 15, 1986 have a framework structure of CrO.sub.2.sup.n, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units (where "n"is 1, 0 or +1) having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Cr.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements chromium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the CAPSO molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the CAPSO molecular sieves, the values f x and y in the above formula are each within the range of about 0.4 to 0.5 and (z+w) is in the range of about 0.02 to 0.15.

Since the exact nature of the CAPSO molecular sieves is not clearly understood at present, although all are believed to contain CrO.sub.2 tetrahedra in the three-dimensional microporous crystal framework structure, it is advantageous to characterize the CAPSO molecular sieves by means of their chemical composition. This is due to the low level of chromium present in certain of the CAPSO molecular sieves prepared to date which makes it difficult to ascertain the exact nature of the interaction between chromium, aluminum, phosphorus and silicon. As a result, although it is believed that CrO.sub.2 tetrahedra are substituted isomorphously for AlO.sub.2, PO.sub.2 or SiO.sub.2 tetrahedra, it is appropriate to characterize certain CAPSO compositions by reference to their chemical composition in terms of the mole ratios of oxides.

CAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of chromium, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the CAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, and preferably about 1 to about 10 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the CAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and "w", "x", "y" and "z" represent the mole fractions of chromium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 0.3 to about 0.5 total moles of silicon and chromium, and from about 0.75 to about 1.25 moles of aluminum, per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing chromium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

CAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare CAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX-LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) chromium acetate, and chromium acetate hydroxide;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH:

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide,

(1) C-hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2 diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

CAPSOs may be prepared by forming a starting solution by dissolving H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture the silica, the chromium acetate or chromium acetate hydroxide and the templating agent are successively added and at each step the resulting mixture is blended until a homogeneous mixture is observed.

Alternatively, the water and aluminum isopropoxide may first be mixed, and then the silica, the chromium acetate or chromium acetate hydroxide, the phosphoric acid and the templating agent added, and again at each step the resulting mixture is blended until a homogeneous mixture is observed.

In either case, the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure

The GaAPSO molecular sieves of U.S. Ser. Nos. 599,925, filed Apr. 13, 1984, and 845,985 filed Mar. 31, 1986 have a framework structure of GaO.sub.2.sup.-, AlO.sub.2.sup.-, PO.sub.2.sup.+ 0 and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Ga.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.2; and "w", "x", "y" and "z" represent the mole fractions of the elements gallium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the GaAPSO molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the GaAPSO molecular sieves, the values of w, x, y and z are as follows:

GaAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of gallium, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the GaAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, and preferably about 2 to about 15 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the GaAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 1.0; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and "w", "x", "y" and "z" represent the mole fractions of gallium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 0.5 to about 1.0 total moles of silicon and gallium, and from about 0.75 about 1.25 moles of aluminum, per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing gallium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

GaAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare GaAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) gallium hydroxide, or gallium sulfate;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2-diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

GaAPSOs may be prepared by forming a starting solution by dissolving H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum hydroxide or isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture is added a second solution prepared by adding silica to a solution containing the gallium hydroxide and the templating agent and then the combined mixture is blended until a homogeneous mixture is observed.

Alternatively, the templating agent may be added to the solution containing the phosphoric acid and water, and a solution of gallium sulfate in water added, followed by successive additions of silica and aluminum oxide and then the combined mixture is blended until a homogeneous mixture is observed.

In either case, the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The GeAPSO molecular sieves of U.S. Ser. Nos. 599,971, filed Apr. 13, 1984, and 852,175 filed Apr. 15, 1986 have a framework structure of GeO.sub.2, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Ge.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements geranium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limited compositional values or points as follows:

In a preferred subclass of the GeAPS molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the GeAPSO molecular sieves, the values of w, x, y and z are as follows:

GeAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of geranium, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the GeAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, and preferably about 12 hours to about 7 days have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the GaAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and desirably not greater than about 10; and "w", "x", "y" and "z" represent the mole fractions of germanium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 0.2 to about 0.3 total moles of silicon and germanium, and from about 0.75 about 1.25 moles of aluminum, per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing germanium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

GeAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare GeAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX-LS: LUDOX LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(e) germanium tetrachloride or germanium ethoxide;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C-hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2-diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate; and

(g) aluminum chlorhydrol.

In some cases, it may be advantageous, when synthesizing the GeAPSO compositions, to first combine sources of germanium and aluminum, or of germanium, aluminum and silicon, to form a mixed germanium/aluminum or germanium/aluminum/silicon compound (this compound being typically a mixed oxide) and thereafter to combine this mixed compound with a source of phosphorus to form the final GeAPSO composition. Such mixed oxides may be prepared for example by hydrolyzing aqueous solutions containing germanium tetrachloride and aluminum chlorhydrol, or germanium ethoxide, tetraethylorthosilicate, and aluminum tri-sec-butoxide.

GeAPSOs may be prepared by forming a starting solution by dissolving H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum isopropoxide or CATAPAL is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture is the templating agent and then a solution containing tetraethylorthosilicate and germanium ethoxide, and the resulting mixture blended until a homogeneous mixture is observed.

Alternatively, the phosphoric acid may first be mixed with the templating agent, and then a solution containing tetraethylorthosilicate and germanium ethoxide combined with the phosphoric acid/templating agent solution. Then the aluminum oxide is added and the resultant mixture blended until homogeneous.

In a third procedure, the phosphoric acid may first be mixed with the templating agent and water, and to the resultant solution is added the solid aluminum/silicon/germanium mixed oxide prepared as described above. The resultant mixture is then blended until homogeneous.

Whichever procedure is adopted, the final mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The LiAPSO molecular sieves of U.S. Ser. No. 599,952, filed Apr. 13, 1984, and U.S. Ser. No. 847,227 filed Apr. 2, 1986 have a framework structure of LiO.sub.2.sup.-3, AlO.sub.2.sup.-, PO.sub.2.sup.+ and SiO.sub.2 tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Li.sub.w Al.sub.x P.sub.y Si.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "w", "x", "y" and "z" represent the mole fractions of the elements lithium, aluminum, phosphorus and silicon, respectively, present as tetrahedral oxides. The mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the LiAPSO molecular sieves, the values of w, x, y and z are as follows:

In an especially preferred subclass of the LiAPSO molecular sieves, the value of w+z is not greater than about 0.20.

Since the exact nature of the LiAPSO molecular sieves is not clearly understood at present, although all are believed to contain LiO.sub.2 tetrahedra in the three-dimensional microporous crystal framework structure, it is advantageous to characterize the LiAPSO molecular sieves by means of their chemical composition. This is due to the low level of lithium present in certain of the LiAPSO molecular sieves prepared to date which makes it difficult to ascertain the exact nature of the interaction between lithium, aluminum, phosphorus and silicon. As a result, although it is believed that LiO.sub.2 tetrahedra are substituted isomorphously for AlO.sub.2, PO.sub.2 or SiO.sub.2 tetrahedra, it is appropriate to characterize certain LiAPSO compositions by reference to their chemical composition in terms of the mole ratios of oxides.

LiAPSO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of lithium, silicon, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the LiAPSO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, and preferably about 1 to about 10 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the LiAPSO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20, and most desirably not greater than about 10; and "w", "x", "y" and "z" represent the mole fractions of lithium, aluminum, phosphorus and silicon, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "w", "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "w", "x", "y" and "z" such that (w+x+y+z)=1.00 mole. Molecular sieves containing lithium, aluminum, phosphorus and silicon as framework tetrahedral oxide units are prepared as follows:

LiAPSO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare LiAPSOs include:

(a) Alipro: aluminum isopropoxide;

(b) CATAPAL: Trademark of Condea Corporation for hydrated pseudoboehmite;

(c) LUDOX LS: LUDOX-LS is the tradename of DuPont for an aqueous solution of 30 weight percent SiO.sub.2 and 0.1 weight percent Na.sub.2 O;

(d) H.sub.3 PO.sub.4 : 85 weight percent aqueous-phosphoric acid;

(e) lithium orthophosphate;

(f) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(g) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(h) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(i) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(j) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(k) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(l) C-hex: cyclohexylamine;

(m) TMAOH: tetramethylammonium hydroxide;

(n) TPAOH: tetrapropylammonium hydroxide; and

(o) DEEA: 2-diethylaminoethanol;

(p) Tetraalkylorthosilicates, such as tetraethylorthosilicate.

LiAPSOs may be prepared by forming a starting reaction mixture mixing lithium phosphate and aluminum oxide, then adding the resultant mixture to the H.sub.3 PO.sub.4. To the resultant mixture is added silica and the templating agent and the resulting mixture is blended until a homogeneous mixture is observed. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

As already mentioned, the AlPO.sub.4 aluminophosphate molecular sieves are described in U.S. Pat. No. 4,310,440 (incorporated herein by reference); these AlPO.sub.4 molecular sieves are also described in U.S. Ser. No. 880,559, filed June 30, 1986.

MeAPO molecular sieves are crystalline microporous aluminophosphates in which the substituent metal is one of a mixture of two or more divalent metals of the group magnesium, manganese, zinc and cobalt and are disclosed in U.S. Pat. No. 4,567,029 (incorporated herein by reference).

As already mentioned, ferroaluminophosphates (FAPO's) are disclosed in U.S. Pat. No. 4,554,143 (incorporated herein by reference).

As already mentioned, TAPO molecular sieves are disclosed in U.S. Pat. No. 4,500,561 (incorporated herein by reference).

