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This disclosure relates to a novel method of making and recovering M41S family molecular sieve materials using synthesis mixtures having high solids-content and without a purification step. The solids-content, for example, is in a range from about 20 wt. % to 50 wt. %. The method also includes the s

This disclosure relates to a novel method of making and recovering M41S family molecular sieve materials using synthesis mixtures having high solids-content and without a purification step. The solids-content, for example, is in a range from about 20 wt. % to 50 wt. %. The method also includes the step of mixing at least a portion of the M41S made with another material to form a composition, wherein the amount of said material to be mixed with said M41S product is such that said composition having less than 10 wt. % free fluid. The material mixed with the M41S made includes metal oxides, metal nitrides, metal carbides and mixtures thereof, as well as absorptive material capable of absorbing mother liquor and selected from the group consisting of carbon silica, alumina, titania, zirconia and mixtures thereof. The amount of the wastewater generated by this novel method is reduced by at least 50% to as much as 100% as comparing with conventional method of making M41S materials. By reducing and/or eliminating at least a portion of the wastewater generated in the synthesis product, the new method reduces cost of making of M41S materials and provides a more environmentally-friendly synthesis product.

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1. A method of making a M41S family composition of matter comprising an inorganic, porous crystalline phase material having, after calcination, a hexagonal arrangement of uniformly-sized pores having diameters of at least about 13 Angstrom Units and exhibiting a hexagonal electron diffraction patter

1. A method of making a M41S family composition of matter comprising an inorganic, porous crystalline phase material having, after calcination, a hexagonal arrangement of uniformly-sized pores having diameters of at least about 13 Angstrom Units and exhibiting a hexagonal electron diffraction pattern that can be indexed with a d100 value greater than about 18 Angstrom Units, comprising the steps of: (a) crystallizing a mixture comprising sources of one oxide or a combination of oxides, an organic (R) directing agent, and solvent or solvent mixture, said oxides selected from the group consisting of divalent element W, trivalent element X, tetravalent element Y and pentavalent element Z, under conditions of pH, temperature and time to form a product comprising a M41S family molecular sieve and a mother liquid, wherein said mixture having a composition, in terms of mole ratios, within the following ranges: X2O3/YO20.001 to 0.05 X2O3/(YO2 + Z2O5)0.1 to 20 X2O3/(YO2 + WO + Z2O5)0.1 to 20 Solvent/(YO2 + WO + Z2O5 + X2O3) 2 to 10OH−/YO2 0 to 10M2/eO/(YO2 + WO + Z2O5 + X2O3) 0 to 10R2/fO/(YO2 + WO + Z2O5 + X2O3)0.01 to 2.0 wherein e and f are the weighted average valences of M and R, respectively, M is an alkali or alkaline earth metal ion and R comprises an ion of the formula R1R2R3R4Q+, wherein Q is nitrogen or phosphorus and wherein at least one of R1, R2, R3 and R4 is selected from the group consisting of aryl of from 6 to about 36 carbon atoms, alkyl of from 6 to about 36 carbon atoms and combinations thereof, the remainder of R1, R2, R3 and R4 being selected from the group consisting of hydrogen, alkyl of from 1 to 5 carbon atoms and combinations thereof;(b) before steps of recovering and/or separating said M41 S molecular sieve from the mother liquor, mixing at least a portion of said product comprising said M41S molecular sieve and said mother liquor as free fluid with a material to form said M41S composition of matter having less than 1 wt. % of said free fluid. 2. The method of claim 1, further comprising the steps of: (c) extruding said M41S family composition of matter of step (b) to form an extrudate, and(d) calcining said extrudate under calcination conditions at a temperature in the range of 100° C. to 700° C. to form said catalyst. 