Metalloaluminophosphate molecular sieves with lamellar crystal morphology and their preparation

Abstract

The present invention relates to metalloaluminophosphate (MeAPO) molecular sieve with lamellar crystal morphology having an empirical chemical composition on an anhydrous basis, after synthesis and calcination, expressed by the formula HxMeyAlzPkO2 wherein, y+z+k=1 and x<=y, said molecular sieve having predominantly a plate crystal morphology in which the width (W) and the thickness (T) are such as : W/T is >= 10 and advantageously ranges from 10 to 100. In a preferred embodiment T is <= 0.15 mum, more desirably <=0.10 mum, more desirably <=0.08 mum, advantageously ranges from 0.01 to 0.07 mumand preferably from 0.04 to 0.07 mum. The above metalloaluminophosphate (MeAPO) molecular sieve can be made by a method which comprises : a) forming a reaction mixture containing a texture influencing agent (TIA), an organic templating agent (TEMP), at least a reactive inorganic source of MeO2 insoluble in the TIA, reactive sources of Al2O3 and P2O5, b) crystallizing the above reaction mixture thus formed until crystals of the metalloaluminophosphate are formed, c) recovering a solid reaction product, d) washing it with water to remove the TIA and e) calcinating it to remove the organic template. In an advantageous embodiment the MeAPO of the invention have essentially a structure CHA or AEI or a mixture thereof. Preferably they have essentially the structure SAPO 18 or SAPO 34 or a mixture thereof. The present invention also relates to catalysts consisting of the above MeAPO molecular sieves or comprising the above MeAPO molecular sieves. The present invention also relates to a process for making an olefin product from an oxygen-containing, halogenide-containing or sulphur-containing feedstock wherein said oxygen-containing, halogenide-containing or sulphur-containing feedstock is contacted with the above catalyst under conditions effective to convert the oxygen-containing, halogenide-containing or sulphur-containing feedstock to olefin products.

Description

Technical field [0001] The invention relates to a metalloaluminophosph-ate (MeAPO) molecular sieve with a layered crystal morphology and its preparation. The metal aluminum phosphate molecular sieve of the present invention can be used as a catalyst in various processes including cracking, hydrocracking, isomerization, reforming, dewaxing, alkylation, transalkylation, and conversion of methanol to light olefins . The limited supply of crude oil and rising costs have prompted research on alternative methods for the manufacture of hydrocarbon products. One such method is to convert oxygen-containing, halide-containing or sulfur-containing organic compounds into hydrocarbons and especially into light olefins (light olefins refer to C 2 ~C 4 Olefins) or gasoline and aromatics. The focus on the process of converting methanol to olefins (MTO) is based on the fact that oxygenates, especially methanol, can be obtained from coal, biomass, organic waste, or natural gas through the produ...

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In all of the above prior art, only templates and/or specific reaction

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