"ELAPO" molecular sieves are a class of crystalline molecular sieves in which at least one element capable of forming a three dimensional microporous framework forms crystal framework structures of AlO.sub.2.sup.-, PO.sub.2.sup.+ and MO.sub.2.sup.n tetrahedral oxide units wherein "MO.sub.2.sup.n " represents at least one different element (other than Al or P) present as tetrahedral oxide units "MO.sub.2.sup.n " with charge "n" where "n" may be -3, -2, -1, 0 or +1. The members of this novel class of molecular sieve compositions have crystal framework structures of AlO.sub.2.sup.-, PO.sub.2.sup.+ MO.sub.2.sup.n tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 ; "M" represents at least one element capable of forming framework tetrahedral oxides; and "x", "y" and "z" represent the mole fraction of "M", aluminum and phosphorus, respectively, present as tetrahedral oxides. "M" is at least one different (i.e., not aluminum, phosphorus or oxygen) element such that the molecular sieves contain at least one framework tetrahedral unit in addition to AlO.sub.2.sup.- and PO.sub.2.sup.+. "M" is at least one element selected from the group consisting of arsenic, beryllium, boron, cobalt, chromium, gallium, germanium, iron, lithium, magnesium, manganese, titanium and zinc, subject to certain restrictions on the combinations of elements as will appear from the discussions of individual groups of ELAPOs below. ELAPOs and their preparation are disclosed in European Patent Application Ser. No. 85104386.9, filed Apr. 11, 1985 (EPC Publication No. 0158976, published Oct. 13, 1985, incorporated herein by reference) and 85104388.5, filed Apr. 11, 1985 (EPC Publication No. 158349, published Oct. 16, 1985, incorporated herein by reference).

The "ELAPO" molecular sieves further include numerous species which are intended herein to be within the scope of the term "non-zeolitic molecular sieves" such being disclosed in the following copending and commonly assigned applications, incorporated herein by reference thereto [(A) following a serial number indicates that the application is abandoned, while (CIP) following a serial number indicates that the application is a continuation in part of the immediately preceding application, and (C) indicates that the application is a continuation of the immediately preceding application]:

The disclosure of the patent listed in the foregoing table is incorporated herein by reference.

The ELAPO molecular sieves are generally referred to herein by the acronym "ELAPO" to designate element(s) "M" in a framework of AlO.sub.2.sup.-, PO.sub.2.sup.+ and MO.sub.2.sup.n oxide units. Actual class members will be identified by replacing the "EL" of the acronym with the elements present as MO.sub.2.sup.n tetrahedral units. For example, "MgBeAPO" designates a molecular sieve comprised of AlO.sub.2.sup.-, PO.sub.2.sup.+, MgO.sub.2.sup.-2 and BeO.sub.2.sup.-2 tetrahedral units. To identify various structural species which make up each of the subgeneric classes, each species is assigned a number and is identified as "ELAPO-i" wherein "i" is an integer. The given species designation is not intended to denote a similarity in structure to any other species denominated by a similar identification system.

The ELAPO molecular sieves comprise at least one additional element capable of forming framework tetrahedral oxide units (MO.sub.2.sup.n) to form crystal framework structures with AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral oxide units wherein "M" represents at least one element capable of forming tetrahedral units "MO.sub.2.sup.n " where "n" is -3, -2, -1, 0 or +1 and is at least one element selected from the group consisting of arsenic, beryllium, boron, cobalt, chromium, gallium, germanium, iron, lithium, magnesium, manganese, titanium and zinc.

The ELAPO molecular sieves have crystalline three-dimensional microporous framework structures of AlO.sub.2.sup.-, PO.sub.2.sup.+ and MO.sub.2.sup.n tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3; "M" represents at least one element capable of forming framework tetrahedral oxides where "M" is at least one element selected from the group consisting of arsenic, beryllium, boron, cobalt, chromium, gallium, germanium, iron, lithium, magnesium, manganese, titanium and zinc.

The relative amounts of element(s) "M", aluminum and phosphorus are expressed by the empirical chemical formula (anhydrous):

where "x", "y" and "z" represent the mole fractions of said "M" aluminum and phosphorus. The individual mole fractions of each "M" (or when M denotes two or more elements, M.sub.1, M.sub.2, M.sub.3, etc.) may be represented by "x.sub.1 ", "x.sub.2 ", "x.sub.3 ", etc wherein "x.sub.1 ", "x.sub.2 ", and "x.sub.3 " etc. represent the individual mole fractions of elements M.sub.1, M.sub.2, M.sub.3, and etc. for "M" as above defined. The values of "x.sub.1 ", "x.sub.2 ", "x.sub.3 ", etc. are as defined for "x", hereinafter, where "x.sub.1 "+"x.sub.2 "+"x.sub.3 " . . . ="x" and where x.sub.1, x.sub.2, x.sub.3, etc. are each at least 0.01.

The ELAPO molecular sieves have crystalline three-dimensional microporous framework structures of MO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units having an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents a molar amount of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3; "M" represents at least one different element (other than Al or P) capable of forming framework tetrahedral oxides, as hereinbefore defined, and "x", "y" and "z" represent the mole fractions of "M", aluminum and phosphorus, respectively present as tetrahedral oxides; in general, said mole fractions "x", "y" and "z" are within the following values for "x", "y" and "z", although as will appear hereinbelow, the limits for "x", "y" and "z" may vary slightly with the nature of the element "M":

Also, in general, in a preferred sub-class of the ELAPOs of this invention, the values of "x", "y" and "z" in the formula above are within the following values for "x", "y" and "z", although again the relevent limits may vary somewhat with the nature of the element "M", as set forth hereinbelow:

ELAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of the elements "M", aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between 50.degree. C. and 250.degree. C., and preferably between 100.degree. C. and 200.degree. C., until crystals of the ELAPO product are obtained, usually a period of from several hours to several weeks. Typical crystallization times are from about 2 hours to about 30 days with from about 2 hours to about 20 days being generally employed to obtain crystals of the ELAPO products. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the ELAPO compositions of the instant invention, it is in general preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "b" has a value of from zero (0) to about 500, preferably between about 2 and 300; "M" represents at least one element, as above described, capable of forming tetrahedral oxide framework units, MO.sub.2.sup.n, with AlO.sub.2.sup.+ and PO.sub.2.sup.+ tetrahedral units; "n" has a value of -3, -2, -1, 0 or +1; and "x", "y" and "z" represent the mole fractions of "M", aluminum and phosphorus, respectively; "y" and "z" each have a value of at least 0.01 and "x" has a value of at least 0.01 with each element "M" having a mole fraction of at least 0.01. In general, the mole fractions "x", "y" and "z" are preferably within the following values for "x", "y" and "z":

Further guidance concerning the preferred reaction mixtures for forming ELAPOs with various elements "M" will be given below.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to a total of (M+Al+P)=(x+y+z)=1.00 mole, whereas in other cases the reaction mixtures are expressed in terms of molar oxide ratios and may be normalized to 1.00 mole of P.sub.2 O.sub.5 and/or Al.sub.2 O.sub.3. This latter form is readily converted to the former form by routine calculations by dividing the total number of moles of "M", aluminum and phosphorus into the moles of each of "M", aluminum and phosphorus. The moles of template and water are similarly normalized by dividing by the total moles of "M", aluminum and phosphorus.

In forming the reaction mixture from which the instant molecular sieves are formed the organic templating agent can be any of those heretofore proposed for use in the synthesis of conventional zeolite aluminosilicates. In general these compounds contain elements of Group VA of the Periodic Table of Elements, particularly nitrogen, phosphorus, arsenic and antimony, preferably nitrogen or phosphorus and most preferably nitrogen, which compounds also contain at least one alkyl or aryl group having from 1 to 8 carbon atoms. Particularly preferred compounds for use as templating agents are the amines, quaternary phosphonium compounds and quaternary ammonium compounds, the latter two being represented generally by the formula R.sub.4 X.sup.+ wherein "X" is nitrogen or phosphorus and each R is an alkyl or aryl group containing from 1 to 8 carbon atoms. Polymeric quaternary ammonium salts such as [(C.sub.14 H.sub.32 N.sub.2)(OH).sub.2 ].sub.x wherein "x" has a value of at least 2 are also suitably employed. The mono-, di- and tri-amines are advantageously utilized, either alone or in combination with a quaternary ammonium compound or other templating compound. Mixtures of two or more templating agents can either produce mixtures of the desired ELAPOs or the more strongly directing templating species may control the course of the reaction with the other templating species serving primarily to establish the pH conditions of the reaction gel. Representative templating agents include tetramethylammonium, tetraethylammonium, tetrapropylammonium or tetrabutylammonium ions; tetrapentylammonium ion; di-n-propylamine; tripropylamine; triethylamine; triethanolamine; piperidine; cyclohexylamine; 2-methylpyridine; N,N-dimethylbenzylamine; N,N-dimethylethanolamine; choline; N,N'-dimethylpiperazine; 1,4-diazabicyclo (2,2,2,) octane; N-methyldiethanolamine; N-methylethanolamine; N-methylpiperidine; 3-methylpiperidine; n-methylcyclohexylamine; 3-methylpyridine; 4-methylpyridine; guinuclidine; N,N'-dimethyl-1,4-diazabicyclo (2,2,2) octane ion; di-n-butylamine, neopentylamine; di-n-pentylamine; isopropylamine; t-butylamine; ethylenediamine; pyrrolidine; and 2-imidazolidone. Not every templating agent will direct the formation of every species of ELAPO, i.e., a single templating agent can, with proper manipulation of the reaction conditions, direct the formation of several ELAPO compositions, and a given ELAPO composition can be produced using several different templating agents The phosphorus source is preferably phosphoric acid, but organic phosphates such as triethyl phosphate may be satisfactory, and so also may crystalline or amorphous aluminophosphates such as the AlPO.sub.4 composition of U.S. Pat. No. 4,310,440. Organophosphorous compounds, such as tetrabutylphosphonium bromide, do not apparently serve as reactive sources of phosphorus, but these compounds may function as templating agents. Conventional phosphorus salts such as sodium metaphosphate, may be used, at least in part, as the phosphorus source, but are not preferred.

