High surface area pentasil zeolite and process for making same

A process for the production of a pentasil-layered zeolite catalyst, comprising:

• forming a reaction mixture comprising reactive compounds M, R, Al and Si;
• and
• reacting the mixture at reaction conditions, wherein the reaction conditions include a temperature between 80° C. and 150° C., and a reaction time between 10 hours and 5 days, to form a microporous crystalline structure comprising a framework of AlO2 and SiO2 tetrahedral units, and an empirical composition in the as synthesized and anhydrous basis expressed by the empirical formula of:
• Mmn+Rrp+ AlSiyOz;
• wherein the reactive compounds include M, a cation selected from the group consisting of alkali and alkaline earth metals;
• R, an organoammonium cation selected from the group consisting of quaternary ammonium cations, diquaternary ammonium cations;
• and wherein “m” is the mole ratio of M to Al and varies from 0 to 3, “r” is the mole ratio of R to Al and has a value of between 0.1 and 30, “n” is the weight average valence of M and has a value of 1 to 2, “p” is the weighted average valence of R and has a value of 1 to 2, “y” is the mole ratio of Si to Al and varies from greater than 32 to 200 and “z” is the mole ratio of O to Al and has a value determined by the equation:
• z=(m·n+r·p+3+4·y)/2.

A process for the production of an MFI-layered zeolite catalyst having a 2-D structure, comprising:

• forming a reaction mixture containing reactive sources of M, R, Al, and Si;
• and
• reacting the reaction mixture at reaction conditions of 80° C. to 150° C. for a period of time of between 10 hours and 5 days the reaction mixture having the a composition expressed in terms of mole ratios of the oxides of:
• aM2/nO:bR1 2/nO:cR2 2/n:Al2O3:eSiO2:hH2O;
• wherein the reactive compounds include M, a cation selected from the group consisting of alkali, alkaline earth metals and mixtures thereof;
• R, an organoammonium cation selected from the group consisting of quaternary ammonium cations, diquaternary ammonium cations and mixtures thereof;
• Al in the form of Al2O3;
• and Si in the form of SiO2;
• and wherein “a” has a value of 0.1 to 3, “b” has a value of 1 to 30, “c” has a value of 0 to 1, “e” has a value of 64 to 400 and “h” has a value of 50 to 1000.