3. The method of claim 2, further comprising the step of drying said M41S composition of matter before extruding step (c). 4. The method of claim 1, wherein said material is selected from the group consisting of metal oxides, metal nitrides, metal carbides, and mixtures thereof. 5. The method of claim 1, wherein said material is an absorptive material selected from the group consisting of carbon, silica-alumina-thoria, silica-alumina-zirconia, silica-thoria, silica-beryllia, silica-titania, silica-alumina-thoria, silica-alumina-zirconia silica-alumina-magnesia and silica-magnesia-zirconia, and mixtures thereof. 6. The method of claim 1, wherein said material is an adsorptive material selected from the group consisting of clays, silica, alumina, and mixtures thereof. 7. The method of claim 1, wherein said mixture of step (a) comprises an additional organic directing agent ion R of the formula R1R2R3R4Q+, wherein R1, R2, R3 and R4 are selected from the group consisting of hydrogen, alkyl of 1 to 5 carbon atoms and combinations thereof. 8. The method of claim 1, wherein R comprises an organic agent selected from the group consisting of cetyltrimethylammonium, octadecyltrimethylammonium, benzyltrimethylammonium, cetylpyridinium, myristyltrimethylammonium, decyltrimethylammonium, dodecyltrimethylammonium and dimethyldidodecylammonium. 9. The method of claim 1, wherein said R1, R2, R3 and R4 are selected from the group consisting of —C6H13, —C10H21, —C12H25, —C14H29, —C16H33, —C18H37, and combinations thereof. 10. The method of claim 1, further comprising a step of adding to said mixture of step (a) an auxiliary organic selected from the group consisting of: (1) aromatic hydrocarbons and amines of from 5 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (2) cyclic aliphatic hydrocarbons and amines of from 5 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (3) polycyclic aliphatic hydrocarbons and amines of from 6 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (4) straight and branched aliphatic hydrocarbons and amines of from 3 to 16 carbons and halogen-substituted derivatives thereof; and (5) combinations thereof, and having a composition, in terms of mole ratios, within the following ranges: Auxiliary Organic/YO20.05 to 20Auxiliary Organic/R2/fO0.02 to 100 11. The method of claim 10, wherein said auxiliary organic is selected from the group consisting of: pentane, hexane, heptane, octane, nonane, decane, dodecane, dihalooctane, p-xylene, trimethylbenzene, triethylbenzene, dimethyladamantane, benzene, alkyl-substituted benzene, alkyl-substituted adamantane, and combinations thereof, alkyl being of from 1 to about 14 carbon atoms. 12. The method of claim 1, wherein said Y is silicon and wherein said X is aluminum. 13. A method of making a M41S family composition of matter comprising an inorganic, porous crystalline phase material having, after calcination, a hexagonal arrangement of uniformly-sized pores having diameters of at least about 13 Angstrom Units and exhibiting a hexagonal electron diffraction pattern that can be indexed with a d100 value greater than about 18 Angstrom Units, comprising the steps of: (a) crystallizing a mixture comprising sources of one oxide or a combination of oxides, an organic (R) directing agent, and solvent or solvent mixture, said oxides selected from the group consisting of divalent element W, trivalent element X, tetravalent element Y and pentavalent element Z, under conditions of pH, temperature and time to form a product comprising a M41S family molecular sieve and a mother liquor as a free fluid, wherein said mixture having a composition, in terms of mole ratios, within the following ranges: X2O3/YO20.001 to 0.05 X2O3/(YO2 + Z2O5)0.1 to 20 X2O3/(YO2 + WO + Z2O5)0.1 to 20 Solvent/(YO2 + WO + Z2O5 + X2O3) 2 to 10OH−/YO2 0 to 10M2/eO/(YO2 + WO + Z2O5 + X2O3) 0 to 10R2/fO/(YO2 + WO + Z2O5 + X2O3)0.01 to 2.0 wherein e and f are the weighted average valences of M and R, respectively, M is an alkali or alkaline earth