The aluminum source is preferably either an aluminum alkoxide, such as aluminum isopropoxide, or pseudoboehmite. The crystalline or amorphous aluminophosphates which are a suitable source of phosphorus are, of course, also suitable sources of aluminum. Other sources of aluminum used in zeolite synthesis, such as gibbsite, sodium aluminate and aluminum trichloride, can be employed but are not preferred.

The element(s) "M" can be introduced into the reaction system in any form which permits the formation in situ of reactive form of the element, i.e., reactive to form the framework tetrahedral oxide unit of the element. The organic and inorganic salts, of "M" such as oxides, alkoxides, hydroxides, halides and carboxyates, may be employed including the chlorides, bromides, iodides, nitrates, sulfates, phosphates, acetates, formates, and alkoxides, including ethoxides, propoxides and the like. Specific preferred reagents for introducing various elements "M" are discussed hereinbelow.

While not essential to the synthesis of ELAPO compositions, stirring or other moderate agitation of the reaction mixture and/or seeding the reaction mixture with seed crystals of either the ELAPO species to be produced or a topologically similar species, such as aluminophosphate, alumino-silicate or molecular sieve compositions, facilitates the crystallization procedure.

After crystallization the ELAPO product may be isolated and advantageously washed with water and dried in air. The as synthesized ELAPO generally contains within its internal pore system at least one form of the templating agent employed in its formation. Most commonly the organic moiety is present, at least in part, as a charge-balancing cation as is generally the case with as-synthesized aluminosilicate zeolites prepared from organic-containing reaction systems. It is possible, however, that some or all of the organic moiety is an occluded molecular species in a particular ELAPO species. As a general rule the templating agent, and hence the occluded organic species, is too large to move freely through the pore system of the ELAPO product and must be removed by calcining the ELAPO at temperatures of 200.degree. C. to 700.degree. C. to thermally degrade the organic species. In a few instances the pores of the ELAPO product are sufficiently large to permit transport of the templating agent, particularly if the latter is a small molecule, and accordingly complete or partial removal thereof can be accomplished by conventional desorption procedures such as carried out in the case of zeolites. It will be understood that the term "as-synthesized" as used herein does not include the condition of the ELAPO phase wherein the organic moiety occupying the intracrystalline pore system as a result of the hydrothermal crystallization process has been reduced by post-synthesis treatment such that the value of "m" in the composition formula:

has a value of less than 0.02. The other symbols of the formula are as defined hereinabove. In those preparations in which an alkoxide is employed as the source of element "M", aluminum or phosphorus, the corresponding alcohol is necessarily present in the reaction mixture since it is a hydrolysis product of the alkoxide. It has not been determined whether this alcohol participates in the synthesis process as a templating agent. For the purposes of this application, however, this alcohol is arbitrarily omitted from the class of templating agents, even if it is present in the as-synthesized ELAPO material.

Since the present ELAPO compositions are formed from MO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral oxide units which, respectively, have a net charge of "n", (where "n" may be -3, -2, -1, 0 or +1), the matter of cation exchangeability is considerably more complicated than in the case of zeolitic molecular sieves in which, ideally, there is stoichiometric relationship between AlO.sub.2.sup.- tetrahedra and charge-balancing cations. In the instant compositions, an AlO.sub.2.sup.- tetrahedron can be balanced electrically either by association with a PO.sub.2.sup.+ tetrahedron or a simple cation such as an alkali metal cation, a proton (H.sup.+), a cation of "M" present in the reaction mixture, or an organic cation derived from the templating agent. Similarly, an MO.sub.2.sup.n tetrahedron, where "n" is negative, can be balanced electrically by association with PO.sub.2.sup.+ tetrahedra, a cation of "M" present in the reaction mixture, organic cations derived from the templating agent, a simple cation such as an alkali metal cation, or other divalent or polyvalent metal cation, a proton (H.sup.+), or anions of cations introduced from an extraneous source. It has also been postulated that non-adjacent AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral pairs can be balanced by Na.sup.+ and OH.sup.- respectively (Flanigen and Grose, Molecular Sieve Zeolites-I, ACS, Washington, D.C. (1971).

The AsAPO molecular sieves of U.S. Ser. No. 600,166, filed Apr. 13, 1984, and U.S. Ser. No. 830,889 filed Feb. 19, 1986 have a framework structure of AsO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units (where "n" is -1 or +1) and have an empirical chemical composition on an anhydrous basis expressed by the formula

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (As.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements arsenic, aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

There are two preferred subclasses of the AsAPO molecular sieves, depending upon whether the value of "n" is -1 or +1 (i.e. whether the arsenic is trivalent or pentavelent), it being understood that mixtures of such are permitted in a given AsAPO. When "n" is -1, the preferred values of x, y and z are within the limiting compositional values or points as follows:

When "n" is +1, the preferred values of x, y and z are within the limiting compositional values or points as follows:

In an especially preferred subclass of the AsAPO molecular sieves in which "n"=+1, the values of x, y and z are as follows:

AsAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of arsenic, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the AsAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 2 hours to about 20 days, and preferably about 12 hours to about 7 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the AsAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and "x", "y" and "z" represent the mole fractions of arsenic, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those wherein the mole fractions "x", "y" and "z" are within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole. Molecular sieve containing arsenic, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

AsAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare AsAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) As.sub.2 O.sub.5, arsenic (V) oxide;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

AsAPOs may be prepared by forming a starting reaction mixture by dissolving the arsenic (V) oxide and the H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum oxide or isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture the templating agent and the resulting mixture blended until a homogeneous mixture is observed. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The BAPO molecular sieves of U.S. Ser. No. 599,812, filed Apr. 13, 1984, U.S. Ser. No. 804,248, filed Dec. 4, 1985, and U.S. Ser. No. 029,540, filed Mar. 24, 1987, have a framework structure of BO.sub.2.sup.-, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (B.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, "x", "y" and "z" represent the mole fractions of the elements boron, aluminum and phosphorus, respectively, present as tetrahedral oxides. The more fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the BAPO molecular sieves the values of x, y, and z are within the limiting compositional values or points as follows:

An especially preferred subclass of the BAPO molecular sieves are those in which the mole fraction, "x", of boron is not greater than about 0.3.

BAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of boron, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the BAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 14 days, and preferably about 1 to about 7 days, have been observed. The product is recovered by any convient method such as centrifugation or filtration.

In synthesizing the BAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

where "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and is an effective amount preferably within the range of greater than zero (0) to about 6, and most preferably not more than about 1.0; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, desirably not greater than about 20, and most desirably not greater than about 10; and "x", "y" and "z" represent the mole fractions of boron, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from 0.5 to 2.0 moles of B.sub.2 O.sub.3 and from 0.75 to 1.25 moles of Al.sub.2 O.sub.3 for each mole of P.sub.2 O.sub.5.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole.

The exact nature of the BAPO molecular sieves is not entirely understood at present, although all are believed to contain BO.sub.2, AlO.sub.2 and PO.sub.2 tetrahedra in the three-dimensional microporous framework structure. The low level of boron present in some of the instant molecular sieves makes it difficult to ascertain the exact nature of the interactions among boron, aluminum and phosphorus. As a result, although it is believed that BO.sub.2 tetrahedra are present in the three-dimensional microporous framework structure, it is appropriate to characterize certain BAPO compositions in terms of the molar ratios of oxides.

Molecular sieves containing boron, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

BAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare BAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) boric acid or trimethylborate;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinulidine, (C.sub.7 H.sub.13 N),

(j) MQuin: Methyl Quinuclide hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) c-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

In the preferred method of synthesizing the BAPO compositions, one first combines sources of boron, aluminum and phosphorus to form an amorphous material containing all three elements, and thereafter heats the amorphous material to produce a crystalline BAPO molecular sieve. It is not necessary that the total quantities of the reactive sources of boron, aluminum and phosphorus to be used in the final reaction mixture be present in the amorphous material, since additional quantities of the elements can be added during the later heat treatment; in particular, it has been found convenient to add additional quantities of phosphorus to the amorphous material before the heat treatment. The preliminary formation of the amorphous material assists in the incorporation of the boron into the final molecular sieve.

For example, BAPOs may be prepared by forming a solution of boric acid in a methanolic solution of the templating agent, then adding a hydrated aluminosphosphate and water and stirring to form a homogeneous reaction slurry. This slurry is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The BeAPO molecular sieves of U.S. Ser. No. 599,776, filed Apr. 13, 1984, and U.S. Ser. No. 835,293 filed Mar. 3, 1986 have a framework structure of BeO.sub.2.sup.-2, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Be.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements beryllium, aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the BeAPO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

In an especially preferred subclass of the BeAPO molecular sieves the values of x, y and z are as follows:

BeAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of beryllium, aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the BeAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 14 days, and preferably about 1 to about 7 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the BeAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 1.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 50; and "x", "y" and "z" represent the mole fractions of beryllium, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those wherein the mole fractions "x", "y" and "z" are within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole. Molecular sieves containing beryllium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

BeAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare BeAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) beryllium sulfate;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclide hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

BeAPOs may be prepared by forming a starting reaction mixture by dissolving the beryllium sulfate and the H.sub.3 PO.sub.4 in at least part of the water. To this solution the aluminum oxide or isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture the templating agent and the resulting mixture blended until a homogeneous mixture is observed. The mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C. for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The CAPO molecular sieves of U.S. Ser. No. 599,813, filed Apr. 13, 1984, and U.S. Ser. No. 830,756 filed Feb. 19, 1986 have a framework structure of CrO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units (where "n" is -1, 0 or +1) and have an empirical chemical composition on an anhydrous basis expressed by the formula

