UZM-22 aluminosilicate zeolite, method of preparation and processes using UZM-22

A process for preparing a microporous crystalline zeolite having a three-dimensional framework of at least AlO2 and SiO2 tetrahedral units and an empirical composition in the as synthesized and anhydrous basis expressed by an empirical formula of:

• Mmn+RrAl1-xExSiyOz
• where M is at least one exchangeable cation selected from the group consisting of alkali, alkaline earth, and rare earth metals, “m” is the mole ratio of M to (Al+E) and varies from 0 to about 1.2, R is a singly charged organoammonium cation selected from the group choline, ethyltrimethylammonium (ETMA), diethyldimethyl ammonium (DEDMA), tetraethyl ammonium (TEA), tetrapropylammonium (TPA), trimethylpropylammonium, trimethylbutylammonium, dimethyldiethanolammonium cations and mixtures thereof “r” is the mole ratio of R to (Al+E) and has a value of about 0.25 to about 2.0, “n” is the weighted average valence of M and has a value of about 1 to about 3, E is an element selected from the group consisting of gallium, iron, boron and mixtures thereof, “x” is the mole fraction of E and has a value from 0 to about 1.0, “y” is the mole ratio of Si to (Al+E) and varies from greater than 2 to about 12 and “z” is the mole ratio of O to (Al+E) and has a value determined by the equation:
• z=(m·n+r+3+4·y)/2
• and is characterized in that it has the x-ray diffraction pattern having at least the d-spacings and intensities set forth in Table A:
• TABLE A
• 2θ
• d (Å)
• I/Io %
• 7.53-7.89
• 11.73-11.20
• vs
• 9.35-9.71
• 9.45-9.10
• w
• 11.01-11.37
• 8.03-7.78
• m
• 13.22-13.53
• 6.69-6.54
• w-m
• 13.41-13.77
• 6.60-6.43
• w-m
• 15.35-15.63
• 5.77-5.66
• w
• 17.28-17.68
• 5.13-5.01
• w-m
• 18.32-18.72
• 4.84-4.74
• w-m
• 18.89-19.33
• 4.69-4.59
• m
• 20.33-20.69
• 4.36-4.29
• w-m
• 21.07-21.51
• 4.21-4.13
• s-vs
• 21.34-21.74
• 4.16-4.08
• s-vs
• 22.24-22.67
• 3.99-3.92
• w-m
• 22.71-23.15
• 3.91-3.84
• w-m
• 23.21-23.65
• 3.83-3.76
• m
• 25.58-26.19
• 3.48-3.40
• w
• 26.38-26.89
• 3.38-3.31
• m
• 26.73-27.17
• 3.33-3.28
• w-m
• 27.41-27.77
• 3.25-3.21
• w-m
• 28.49-28.85
• 3.13-3.09
• m
• 29.10-29.47
• 3.07-3.03
• m
• 30.09-30.51
• 2.97-2.93
• w
• 30.42-30.82
• 2.94-2.90
• w
• 31.06-31.54
• 2.88-2.83
• w-m
• 32.15-32.54
• 2.78-2.75
• w
• 32.31-32.82
• 2.77-2.73
• w
• 32.69-33.13
• 2.74-2.70
• w
• 32.98-33.49
• 2.71-2.67
• w
• 33.80-34.36
• 2.65-2.61
• w
• 34.82-35.35
• 2.57-2.54
• w
• 35.73-36.17
• 2.51-2.48
• w-m
• 37.91-38.56
• 2.37-2.33
• w
• and is thermally stable up to a temperature of at least 400° C.;
• the process comprising forming a reaction mixture containing reactive sources of M, R, Al, Si and optionally E and heating the reaction mixture at a temperature of about 60° C. to about 175° C., for a time sufficient to form the zeolite, the reaction mixture having a composition expressed in terms of mole ratios of the oxides of:
• aM2/nO:bR2/pO:1−cAl2O3:cE2O3:dSiO2:eH2O
• where “a” has a value of about 0.05 to about 1.25, “b” has a value of about 1.5 to about 40, “c” has a value of 0 to about 1.0, “d” has a value of about 4 to about 40, “e” has a value of about 25 to about 4000.