metal ion and R comprises an ion of the formula R1R2R3R4Q+, wherein Q is nitrogen or phosphorus and wherein at least one of R1, R2, R3 and R4 is selected from the group consisting of aryl of from 6 to about 36 carbon atoms, alkyl of from 6 to about 36 carbon atoms and combinations thereof, the remainder of R1, R2, R3 and R4 being selected from the group consisting of hydrogen, alkyl of from 1 to 5 carbon atoms and combinations thereof;(b) before steps of recovering and/or separating said M41 S molecular sieve from the mother liquor, mixing at least a portion of said product comprising said M41S molecular sieve and said mother liquor as free fluid with a material to form said M41S composition of matter having less than 1 wt. % of said free fluid;(c) extruding said M41S composition of matter to form a self-bound extrudate; and(d) calcining said self-bound extrudate under calcination conditions at a temperature in the range of 100° C. to 700° C. to form a self-bound MCM-41 catalyst having less than 1 wt. % of said free liquid. 14. The method of claim 13, further comprising the step of drying said M41S composition of matter before extruding step (c). 15. The method of claim 13, wherein said mixture of step (a) comprises an additional organic directing agent ion R of the formula R1R2R3R4Q+, wherein R1, R2, R3 and R4 are selected from the group consisting of hydrogen, alkyl of 1 to 5 carbon atoms and combinations thereof. 16. The method of claim 13, wherein R comprises an organic agent selected from the group consisting of cetyltrimethylammonium, octadecyltrimethylammonium, benzyltrimethylammonium, cetylpyridinium, myristyltrimethylammonium, decyltrimethylammonium, dodecyltrimethylammonium and dimethyldidodecylammonium. 17. The method of claim 13, wherein said R1, R2, R3 and R4 are selected from the group consisting of —C6H13, —C10H21, —C12H25, —C14H29, —C16H33, —C18H37, and combinations thereof. 18. The method of claim 13, further comprising a step of adding to said mixture of step (a) an auxiliary organic selected from the group consisting of: (1) aromatic hydrocarbons and amines of from 5 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (2) cyclic aliphatic hydrocarbons and amines of from 5 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (3) polycyclic aliphatic hydrocarbons and amines of from 6 to 20 carbons and halogen- and C1-C14 alkyl-substituted derivatives thereof; (4) straight and branched aliphatic hydrocarbons and amines of from 3 to 16 carbons and halogen-substituted derivatives thereof; and (5) combinations thereof, and having a composition, in terms of mole ratios, within the following ranges: Auxiliary Organic/YO20.05 to 20 Auxiliary Organic/R2/fO0.02 to 100 19. The method of claim 18, wherein said auxiliary organic is selected from the group consisting of: pentane, hexane, heptane, octane, nonane, decane, dodecane, dihalooctane, p-xylene, trimethylbenzene, triethylbenzene, dimethyladamantane, benzene, alkyl-substituted benzene, alkyl-substituted adamantane, and combinations thereof, alkyl being of from 1 to about 14 carbon atoms. 20. The method of claim 13, wherein said Y is silicon and wherein said X is aluminum. 21. A hydrocarbon conversion process comprising the steps of: (a) crystallizing a mixture comprising sources of one oxide or a combination of oxides, an organic (R) directing agent, and solvent or solvent mixture, said oxides selected from the group consisting of divalent element W, trivalent element X, tetravalent element Y and pentavalent element Z, under conditions of pH, temperature and time to form a product comprising a M41S family molecular sieve and a mother liquor as free fluid, said mixture having a composition, in terms of mole ratios, within the following ranges: X2O3/YO20.001 to 0.05 X2O3/(YO2 + Z2O5)0.1 to 20 X2O3/(YO2 + WO + Z2O5)0.1 to 20 Solvent/(YO2 + WO + Z2O5 + X2O3) 2 to 10OH−/YO2 0 to 10M2/eO/(YO2 + WO + Z2O5 + X2O3) 0 to 10R2/fO/(YO2 + WO + Z2O5 + X2O3)0.01 to 2.0 wherein e and f are the weighted average valences of M and R, respectively, M is an alkali or alkaline earth metal ion and R