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Cr.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements chromium, aluminum and phosphorus, respectively, present as tetrahedral oxides. When "n" is -1 or +1, the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

When "n" is 0, the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

There are three preferred subclasses of the CAPO molecular sieves, depending upon whether the value of "n" is -1, 0 or +1 (i.e. whether the chromium has an oxidation number of 3, 4 or 5), it being understood that mixtures of such are permitted values of x, y and z are within the limiting compositional values or points as follows:

In an especially preferred subclass of these CAPO molecular sieves in which "n"=-1, the values of x, y and z are follows:

When "n" is 0, the preferred values of x, y and z are within the limiting compositional values or points as follows:

When "n" is +1, the preferred values of x, y and z are within the limiting compositional values or points as follows:

Since the exact nature of the CAPO molecular sieves is not clearly understood at present, although all are believed to contain CrO.sub.2 tetrahedra in the three-dimensional microporous crystal framework structure, it is advantageous to characterize the CAPO molecular sieves by means of their chemical composition. This is due to the low level of chromium present in certain of the CAPO molecular sieves prepared to date which makes it difficult to ascertain the exact nature of the interaction between chromium, aluminum and phosphorus. As a result, although it is believed that CrO.sub.2 tetrahedra are substituted isomorphously for AlO.sub.2 or PO.sub.2 tetrahedra, it is appropriate to characterize certain CAPO compositions by reference to their chemical composition in terms of the mole ratios of oxides.

CAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of chromium, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the CAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 2 hours to about 20 days, and preferably about 1 to about 10 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the CAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.6; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20; and "x", "y" and "z" represent the mole fractions of chromium, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from about 0.1 to about 0.4 moles of chromium, and from about 0.75 to about 1.25 moles of aluminum, per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole. Molecular sieves containing chromium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

CAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare CAPOs include:

(a) aluminum isopropoxide, or aluminum chlorhydrol;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) chromium (III) orthophosphate, chromium (III) acetate and chromium acetate hydroxide, (Cr.sub.3 (OH).sub.2 (CH.sub.3 COO).sub.7);

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

CAPOs may be prepared by forming a starting reaction mixture by adding aluminum chlorhydrol or aluminum oxide to a solution of chromium acetate hydroxide in water, then adding successively phosphoric acid and the templating agent. Between each addition, and after formation of the final mixture, the mixture is blended until a homogeneous mixture is observed.

Alternatively, the phosphoric acid may be mixed with at least part of the water, and aluminum oxide or isopropoxide mixed in. A solution of chromium acetate hydroxide is then added, followed by the templating agent, and the resultant mixture mixed until homogeneous.

In a third procedure, amorphous chromium phosphate is ground dry with aluminum oxide and the resultant dry mixture added to an aqueous solution of phosphoric acid in an ice bath. The templating agent is then added, and the final mixture mixed until homogeneous.

Whichever technique is employed to produce the reaction mixture, this mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The GaAPO molecular sieves of U.S. Ser. No. 599,771, filed Apr. 13, 1984, and U.S. Ser. No. 830,890 filed Feb. 19, 1986 have a framework structure of GaO.sub.2.sup.-, AlO.sub.2 and PO.sub.2.sup.+ tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Ga.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements gallium, aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In general, the value of "z" in the GaAPO molecular sieves is not greater than about 0.60.

In a preferred subclass of the GaAPO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

In an especially preferred subclass of the GaAPO molecular sieves the values of x, y and z are as follows:

GaAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of gallium, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the GaAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 4 hours to about 20 days, and preferably about 1 to about 7 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the GaAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 1.0; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably between about 2 and 20; and "x", "y" and "z" represent the mole fractions of gallium, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from 0.2 to 0.5 mole of Ga.sub.2 O.sub.3 and from 0.3 to 1 mole of Al.sub.2 O.sub.3 for each mole of P.sub.2 O.sub.5.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole. Molecular sieves containing gallium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

GaAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare GaAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) gallium sulfate or gallium (III) hydroxide;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH:

(h) Pr.sub.3 N tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

GaAPOs may be prepared by forming a starting reaction mixture by mixing the phosphoric acid with at least part of the water. To this solution the aluminum oxide or isopropoxide is added. This mixture is then blended until a homogeneous mixture is observed. To this mixture the gallium sulfate or gallium hydroxide and the templating agent are successively added and the resulting mixture blended until a homogeneous mixture is observed.

Alternatively, the aluminum oxide may be mixed with a solution of the gallium sulfate or hydroxide, and then the phosphoric acid and the templating agent successively added. The resulting mixture is then blended until a homogeneous mixture is observed.

In a third process, the templating agent may be dissolved in water, the gallium hydroxide or sulfate added with stirring, a solution of the phosphoric acid added, and finally the aluminum oxide mixed in. The resulting mixture is then blended until a homogeneous mixture is observed.

Whichever technique is employed to form the reaction mixture, the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressures.

The GeAPO molecular sieves of U.S. Ser. No. 599,807, filed Apr. 13, 1984, and U.S. Ser. No. 841,753 filed Mar. 20, 1986 have a framework structure of GeO.sub.2, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Ge.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.2; and "x", "y" and "z" represent the mole fractions of the elements germanium, aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the GeAPO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

An especially preferred subclass of the GeAPO molecular sieves are those in which the value of "x" is not greater than about 0.13.

GeAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of germanium, aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C., until crystals of the GeAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 2 hours to about 20 days, and preferably about 1 to about 10 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the GeAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 0.6; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably between about 10 and about 60; and "x", "y" and "z" represent the mole fractions of germanium aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Especially preferred reaction mixtures are those containing from 0.2 to 0.4 mole of GeO.sub.2 and from 0.75 to 1.25 mole of Al.sub.2 O.sub.3 for each mole of P.sub.2 O.sub.5.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole. Molecular sieves containing germanium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

GeAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare GeAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) germanium tetrachloride, germanium ethoxide and germanium dioxide;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

In some cases, it may be advantageous, when synthesizing the GeAPO compositions, to first combine sources of germanium and aluminum, to form a mixed germanium/aluminum compound (this compound being typically a mixed oxide) and thereafter to combine this mixed compound with a source of phosphorus to form the final GeAPO composition. Such mixed oxides may be prepared for example by hydrolyzing aqueous solutions containing germanium tetrachloride and aluminum chlorhydrol, or aluminum tri-sec-butoxide.

GeAPOs may be prepared by forming a starting reaction mixture by mixing the phosphoric acid with at least part of the water. To this solution is added the mixed germanium/aluminum oxide prepared as described above. This mixture is then blended until a homogeneous mixture is observed. To this mixture the templating agent is added and the resulting mixture blended until a homogeneous mixture is observed.

Alternatively, to a solution of aluminum isopropoxide may be added germanium ethoxide. The resultant solution may optionally be dried to produce a mixed oxide. To the mixed solution or dried oxide are added successively the phosphoric acid and the templating agent. The resulting mixture is then blended until a homogeneous mixture is observed.

In a third process, a solution is formed by dissolving the phosphoric acid in water, adding aluminum oxide or isopropoxide and mixing thoroughly. To the resultant mixture is added a solution containing the templating agent and germanium dioxide. The resulting mixture is then blended until a homogeneous mixture is observed.

Whichever technique is employed to form the reaction mixture, the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The LiAPO molecular sieves of U.S. Ser. No. 599,811, filed Apr. 13, 1984, and U.S. Ser. No. 834,921 filed Feb. 28, 1986 have a framework structure of LiO.sub.2.sup.-3, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (Li.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements lithium, aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the LiAPO molecular sieves the values of x, y and z are within the limiting composition values or points as follows:

In an especially preferred subclass of the LiAPO molecular sieves the values of x, y and z are within the following limits:

LiAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of lithium, aluminum and phosphorus, preferably an organic templating, i.e., structure-directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the LiAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 12 hours to about 5 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the LiAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than about 2; "b" has a value of from zero (0) to about 500, preferably between 2 and 300, most preferably not greater than about 40; and "x", "y" and "z" represent the mole fractions of lithium, aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In an especially preferred subclass of the reaction mixtures, the values of "x", "y" and "z" are within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole.

Since the exact nature of the LiAPO molecular sieves is not clearly understood at present, although all are believed to contain LiO.sub.2 tetrahedra in the three dimensional microporous crystal framework structure, it is advantageous to characterize the LiAPO molecular sieves by means of their chemical composition. This is due to the low level of lithium present in certain of the LiAPO molecular sieves prepared to date which makes it difficult to ascertain the exact nature of the interaction between lithium, aluminum and phosphorus. As a result, although it is believed that LiO.sub.2 tetrahedra are substituted isomorphously for AlO.sub.2 or PO.sub.2 tetrahedra, it is appropriate to characterize certain LiAPO compositions by reference to their chemical composition in terms of the mole ratios of oxides.

Molecular sieves containing lithium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as followed:

LiAPO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare LiAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) lithium sulfate or lithium orthophosphate;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(g) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide,

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

LiAPOs may be prepared by forming a starting reaction mixture by suspending aluminum oxide in at least part of the water. To this mixture the templating agent is added. The resultant mixture is then blended until a homogeneous mixture is observed. To this mixture the lithium phosphate or sulfate is added and the resulting mixture blended until a homogeneous mixture is observed. Alternatively, an initial mixture may be formed by mixing aluminum oxide and lithium phosphate or sulfate. To the resultant mixture are added successively phosphoric acid and an aqueous solution of the templating agent, and the resulting mixture blended until a homogeneous mixture is observed.

In a third procedure, the phosphoric acid is mixed with at least part of the water, and the aluminum oxide is mixed in. To the resultant mixture are added lithium sulfate and the templating agent, and the resulting mixture blended until a homogeneous mixture is observed.

Whichever procedure is adopted to form the reaction mixture, the mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The FeTiAPO molecular sieves of U.S. Ser. No. 599,824, filed Apr. 13, 1984, and U.S. Ser. No. 902,129 filed Sept. 2, 1986 have three-dimensional microporous framework structures of FeO.sub.2.sup.n, TiO.sub.2, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral oxide units, where "n" is -2 or -1, and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "M" represents iron and titanium; "m" represents the molar amount of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero (0) to about 0.3; and "x", "y" and "z" represent the mole fractions of "M", aluminum and phosphorus, respectively present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the FeTiAPO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

FeTiAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of iron, titanium, aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the FeTiAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 12 hours to about 5 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the FeTiAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "x", "y" and "z" represent the mole fractions of "M" (iron and titanium), aluminum and phosphorus, respectively, and each has a value of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole.

Molecular sieves containing iron, titanium, aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

FeTiAPO compositions may be prepared by numerous reagents. The preferred sources of iron and titanium for preparing FeTiAPOs are the same as those for preparing the FeAPOs and TiAPOs already described above. Other reagents which may be employed to prepare FeTiAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(e) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(f) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(g) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(h) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(i) MQuin: Methyl Quinuclidine hydroxide, (C.sub.3 H.sub.13 NCH.sub.3 OH);

(j) C-hex: cyclohexylamine;

(k) TMAOH: tetramethylammonium hydroxide;

(l) TPAOH: tetrapropylammonium hydroxide; and

(m) DEEA: 2-diethylaminoethanol.

FeTiAPOs may be prepared by forming a homogeneous reaction mixture containing reactive sources of iron, titanium, aluminum and phosphorus. The reaction mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The XAPO molecular sieves of U.S. Ser. No. 599,810, filed Apr. 13, 1984, and U.S. Ser. No. 902,020 filed Sept. 2, 1986 have a three-dimensional microporous framework structure of MO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral oxide units, where "n" is 0, -1 or -2, and have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "M" represents at least one element from each of the classes of: (1) iron and titanium; and (2) cobalt, magnesium, manganese and zinc; "n" is 0, -1 or -2; "m" represents a molar amount of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero (0) to about 0.3; and "x", "y" and "z" represent the mole fractions of "M", aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the XAPO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

XAPO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of "M", aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the XAPO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 2 hours to about 20 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the XAPO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6; "M" represents at least one element from each of the classes of: (1) iron and titanium; and (2) cobalt, magnesium, manganese and zinc; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300; and "x", "y" and "z" represent the mole fractions of "M" (iron and/or titanium, and at least one of cobalt, magnesium, manganese and zinc), aluminum and phosphorus, respectively, and each has a value of at least 0.01, with the proviso that "x" has a value of at least 0.02.

In one embodiment the mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole.

XAPO molecular sieves are prepared as follows:

XAPO compositions may be prepared by using numerous reagents. The preferred sources of elements "M" for preparing XAPOs are the same as those for preparing other APOs containing the same elements, as described above and below. Other reagents which may be employed to prepare XAPOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 : 85 weight percent aqueous phosphoric acid;

(d) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(e) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

(f) Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(g) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N

(h) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(i) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(j) C-hex: cyclohexylamine;

(k) TMAOH: tetramethylammonium hydroxide

(l) TPAOH: tetrapropylammonium hydroxide; and

(m) DEEA: 2-diethylaminoethanol.

XAPOs may be prepared by forming a homogeneous reaction mixture containing reactive sources of element "M", aluminum and phosphorus. The reaction mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The mixed element APO molecular sieves of U.S. Ser. No. 599,978, filed Apr. 13, 1984, and U.S. Ser. No. 846,088 filed Mar. 31, 1986 have a framework structure of MO.sub.2.sup.n, AlO.sub.2.sup.- and PO.sub.2.sup.+ tetrahedral units, wherein MO.sub.2.sup.n represents at least two different elements present as tetrahedral units "MO.sub.2.sup.n " with charge "n", where "n" may be -3, -2, -1, or 0 or +1. One of the elements "M" is selected from the group consisting of arsenic, beryllium, boron, chromium, gallium, germanium, lithium and vanadium, while a second one of the elements "M" is selected from the group consisting of cobalt, iron, magnesium, manganese, titanium and zinc. Preferably, "M" is a mixture of lithium and magnesium. The mixed-element molecular sieves have an empirical chemical composition on an anhydrous basis expressed by the formula:

wherein "R" represents at least one organic templating agent present in the intracrystalline pore system; "m" represents the molar amount of "R" present per mole of (M.sub.x Al.sub.y P.sub.z)O.sub.2 and has a value of zero to about 0.3, but is preferably not greater than 0.15; and "x", "y" and "z" represent the mole fractions of the elements "M" (i.e. "x" is the total of the mole fractions of the two or more elements "M"), aluminum and phosphorus, respectively, present as tetrahedral oxides. The mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

In a preferred subclass of the mixed element APO molecular sieves the values of x, y and z are within the limiting compositional values or points as follows:

An especially preferred subclass of the mixed element APO molecular sieves are those in which the value of x is not greater than about 0.10.

A second group (FCAPO's) of mixed element APO molecular sieves are described in U.S. Pat. No. 4,686,093 issued Aug. 11, 1987 (incorporated herein by reference).

The mixed element APO compositions are generally synthesized by hydrothermal crystallization from a reaction mixture containing reactive sources of the elements "M", aluminum and phosphorus, preferably an organic templating, i.e., structure directing, agent, preferably a compound of an element of Group VA of the Periodic Table, and/or optionally an alkali or other metal. The reaction mixture is generally placed in a sealed pressure vessel, preferably lined with an inert plastic material such as polytetrafluoroethylene and heated, preferably under autogenous pressure at a temperature between about 50.degree. C. and about 250.degree. C., and preferably between about 100.degree. C. and about 200.degree. C. until crystals of the APO product are obtained, usually a period of from several hours to several weeks. Typical effective times of from 2 hours to about 30 days, generally from about 2 hours to about 20 days, and preferably about 12 hours to about 5 days, have been observed. The product is recovered by any convenient method such as centrifugation or filtration.

In synthesizing the mixed-element APO compositions, it is preferred to employ a reaction mixture composition expressed in terms of the molar ratios as follows:

wherein "R" is an organic templating agent; "a" is the amount of organic templating agent "R" and has a D-15909 value of from zero to about 6 and is preferably an effective amount within the range of greater than zero (0) to about 6, and most preferably not more than 0.5; "b" has a value of from zero (0) to about 500, preferably between about 2 and about 300, most preferably not greater than about 20, and most desirably not more than about 10; and "x", "y" and "z" represent the mole fractions of "M", aluminum and phosphorus, respectively, "y" and "z" each having a value of at least 0.01 and "x" having a value of at least 0.02, with each element "M" having a mole fraction of at least 0.01.

In one embodiment the reaction mixture is selected such that the mole fractions "x", "y" and "z" are generally defined as being within the limiting compositional values or points as follows:

Preferred reaction mixtures are those containing not more than about 0.2 moles of the metals "M" per mole of phosphorus.

In the foregoing expression of the reaction composition, the reactants are normalized with respect to the total of "x", "y" and "z" such that (x+y+z)=1.00 mole.

Since the exact nature of the mixed-element APO molecular sieves is not clearly understood at present, although all are believed to contain M02 tetrahedra in the three-dimensional microporous crystal framework structure, it is advantageous to characterize the mixed-element APO molecular sieves by means of their chemical composition. This is due to the low level of the elements "M" present in certain of the mixed element APO molecular sieves prepared to date which makes it difficult to ascertain the exact nature of the interaction between the metals "M", aluminum and phosphorus. As a result, although it is believed that MO.sub.2 tetrahedra are substituted isomorphously for AlO.sub.2 or PO.sub.2 tetrahedra, it is appropriate to characterize certain mixed-element APO compositions by reference to their chemical composition in terms of the mole ratios of oxides.

Molecular sieves containing the metals "M", aluminum and phosphorus as framework tetrahedral oxide units are prepared as follows:

Mixed-element APO compositions may be prepared by using numerous reagents. Reagents which may be employed to prepare mixed element APOs include:

(a) aluminum isopropoxide;

(b) pseudoboehmite or other aluminum oxide;

(c) H.sub.3 PO.sub.4 :85 weight percent aqueous phosphoric acid;

(d) lithium phosphate or magnesium hydroxide or appropriate salts of the other elements "M", as described above;

(e) TEAOH: 40 weight percent aqueous solution of tetraethylammonium hydroxide;

(f) TBAOH: 40 weight percent aqueous solution of tetrabutylammonium hydroxide;

Pr.sub.2 NH: di-n-propylamine, (C.sub.3 H.sub.7).sub.2 NH;

(h) Pr.sub.3 N: tri-n-propylamine, (C.sub.3 H.sub.7).sub.3 N;

(i) Quin: Quinuclidine, (C.sub.7 H.sub.13 N);

(j) MQuin: Methyl Quinuclidine hydroxide, (C.sub.7 H.sub.13 NCH.sub.3 OH);

(k) C-hex: cyclohexylamine;

(l) TMAOH: tetramethylammonium hydroxide;

(m) TPAOH: tetrapropylammonium hydroxide; and

(n) DEEA: 2-diethylaminoethanol.

The reaction mixture is then placed in a lined (polytetrafluoroethylene) stainless steel pressure vessel and digested at a temperature (150.degree. C. or 200.degree. C.) for a time or placed in lined screw top bottles for digestion at 100.degree. C. Digestions are typically carried out under autogenous pressure.