comprises an ion of the formula R1R2R3R4Q+, wherein Q is nitrogen or phosphorus and wherein at least one of R1, R2, R3 and R4 is selected from the group consisting of aryl of from 6 to about 36 carbon atoms, alkyl of from 6 to about 36 carbon atoms and combinations thereof, the remainder of R1, R2, R3 and R4 being selected from the group consisting of hydrogen, alkyl of from 1 to 5 carbon atoms and combinations thereof;(b) before steps of recovering and/or separating said M41 S molecular sieve from the mother liquor, mixing at least a portion of said product comprising said M41S molecular sieve and said mother liquor as free fluid with a material to form said M41S composition of matter having less than 1 wt. % of said free fluid;(c) extruding said M41S family composition of matter to form an extrudate;(d) calcining said extrudate under calcination conditions at a temperature in the range of 100° C. to 700° C. to form MCM-41 catalyst; and(e) thereafter contacting a hydrocarbon with said M41S catalyst to form a converted hydrocarbon. 22. The hydrocarbon conversion process of claim 21, further comprising the step of drying said M41S composition of matter before extruding step (c). 23. The hydrocarbon conversion process of claim 21, wherein said material is selected from the group consisting of metal oxides, metal nitrides, metal carbides, and mixtures thereof. 24. The hydrocarbon conversion process of claim 21, wherein said material is an absorptive material selected from the group consisting of carbon, silica-alumina-thoria, silica-alumina-zirconia, silica-thoria, silica-beryllia, silica-titania, silica-alumina-thoria, silica-alumina-zirconia silica-alumina-magnesia and silica-magnesia-zirconia, and mixtures thereof. 25. The hydrocarbon conversion process of claim 21, wherein said material is an adsorptive material selected from the group consisting of clays, silica, alumina, and mixtures thereof. 26. A hydrocarbon conversion process comprising the steps of: (a) crystallizing a mixture comprising sources of one oxide or a combination of oxides, an organic (R) directing agent, and solvent or solvent mixture, said oxides selected from the group consisting of divalent element W, trivalent element X, tetravalent element Y and pentavalent element Z, under conditions of pH, temperature and time to form a product comprising a M41S family molecular sieve and a mother liquor, wherein said mixture having a composition, in terms of mole ratios, within the following ranges: X2O3/YO20.001 to 0.05 X2O3/(YO2 + Z2O5)0.1 to 20 X2O3/(YO2 + WO + Z2O5)0.1 to 20 Solvent/(YO2 + WO + Z2O5 + X2O3) 2 to 10OH−/YO2 0 to 10M2/eO/(YO2 + WO + Z2O5 + X2O3) 0 to 10R2/fO/(YO2 + WO + Z2O5 + X2O3)0.01 to 2.0 wherein e and t are the weighted average valences of M and R, respectively, M is an alkali or alkaline earth metal ion and R comprises an ion of the formula R1R2R3R4Q+, wherein Q is nitrogen or phosphorus and wherein at least one of R1, R2, R3 and R4 is selected from the group consisting of aryl of from 6 to about 36 carbon atoms, alkyl of from 6 to about 36 carbon atoms and combinations thereof, the remainder of R1, R2, R3 and R4 being selected from the group consisting of hydrogen, alkyl of from 1 to 5 carbon atoms and combinations thereof;(b) before steps of recovering and/or separating said M41 S molecular sieve from the mother liquor, mixing at least a portion of said product comprising said M41S molecular sieve and said mother liquor as free fluid with a material to form said M41S composition of matter having less than 1 wt. % of said free fluid;(c) extruding said M41S composition of matter to form a self-bound extrudate;(d) calcining said self-bound extrudate under calcination conditions at a temperature in the range of 100° C. to 700° C. to form a self-bound MCM-41 catalyst having less than 1 wt. % of said free fluid; and(e) thereafter contacting a hydrocarbon with said M41S catalyst to form a converted hydrocarbon. 27. The hydrocarbon conversion process of claim 26, further comprising the step of drying said M41S composition of matter before extruding step (b) step (c).