The preferred NZMSs, to date, are the silicoaluminophosphate molecular sieves described in U.S. Pat. No. 4,440,871 (incorporated herein by reference), and U.S. Ser. No. 575,745, filed Jan. 31, 1984.

Medium pore (MP)-SAPOs include SAPO 11, SAPO-31, SAPO-40 and SAPO 41.

The species SAPO-11 has a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth below:

The species SAPO 31 has a characteristic X-ray powder diffraction pattern which contains at least the d spacings set forth below:

The species SAPO-40 has a characteristic X-ray powder diffraction pattern which contains at least the D-spacings set forth below:

The species SAPO-41 has a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth below:

Large pore(LP) SAPOs include SAPO 5 and SAPO-37.

The species SAPO-5 has a characteristic X-ray powder diffraction pattern which contains at least the d-spacings set forth below:

The NZMSs which may be employed in the instant invention can be characterized in their calcined form by an adsorption of isobutane of at least 2 percent by weight, preferably at least 4 percent by weight, at a partial pressure of 500 torr a temperature of 20.degree. C. The non-zeolitic molecular sieves are also desirably characterized by an adsorption of triethylamine of from zero to less than 5 percent by weight, preferably less than 3 weight percent, at a partial pressure of 2.6 torr and a temperature of 22.degree. C. NZMSs characterized by the above described adsorption of isobutane include, but are not limited to, ELAPSO 5, ELAPSO 11, ELAPSO 31, ELAPSO 36, ELAPSO-37, ELAPSO-40, ELAPSO 41, SAPO-5, SAPO 11, SAPO 31, SAPO 36, SAPO-37, SAPO 40, SAPO-41, CoAPSO 5, CoAPSO 11, CoAPSO-31, CoAPSO 36, CoAPSO 37, CoAPSO-40, CoAPSO 41, FeAPSO 5, FeAPSO 11, FeAPSO 31, FeAPSO-36, FeAPSO 37, FeAPSO 40, FeAPSO-41, MgAPSO-5, MgAPSO 11, MgAPSO-31, MgAPSO-36, MgAPSO 37, MgAPSO 40, MgAPSO 41, MnAPSO 5, MnAPSO 11, MnAPSO 31, MnAPSO-36, MnAPSO-37, MnAPSO 40, MnAPSO-41, TiAPSO 5, TiAPSO 11, TiAPSO 31, TiAPSO 36, TiAPSO-37, TiAPSO-40, TiAPSO-41, ZnAPSO-5, ZnAPSO-11, ZnAPSO-31, ZnAPSO 36, ZnAPSO-37, ZnAPSO-40, ZnAPSO-41, CoMnAPSO-5, CoMnAPSO 11, CoMnAPSO 36, CoMnAPSO-37, CoMnAPSO-40, CoMnAPSO-41, CoMnMgAPSO 5, CoMnMgAPSO 11, CoMnMgAPSO 31, CoMnMgAPSO-36, CoMnMgAPSO-37, CoMnMgAPSO-40, CoMnMgAPSO-41, AsAPSO 5, AsAPSO 11, AsAPSO 31, AsAPSO-36, AsAPSO 37, AsAPSO 40, AsAPSO 41, BAPSO-5, BAPSO 11, BAPSO 31, BAPSO 36, BAPSO 37, BAPSO 40, BAPSO 41, BeAPSO-5, BeAPSO-11, BeAPSO 31, BeAPSO 36, BeAPSO-37, BeAPSO-40, BeAPSO 41, CAPSO 5, CAPSO 11, CAPSO-31, CAPSO-36, CAPSO 37, CAPSO-40, CAPSO-41, GaAPSO 5, GaAPSO 11, GaAPSO-31, GaAPSO 36, D-15909 GaAPSO-37, GaAPSO-40, GaAPSO 41, GeAPSO-5, GeAPSO 11, GeAPSO 31, GeAPSO 36, GeAPSO 37, GeAPSO-40, GeAPSO 41, LiAPSO 5, LiAPSO 11, LiAPSO 31, LiAPSO 36, LiAPSO 37, LiAPSO 40, LiAPSO-41, MeAPO 5, MeAPO 11, MeAPO-31, MeAPO 36, MeAPO-37, MeAPO-40, MeAPO 41, TiAPO 5, TiAPO 11, TiAPO-31, TiAPO 36, TiAPO 37, TiAPO-40, TiAPO 41, FCAPO 5, FCAPO 11, FCAPO-31, FCAPO 36, FCAPO 37, FCAPO-40, FCAPO 41, AsAPO 5, AsAPO-11, AsAPO-31, AsAPO 36, AsAPO 37, AsAPO 40, AsAPO 41, BAPO 5, BAPO-11, BAPO-31, BAPO-36, BAPO-37, BAPO-40, BAPO 41, BeAPO 5, BeAPO 11, BeAPO 31, BeAPO-36, BeAPO 37, BeAPO 40, BeAPO-41, CAPO-5, CAPO 11, CAPO-31, CAPO 36, CAPO-37, CAPO 40, CAPO 41, GaAPO 5, GaAPO-11, GaAPO 31, GaAPO 36, GaAPO 37, GaAPO 40, GaAPO 41, GeAPO 5, GeAPO 11, GeAPO 31, GeAPO-36, GeAPO 37, GeAPO 40, GeAPO-41, LiAPO 5, LiAPO 11, LiAPO-31, LiAPO 36, LiAPO 37, LiAPO 40, LiAPO 41, and the mixed-element APOs which may be designated MAPO-5, MAPO-11, MAPO-31, MAPO-36, MAPO 37, MAPO-40 and MAPO 41, and mixtures thereof.

The above characterization of the NZMSs which may be employed in the instant invention relates to an adsorption characterization that is carried out on a NZMS which has been subjected to a post synthesis treatment, e.g., calcination, hydrothermal treatment or chemical treatment, to remove a substantial portion of the template "R" which is present as a result of synthesis. Although a particular NZMS is characterized herein by reference to its adsorption of isobutane as being to the adsorption characteristics of the NZMS in its D-15909 calcined form, the instant invention necessarily includes the use of a non-calcined or modified NZMSs which may be characterized by such adsorption in its calcined form, since upon use of such a non-calcined NZMS in the instant process at effective isomerization process conditions the NZMS may be calcined or hydrothermally treated in situ so as to have the characteristic adsorption of isobutane. Thus, the NZMS may be rendered in situ to a form characterized by the aforementioned adsorption characteristics. For example, an as-synthesized MgAPO 11 or MgAPSO 11 may not be characterized by the aforementioned adsorption of isobutane due to the presence of template "R" which is present as a result of synthesis, although the calcined form of MgAPO-11 and MgAPSO 11 will be characterized by the aforementioned adsorption of isobutane. Thus, reference to a NZMS having a particular adsorption characteristic in its calcined or anhydrous form is not intended to exclude the use of the NZMS in its as-synthesized form which upon in-situ calcination, hydrothermal treatment and/or other treatment, e.g., ion exchange with suitable atoms, would have such adsorption characteristics.

Prior to contacting the gaseous stream and ammonia with the microporous molecular sieve composition, the composition undergoes dealuminization by extraction with an acid, preferably a mineral acid such as nitric acid. The dealuminization proceeds readily at ambient or elevated temperatures and occurs with minimal losses in crystallinity, to form high silica forms of D 15909 molecular sieve compositions with silica:almumina ratios of at least 6.5:1, with ratios of 100:1 or even higher being readily attainable. Acid treatment with an inorganic or organic acid is not required for certain non zeolitic molecular seive compositions which do not contain Si (z is 0 in formula 1 above), for example, the aluminophosphate molecular sieves.

The molecular sieve composition is conveniently used in the ammonium or hydrogen form for the dealuminization process although other cationic forms may also be employed, for example, the sodium form. If these other forms are used, sufficient acid should be employed to allow for the replacement by protons of the original cations in the molecular sieve composition. The amount of molecular sieve composition in the molecular sieve composition/acid mixture should generally be from about 5 to about 60 percent by weight.

The acid may be a mineral acid, i.e., an inorganic acid or an organic acid. Typical inorganic acids which can be employed include mineral acids such as hydrochloric, sulfuric, nitric and phosphoric acids, peroxydisulfonic acid, dithionic acid, sulfamic acid, peroxymonosulfuric acid, amidodisulfonic acid, nitrosulfonic acid, chlorosulfuric acid, pyrosulfuric acid, and nitrous acid. Representative organic acids which may be used include formic acid, trichloroacetic acid, and trifluoroacetic acid.

The concentration of added acid should be such as not to lower the pH of the molecular sieve D 15909 composition/acid mixture to an undesirably low level which could affect the crystallinity of the molecular sieve composition undergoing treatment. The acidity which the molecular sieve composition can tolerate will depend, at least in part, upon the silica/alumina ratio of the starting material. Generally, it has been found that the molecular sieve composition can withstand concentrated acid without undue loss in crystallinity but, as a general guide, the acid will be from 0.In to 4.0N, usually 1N to 2N. These values hold good regardless of the silica:alumina ratio of the molecular sieve composition starting material. Stronger acids tend to effect a relatively greater degree of aluminum removal than weaker acids.

The dealuminization reaction proceeds readily at ambient temperatures, but elevated temperatures may be employed, e.g., up to about 100 .degree. C. The duration of the extraction will affect the silica:alumina ratio of the product since extraction is time dependent. However, because the molecular sieve composition becomes progressively more resistant to loss of crystallinity as the silica:alumina ratio increases, i.e., it becomes progressively more stable as the aluminum is removed, higher temperatures and more concentrated acids may be used, if desired, towards the end of the treatment than at the beginning without the attendant risk of losing crystallinity.

After the extraction treatment, the product may be water washed free of impurities, preferably with distilled water, until the effluent wash water has a pH within the approximate range of from about 5 to about 8.

The crystalline dealuminized products obtained by this acid extraction method have substantially the same crystallographic structure as that of the starting molecular sieve composition but with increased silica:alumina ratios as appropriate. The silica:alumina ratio will generally be in the range of from about 6.5:1 to about 500:1, more usually from about 10:1 to about 250:1, e g., 100:1 or more. Water of hydration may also be present in varying amounts.

If desired, the molecular sieve composition may be hydrothermally treated or steamed prior to acid extraction so as to increase the framework silica:alumina ratio as appropriate and render the molecular sieve composition more stable to the acid. In general, hydrothermal treatment can be applied at a temperature of from about 500.degree. C. to about 850.degree. C. or greater depending on the particular starting molecular sieve composition. The steaming may also serve to increase the ease with which the aluminum is removed and to promote the retention of crystallinity during the extraction procedure.

The molecular sieve composition is ion exchanged by contacting (with or without the presence of an inorganic oxide matrix component) said molecular sieve catalyst composition with a solution of at east one hydrogen-forming cation, such as NH.sub.4.sup.+, and H.sup.+ and quaternary ammonium, such as NH4 either after the acid extraction or simultaneously with the acid extraction described hereinabove. D-15909 acid treatment with an inorganic or organic acid and hydrogen forming cation exchange, the molecular sieve composition is metal cation exchanged. Suitable metal cations include the cations of Group IIA, Group IIIA, Groups IIIB to VIIB, e.g., nickel, cobalt, iron, manganese, copper, platinum, palladium, rhodium and the like including mixtures thereof, and rare earth cations selected from cerium, lanthanum, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium and mixtures thereof. Of course, the metal cation present as a result of ion exchange should have no substantial adverse effect on the desired catalytic reduction of nitrogen oxides. As a result of the ion exchange, the molecular sieve composition contains at least one cation, e.g., hydrogen forming cation and/or a metal cation, which is different form the cations initially associated with the molecular sieve composition as a result of its synthesis. The metal cation present as a result of ion exchange is preferably present in an effective amount between about 0.1 weight percent and about 20 weight percent, based on the weight of the starting molecular sieve composition and is typically present in an effective amount between about 0.5 weight percent and about 10 weight percent.

The metal cation exchange step is not required for certain non zeolitic molecular sieve compositions which already contain a metal cation in their as synthesized form, for example, MeAPO, MeAPSO, ELAPSO and the like. However, non zeolitic D 15909

ions which contain a metal in their as-synthesized form may be further metal cation exchanged to provide a combination of different metals which may exhibit enhanced catalytic properties.

The ion-exchange is generally carried out by preparing a slurry of the molecular sieve composition by adding about 5 to 15 volumes of water per volume of molecular sieve composition after which a solution of a selected cation is added. The ion exchange is generally carried out at room temperature and the resulting solution is then heated to above about 50.degree. C. and stirred at this temperature for about 0.5 to 3 hours. This mixture is then filtered and water washed to remove excess anion present as a result of the solution of the cation salt.

For high silica molecular sieve compositions, e.g., silicalite, in particular and other molecular sieve compositions in general, the desired metal can be incorporated into the molecular sieve structure by conventional pore filling techniques. As used herein, the term "metal cation exchanged" includes not only ion exchange but also pore filling and other techniques which may be used to incorporate a cation into the molecular sieve structure.

Copending and commonly assigned U. S. Patent Application Ser. No. (178,907), filed on an even date herewith and incorporated herein by reference, relates to a hydrocracking process for the production of gasoline products utilizing catalysts which incorporate novel catalyst bases prepared by sequentially hydrothermally treating followed by low pH ammonium ion exchanging of a sodium Y-type zeolite. Such novel catalyst bases are highly desirable for use as molecular sieve

o compositions herein.

The molecular sieve compositions are typically employed with at least one inorganic oxide matrix component, such inorganic oxide matrix components typically employed heretofore in formulating molecular sieve catalyst compositions, including: amorphous catalytic inorganic oxides such as catalytically active silica/aluminas, clays, silicas, aluminas, silica aluminas, silica zirconias, silica-magnesias, silica-thorias. silica berylias, silica-alumina thorias, silica alumina zirconias, alumina-borias, alumina-titanias and the like and mixtures thereof. The matrix may be in the form of a sol, hydrogel or gel and is typically an alumina, silica or silica alumina component such as a conventional silica-alumina catalyst, several types and compositions of which are commercially available. The matrix may itself provide a catalytic effect, such as that observed for catalytically active silica/aluminas, or it may be essentially inert. The matrix may act as a "binder" in some instances although in some instances the final molecular sieve catalyst composition may be spray dried or formed without the need of a binder.

These matrix materials may be prepared as a cogel of silica and alumina or as alumina D 15909 precipitated on the preformed and preaged hydrogel. Silica may be present as a major matrix component in the solids present in the matrix, e.g., present in an amount between about 5 and about 40 weight percent and preferably between about 10 and about 30 weight percent. The silica may also be employed in the form of a cogel comprising about 75 weight percent silica and about 25 weight percent alumina or comprising about 87 weight percent silica and about 13 weight percent alumina. The inorganic oxide matrix component will typically be present in the final molecular sieve catalyst composition in an amount between about 0 and 99 weight percent, preferably between about 5 and about 90 weight percent, based on the total molecular sieve catalyst composition. It is also within the scope of the instant invention to employ other materials with the molecular sieve compositions in the final catalysts, including clays, carbon monoxide oxidation promoters, etc.

Representative of matrix systems employable herein are disclosed in British patent specification NO. 1,315,553, published May 2, 1973 and U.S. Patent Nos. 3,446,727 and 4,086,187.

As above mentioned, the molecular sieve compositions used in the present invention may be employed with a matrix component and this may be a silica or alumina component. The alumina component may comprise discrete particles of various aluminas, e.g., pseudoboehmite. The alumina component may be in the form of discrete particles having a total surface area, as measured by the method of Brunauer, D 15909 Emmett and Teller (BET), greater than about 20 square meters per gram (M.sup.2 /g), preferably greater than 145 M.sup.2 /g, for example, from about 145 to about 300 M.sup.2 /g. The pore volume of the alumina component will typically be greater than 0.35 cc/g. The average particle size of the alumina particles is generally less than 10 microns and preferable less than 3 microns. The alumina may be employed alone as the matrix or composited with the other matrix components.

The alumina component may be any alumina and has preferably been preformed and placed in a physical form such that its surface area and pore structure are stabilized so that when the alumina is added to an impure, inorganic gel containing considerable amount of residual soluble salts, the salts will not alter the surface and pore characteristics measurably nor will they promote chemical attack on the preformed porous alumina which could undergo change. For example, the alumina is typically an alumina which has been formed by suitable chemical reaction, the slurry aged, filtered, dried, washed free of residual salt and then heated to reduce its volatile content to less than about 15 weight percent. The alumina component may be present in the final molecular sieve catalyst composition in an amount ranging between about 5 and about 95 weight percent, preferably between about 10 and about 30 weight percent based on the total molecular sieve catalyst composition. Further, an alumina hydrosol or hydrogel or hydrous alumina slurry may be used in the catalyst preparation. Mixtures of the molecular sieve compositions and one or more inorganic oxide matrix components may be formed into a final form for the molecular sieve catalyst composition by standard catalyst forming techniques including spray drying, pelleting, extrusion and other suitable conventional means. The use of spray drying procedures is the preferred means by which catalysts are prepared and such procedures are well known in the art. The shape and size of the final molecular sieve catalyst composition can be chosen depending upon the applications intended. Various sizes of spherical, pellet and honeycomb monolith shaped structures can be used. The honeycomb type structure has the advantage that it provides a system that has little pressure loss, even when the flow velocity, i.e. the space velocity of the gaseous stream and ammonia is high. Honeycomb structures include those having quadrangular, triangular and circular sectional shapes. It is also possible to use those having a sinusoidal wave, spider's web or spiral shape.

Catalysts containing the molecular sieve compositions may be prepared by any conventional method. One method of preparing such catalysts employing silica alumina and porous alumina is to react sodium silicate with a solution of aluminum sulfate to form a silica/alumina hydrogel slurry which is then aged to give the desired pore properties, filtered to remove a considerable amount of the extraneous and undesired sodium and sulfate ions and then reslurried in water. The alumina may be prepared by reacting solutions of sodium aluminate and aluminum sulfate under suitable conditions, aging the slurry to give the desired pore properties of the alumina, filtering, drying, reslurry in water to remove sodium and sulfate ions and drying to reduce volatile matter content to less than 15 weight percent. The alumina may then be slurried in water and blended in proper amounts, with a slurry of impure silica alumina hydrogel. The molecular sieve composition may then be added to this blend. A sufficient amount of each component is utilized to give the desired final composition. The resulting mixture is then filtered to remove a portion of the remaining extraneous soluble salts therefrom. The filtered mixture is then dried to produce dried solids. The dried solids are subsequently reslurried in water and washed substantially free of the undesired soluble salts. The molecular sieve catalyst composition is then dried to a residual water content of less than about 15 weight percent. The molecular sieve catalyst composition is typically employed after a calcination or activation.

Calcination or activation is typically conducted after preparation of the molecular sieve catalyst composition. It is understood that calcination or activation treatment may be carried out one or more times in any order and that such variations are within the scope of this invention. For example, one calcination or activation may be carried out prior to combining the molecular sieve composition with an inorganic oxide matrix component and a second calcination or activation may be D-15909 carried out after combining the molecular sieve composition with an inorganic oxide matrix component.

The conditions at which the catalytic reduction of nitrogen oxides occurs can vary widely. The reduction reaction temperature can be conducted over a wide range, but, in general, in the range from about 200.degree. C. to about 650.degree. C., which is the expected temperature range for the usual flue gas. Although pressure is not a critical factor in the method of this invention, the preferred pressure of the gaseous stream will be from about atmospheric to about 10 pounds per square inch gauge, which is the - expected pressure range for the usual flue gas. Space velocities of from about 1,000 hr.sup.-1 up to about a million hr.sup.-1, preferably from about 5,000 hr.sup.-1 to about 500,000 hr.sup.-1, can be used in the catalytic reduction of nitrogen oxides according to this invention. The microporous molecular sieve composition should be sufficiently stable to maintain its crystalline structure and catalytic activity after exposure to the gaseous stream.

In a preferred embodiment of this invention, a gaseous stream composition containing nitrogen oxide and sulfur dioxide such as a flue gas obtained from power plants, gas turbines or the like or tail gas streams from nitric acid manufacture is mixed with ammonia and contacted with the molecular sieve catalyst composition. Depending upon the nitrogen oxide concentration, the concentration of ammonia is preferably from slightly greater than about 1.0 to about 1.3 moles per mole of nitrogen oxide (NO.sub.x) in the gaseous stream. The reaction temperature which can be utilized in the method wherein the production of nitrogen is maximized and the production of nitrogen oxide is minimized is preferably between about 100.degree. C. and about 450.degree. C. The molecular sieve catalyst composition is employed at space velocities preferably between about 2500 hr.sup.-1 and 25,000 hr.sup.-1. In addition, increased conversion rates can be attained by utilizing a plurality of catalyst beds which the gaseous stream contacts serially. The plurality of catalyst beds can contain the same or different molecular sieve catalyst compositions and can be arranged in any sequence.

The following examples are illustrative of this invention.

LZ-210, a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2).sub.3 molar ratio of 12 and obtained from Union Carbide Corporation, Danbury, Connecticut, was copper exchanged three times using one part by weight copper sulfate to one part by weight LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The resulting copper exchanged LZ-210 was then dried at a temperature of 100.degree. C. After drying, the copper exchanged LZ-210 product was combined with 20 weight percent Ludox AS 40 gelled with ammonium acetate and extruded as a 1/16-inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter maintained at that temperature for an additional 1.5 hours. The extrudate product contained 5.2 weight percent of copper.

This product is referred to hereinafter as Catalyst A.

EXAMPLE 2

LZ-210, a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of 12 and obtained from Union Carbide Corporation, Danbury, Connecticut, was potassium exchanged 3 times using one part by weight potassium chloride to one part by weight LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The potassium exchanged LZ-210 was then copper exchanged two times using one part by weight copper sulfate to one part by weight potassium exchanged LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The resulting copper potassium exchanged LZ-210 was then dried at a temperature of 100.degree. C. After drying, the copper-potassium exchanged LZ-210 product was combined with 20 weight percent Ludox AS-40 gelled with ammonium acetate and extruded as a 1/16 inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter maintained at that temperature for an additional 1 5 hours. The extrudate product contained 5.0 weight percent of copper and 2.2 weight percent of potassium.

This product is referred to hereinafter as Catalyst B.

LZ-210, a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of 12 and obtained from Union Carbide Corporation, Danbury, Connecticut, was copper exchanged three times using one part by weight copper sulfate to one part by weight LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The copper exchanged LZ-210 was then potassium exchanged 3 times using one part by weight potassium chloride to one part by weight copper exchanged LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The resulting potassium copper exchanged LZ-21 was then dried at a temperature of 100.degree. C. After drying, the potassium copper exchanged LZ-210 product was combined with 20 weight percent peptized alumina and extruded as a 1/16 inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter maintained at that temperature for an additional 1.5 hours. The extrudate product contained 5.2 weight percent of copper and 2.3 weight percent of potassium.

This product is referred to hereinafter as Catalyst C.

Nitric acid extracted, ammonium exchanged mordenite, a one dimensional crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of 18 Union Carbide Corporation, Danbury, Connecticut, was copper exchanged two times using 0.33 moles of copper to one mole of Al.sub.2 O.sub.3 at a temperature of 85.degree. C. for a period of one hour for each exchange. The resulting copper exchanged mordenite was then dried at a temperature of 100.degree. C. After drying, the copper exchanged mordenite product was combined with 20 weight percent Ludox AS-40 gelled with ammonium acetate and extruded as a 1/16-inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 50.degree. C. and thereafter maintained at that temperature for an additional 1.5 hours. The extrudate product contained 1.4 weight percent of copper.

This product is referred to hereinafter as Catalyst D.

LZ-210, a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of 9 and obtained from Union Carbide Corporation, Danbury, Connecticut, was copper exchanged three times using one part by weight copper sulfate to three parts by weight LZ-210 at a temperature of 85.degree. C. for a period of one hour for each exchange. The resulting copper exchanged LZ-210 was then dried at a temperature of 100.degree. C. After drying, the copper exchanged LZ-210product was combined with 20 weight percent Ludox AS 40 gelled with ammonium acetate and extruded as a 1/16-inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter maintained at that temperature for an additional 1.5 hours. The extrudate product contained 4.3 weight percent of copper.

This product is referred to hereinafter as Catalyst E.

Silicalite, a crystalline silica molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of about 225 and commercially available, was combined with 20 weight percent Ludox AS 40 gelled with ammonium acetate, pore filled with about 3.5 weight percent of copper, and then extruded as a 1/16 l inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C and thereafter maintained at that temperature for an additional 1.5 hours. The extrudate product contained 3.7 weight percent of copper.

This product is referred to hereinafter as Catalyst F.

LZ-105, a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of 40 and obtained from Union Carbide Corporation, Danbury, Connecticut, was calcined at a temperature of about 600.degree. C. for a period of 2.0 hours.

After calcination, the LZ-105 was acid extracted with a 70 percent nitric acid aqueous solution at a temperature of 93.degree. C. for a period of one hour, and then ammonium exchanged 3 times with a 15 weight percent ammonium nitrate aqueous solution using 1.5 parts by weight ammonium nitrate to 1.0 part by weight LZ-105 at a temperature of 93.degree. C. for a period of one hour for each exchange.

After acid extraction and ammonium exchange, LZ-105 was copper exchanged three times using one part by weight copper sulfate to three parts by weight LZ-105 at a temperature of 85.degree. C. for a period of 1.0 hour for each exchange.

The resulting ammonium copper exchanged LZ-105 was then combined with 20 weight percent peptized alumina and extruded as a 1/16 inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter held at that temperature for an additional 1.5 hours. The extrudate product contained 3.0 weight percent of copper.

This product is referred to hereinafter as Catalyst 1.

Sodium Y zeolite (Y-52), a crystalline aluminosilicate zeolite molecular sieve having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of about 5.0 and commercially available, was ammonium exchanged 3 times with a 15 weight percent ammonium nitrate aqueous solution using 1.0 part by weight ammonium nitrate to 1.0 part by weight Y-52 at a temperature of 85.degree. C. for a period of one hour for each exchange. The ammonium exchanged Y 52 was washed between exchanges with 2 gallons of water to one pound of Y-52. The resulting ammonium exchanged Y 52 was then dried at a temperature of 100.degree. C.

After drying, the resulting ammonium exchanged Y 52 was hydrothermally treated (100 percent steam) at a temperature of about 700.degree. C. for a period of 1.0 hour. The hydrothermally treated ammonium exchanged Y 52 was designated as Y 72.

After hydrothermal treatment, the resulting Y-72 was again ammonium exchanged three times with a 15 weight percent ammonium nitrate aqueous solution using 1.5 parts by weight ammonium nitrate to 1.0 part by weight Y 72 at a temperature of 85.degree. C. for a period of one hour for each exchange. In addition, 70 percent nitric acid aqueous solution was added to each exchange to lower the pH of each exchange to less than 4.0. The pH was adjusted with 70 percent nitric acid aqueous solution at the beginning of each exchange without further addition thereof.

After the final ammonium exchange at low pH, the ammonium exchanged Y-72 was copper exchanged three times using one part by weight copper sulfate to one part by weight Y-72 at a temperature of 85.degree. C. for a period of 1.0 hour for each exchange.

The resulting ammonium copper exchanged Y 72 having a SiO.sub.2 /Al.sub.2 O3 molar ratio of 12 was then combined with 20 weight percent peptized alumina and extruded as a 1/16-inch extrudate. The extrudate was activated in a dry air purged oven over a period of 2.5 hours to a temperature of 500.degree. C. and thereafter held at that temperature for an additional 1.5 hours. The extrudate product contained 3.0 weight percent of copper.

This product is referred to hereinafter as Catalyst 2.

The catalyst compositions prepared in Examples 1-8 above were evaluated for reductive removal of nitrogen oxide (NO) from a simulated flue gas using ammonia as a reducing agent. The simulated flue gas contained NO and SO.sub.2 in the amounts (parts per million) specified in Table A below in addition to oxygen, carbon dioxide, water vapor and nitrogen in varying proportions. The weight percent ratio of oxygen to ammonia for each of the examples in Table A was 5.0. The simulated flue gas and ammonia were passed through a tubular reactor (22 millimeter internal diameter) containing a catalyst packed bed at a flow rate of 50 h.sup.-1 (50 .times.10.sup.-3 cubic meters/hour). The catalyst packed bed contained 5.0 grams of the catalyst (pellet form) specified for each example in Table A and the density of the catalyst packed bed was 500 kilograms/cubic meter. The reactor temperature for each example in Table A was 350.degree. C. and the space velocity (volume flow/total volume) was 20,000 h.sup.-1. The performance of the catalyst used in each example in Table A was evaluated in terms of percent NO reduction (percent NO removal). The results are given in Table A.

Although the invention has been illustrated by the preceding examples, it is not to be construed as being limited thereby; but rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof.