Chapter 13
Zeolite Synthesis in the Presence of Fluoride Ions A Comparison with Conventional Synthesis Methods
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J. L. Guth, H. Kessler, J. M. Higel, J. M. Lamblin, J. Patarin, A. Seive, J. M. Chezeau, and R. Wey Laboratoire de Matériaux Minéraux, Unité Associée au Centre National de la Recherche Scientifique No. 428, Ecole Nationale Supérieure de Chimie, 3 rue Alfred Werner, 68093 Mulhouse Cedex, France -
-
Replacement of OH by F makes it possible to obtain zeolites in media where pH values can be lowered to acidic ones. Under such conditions MFI-, FER-, MTT-, MTN- and TON-structure type materials could be prepared. This route is especially suited for high-silica materials synthesis, but partial substitution of silicon by Β , Al , Ga , Fe , Ge and Ti has been possible too. The ease of substitution decreases with increasing stability of the corresponding fluorocomplezes in the solution. As the supersaturation of crystallizing species i s lower for fluoride-containing media, the number of phases that could be obtained i s smaller (fewer metastable phases), but crystallization is more regular (formation of large crystals with less defects). The choice of templates i s therefore more critical. The new medium enables the incorporation of elements sparingly soluble in alkaline solutions (e.g., Fe ) or of cations such as NΗ +, Co . Finally the presence of F in the materials leads to catalytic pro perties modifications which will be discussed. III
III
III
III
IV
III
IV
2+
4
In a r e c e n t paper ( 1). o u r l a b o r a t o r y reported the hydrothermal s y n t h e s i s o f s i l i o a - r i c h , A l , Β and (Al+B) HFI-type z e o l i t e s i n nona l k a l i n e medium ( 2 - 4 ) . The v e r y pure m a t e r i a l s so o b t a i n e d e x h i b i t a high c r y s t a l l i n i t y and a r e g u l a r morphology which seem t o be rela ted t o t h e i r growth i n m o d e r a t e l y s u p e r s a t u r a t e d solutions. Their characterization (5,6) and t h e s t u d y o f t h e i r p r o p e r t i e s ( 7) has d i s c l o s e d d i f f e r e n c e s t o z e o l i t e s o f t h e same s t r u c t u r e and s i m i l a r c o m p o s i t i o n o b t a i n e d i n a l k a l i n e medium. The development o f t h e s y n t h e s i s i n f l u o r i d e medium has been studied i n c o n n e c t i o n w i t h t h e new p o s s i b i l i t i e s opened by t h i s method ( i n c o r p o r a t i o n i n t h e framework o f e l e m e n t s s p a r i n g l y solu ble i n a l k a l i n e medium, s y n t h e s i s w i t h o u t alkaline cations, new p o s s i b l i l i t y t o d i r e c t l y i n c o r p o r a t e c a t i o n s such a s N H 4 + , divalent c a t i o n s , t h e good s t a b i l i t y o f u s u a l t e m p l a t e s i n t h i s medium,...).
0097-6156/89/0398-0176$06.00A)
ο 1989 American Chemical Society In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
13. GUTH ET AL.
177
Zeolite Synthesis with Fluoride Ions
Synthesis and c h a r a c t e r i z a t i o n has been s p e c i a l l y investigated i n the c a s e o f i ) HFI s t r u c t u r a l t y p e m a t e r i a l s w i t h a p u r e l y s i l i c e o u s framework, or w i t h s i l i c o n p a r t l y s u b s t i t u t e d by t r i v a l e n t ( B , A l , F e , Ga) o r t e t r a v a l e n t (Ge, T i ) elements. i i ) p u r e l y s i l i c e o u s and s i l i c o a l u m i n a t e z e o l i t e s o f t h e s t r u c t u r a l t y p e s FER, TOM, HTT and HTH ( 8 ) .
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EXPERIMENTAL 125 ml P T F B - l i n e d s t e e l a u t o c l a v e s were used. I n o r d e r t o remove any solid which might have been s t u c k on t h e c o a t i n g , a washing w i t h a 50 % HF aqueous s o l u t i o n was performed b e f o r e e v e r y new synthesis. The s o l i d p r o d u c t s were c a r e f u l l y examined under t h e o p t i c a l pola r i z i n g m i c r o s c o p e (morphology and s i z e , p r e s e n c e o f amorphous impu rities) . I d e n t i f i c a t i o n was t h e n performed u s i n g powder X-ray dif f r a c t i o n ( P h i l i p s PR 1130 d i f f r a c t o m e t e r ) ( 1). C a l c i n a t i o n i n o r d e r t o decompose and remove t h e t e m p l a t e was m o n i t o r e d by thermogravimet r y ( M e t t l e r 1 Thermoanalyzer), d i f f e r e n t i a l thermal a n a l y s i s ( S e t a ram M2) o r d i f f e r e n t i a l s c a n n i n g c a l o r i m e t r y (Setaram DSC-111). The c h e m i c a l environment o f atoms i n t h e s o l i d s was s t u d i e d by NMR (MAS and CP-MAS). Resonance o f B , C , F , A l and S i nuclei was r e c o r d e d on a B r u k e r MSL-300 s p e c t r o m e t e r o p e r a t i n g a t a 7 T e s l a magnetic f i e l d . Chemical a n a l y s i s o f s i l i c o n and o f i t s s u b s t i t u e n t s was performed by atomic a b s o r p t i o n s p e c t r o s c o p y a f t e r d i s s o l v i n g t h e material i n HF ( 9). I n some c a s e s , a s p o t a n a l y s i s and X-ray emis s i o n mapping o f t h e s e elements i n t h e c r y s t a l s was c a r r i e d o u t on a C a s t a i n g t y p e ( Camebaz) e l e c t r o n microscope. The f l u o r i n e c o n t e n t was determined by n e u t r o n a c t i v a t i o n or, a f t e r dissolution o f t h e s o l i d , by p o t e n t i o m e t r y u s i n g a F"-selective e l e c t r o d e ( 1 0 ) . The c a t a l y t i c a c t i v i t y was e s t i m a t e d w i t h a methanol conversion test a t 370°C and v a r i a b l e H. H. S. V. 1 1
1 3
1 9
2 7
2 9
RESULTS AMD DISCUSSION CRYSTALLIZATION o f ZEOLITES i n OH" o r i n F" MEDIA. Due t o t h e low s o l u b i l i t y o f z e o l i t e s , t h e y i e l d o f c r y s t a l l i z a t i o n i s poor when i t is c a r r i e d o u t from a c l e a r s o l u t i o n . To a v o i d t h i s drawback, t h e s o l u t i o n i s f e d by c o n t i n u o u s l y d i s s o l v i n g a s o l i d which i s m o s t l y an o x i d e o r h y d r o x i d e g e l o f t h e framework-forming elements Τ (11). Silicate, a l u m i n a t e and a l u m i n o s i l i c a t e a n i o n s a r e t h u s formed by s o l u b i l i z a t i o n o f t h e S i and A l s o u r c e s i n t h e p r e s e n c e o f OH". The latter i s t h e m o b i l i z i n g agent used t o t r a n s f e r these elements t h r o u g h t h e s o l u t i o n : i t i s consumed on d i s s o l u t i o n and r e g e n e r a t e d on c r y s t a l l i z a t i o n . I n t h e new r o u t e , t h i s r o l e i s p l a y e d by fluo r i d e ( F~) a n i o n s . The c r y s t a l l i z a t i o n becomes t h u s p o s s i b l e i n neu t r a l and even i n a c i d i c media. The l i q u i d phase must f u r t h e r c o n t a i n s p e c i e s which w i l l g e n e r a t e t h e m i c r o p o r o u s volume by o c c u p y i n g t h e c a v i t i e s and c h a n n e l s o f t h e framework. These t e m p l a t e s a r e e i t h e r c a t i o n s t o compensate t h e n e g a t i v e c h a r g e s o f t h e framework o r neu t r a l s p e c i e s ( i o n p a i r s , m o l e c u l e s ) . Due t o t h e i r i n t e r a c t i o n s , they s t a b i l i z e t h e s t r u c t u r e and make c r y s t a l l i z a t i o n p o s s i b l e . The s y n t h e s i s p r o c e s s c a n be r e p r e s e n t e d as f o l l o w s :
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
178
ZEOLITE SYNTHESIS S o l i d r e a c t a n t s source ( m o s t l y amorphous) •OH"
dissolution
Solution containing species f o r - framework b u i l d i n g - micropore f i l l i n g
e. g., s i l i c a t e s e. g., a l unifiâtes
e. g., f l u o s i l i c a t e s e. g., f l u o a l u m i n a t e s
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polycondensation crystalline zeolite The zeolites
OH~and F~ s y n t h e s i s media a r e compared i n T a b l e I and t h e o b t a i n e d so f a r i n F~ media a r e l i s t e d i n t a b l e I I .
T a b l e I. Comparison o f t h e OH" and F~ r e a c t i o n media used i n z e o l i t e s y n t h e s i s
F~ medium
0H~ medium PH Hobilizing agents
> 10 = (1-11) OH" F" Bases: NaOH, Pr 0H,. . . A c i d s : HF,. . . Salts: Ν β σ θ . . . S a l t s : HH F,. .. M o l e c u l e s : amines,... Molecules: B F 3 , Oxides, h y d r o x i d e s , a l k o x i d e s , s a l t s (amorphous o r c r y s t a l l i n e s o l i d s ) I o n i c compounds ( s a l t s , bases) : P^NBr,. . . M o l e c u l e s : P r 3 N,. . . > 20° > 40° From a few hours t o s e v e r a l days 4
2
Τ element sources Template Temperature Duration
Table II. Z e o l i t e s
3 >
4
o b t a i n e d so f a r i n F" media
S t r u c t u r e type
MFI
FER
TOM
Τ elements
Si Si+Be, B, A l , Ga, Fe, Ge, T i
Si* Si+Al, Fe
Si Si+Al*
* difficult
MTT Si Si+Al*
Si+Al
t o s y n t h e s i z e ; ** non r e p r o d u c i b l e s y n t h e s i s .
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
Si+Al
13. GUTHETAL.
179
Zeolite Synthesis with Fluoride Ions
HFI-type ZEOLITES. A large number o f MFI-type z e o l i t e s c o u l d be obtained i n F~ media (2-4. 12-15) a c c o r d i n g t o t h e d e s c r i b e d route ( 1) w i t h P r H H ( 4 _ ) ( P r = η-propyl, χ = 1 t o 4) t e m p l a t e s and f o r the Τ elements quoted above. P ^ N * i s t h e b e s t t e m p l a t e ( T a b l e I I I ) . +
x
X
+
Table III.
T e m p l a t i n g e f f i c i e n c y o f P r N H ( 4_ ) i n t h e absence and i n t h e presence of A l s u b s t i t u t i n g f o r S i x
+
Pr H Pr MH Pr MH2 PrNH * 4
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+
3
+
2
3
(
X
Τ = Si
Τ = Si, Al
MFI HFI MTT ( HFI) HTH (FER) (HFI)
HFI HFI HFI (HTT) FER (HFI)
) g e n e r a l l y as a s e c o n d a r y phase.
C r y s t a l s a r e always o f good q u a l i t y and t h e s i z e exceeds gene rally the values observed i n a l k a l i n e - t y p e s y n t h e s i s . A d d i t i o n of seeds d e c r e a s e s t h e c r y s t a l l i z a t i o n time and a l l o w s t a i l o r i n g o f t h e size. The morphology i s t h e same as f o r c r y s t a l s o b t a i n e d by t h e u s u a l a l k a l i n e r o u t e . The l e n g t h / w i d t h r a t i o d e c r e a s e s w i t h χ i n t h e t e m p l a t e and t h e s u b s t i t u t i o n degree o f S i ( 1 6 ) . The s u b s t i t u t i o n by t r i v a l e n t elements leads g e n e r a l l y t o c r y s t a l s with l e s s f l a t faces which i n d i c a t e s t h a t c r y s t a l l i z a t i o n o c c u r e d i n a more super-satu r a t e d medium. PURELY SILICEOUS HFI-tvpe ZEOLITES. Among t h e t e m p l a t i n g cations which were used, P r N proved t o be t h e most e f f i c i e n t f o r easy and fast crystallization. I n T a b l e IV a r e g i v e n the c r y s t a l l o g r a p h i c c h a r a c t e r i s t i c s o f t h e o b t a i n e d s i l i c e o u s HFI-type z e o l i t e s (16) as a f u n c t i o n o f t h e template. +
4
T a b l e IV. U n i t c e l l f o r m u l a and c r y s t a l p a r a m e t e r s of t h e s i l i c e o u s HFI-type z e o l i t e s ( a s s y n t h e s i z e d and (*) c a l c i n e d )
unit c e l l JSi
9 6
0
1 9 2
formula
a (A)
| 4Pr KF
b ( A)
c ( Α)
20.039(3) 19.928(3) 13.382(3)
4
I 96°19214Pr NHF Si
20.048( 2) 19.889( 2) 13.383(3)
3
β (°) 90 90
vol. ( A )
3
5344(3) 5337( 3)
8H 0 2
|Si
9 6
0
1 9
2 | 4 . 8 P r M H F 20.045( 4) 19.886(3) 13.379(5) 2
6. 5H 0 *Si 0 2
2
90
5334(3)
2
9 6
1 9
13.383(5) 20.107(4) 19.887(3)
90.63(3) 5351(3)
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
180
ZEOLITE SYNTHESIS
R a t e r m o l e c u l e s occupy the volume o f t h e c h a n n e l s which i s l e f t emp ty by t h e t e m p l a t e s c a r r y i n g l e s s t h a n f o u r p r o p y l groups. The cat i o n i c n a t u r e o f t h e t e m p l a t e s was e s t a b l i s h e d by C NMR. Rhereas P^N* o c c u p i e s t h e s t r a i g h t and z i g z a g c h a n n e l s ( 17) « the Pr3ifH and P r N H 2 c a t i o n s are l o c a t e d p r e f e r e n t i a l l y i n t h e z i g z a g chan nels. Such a c o n c l u s i o n c o u l d be drawn from the f o l l o w i n g observa t i o n s (16) : i) b ( p a r a l l e l t o the s t r a i g h t c h a n n e l s ) d e c r e a s e s , a increases and c s t a y s c o n s t a n t on g o i n g from P ^ N * to Pr NH2 . i i ) The P^NH* and Pr2NH2 s p e c i e s decompose a c c o r d i n g t o DSC under argon a t about t h e same temperature (535 and 515°C). Such a tempera ture i s much h i g h e r t h a n t h e d e c o m p o s i t i o n temperature of Pr NH2 occluded i n t h e MTT s t r u c t u r e ( 5
2 >5
0 0
2 #5
7 1
7
7 1β 7
F . ] 1. 4PrNH F 1. 5H 0 F . ] 18H 0. 0
3
0
3
3
2
2
I t may t h e n be c o n c l u d e d t h a t 12 % o f t h e n e g a t i v e c h a r g e s i n by A l a r e not r e v e a l e d owing t o t h e p r e s e n c e o f F ( 20). The e f f e c t o f t h e a d d i t i o n o f F t o t h e s t a r t i n g m i x t u r e on t h e adsorption and t h e c a t a l y t i c p r o p e r t i e s i s q u i t e significant. For example, t h e h y d r o p h o b i c i t y o f p u r e l y s i l i c e o u s samples i s c o n s i d e rably enhanced ( l e s s Si-OH g r o u p s ) . F i g u r e 6 shows t h a t such a ma terial adsorbs more n-propanol from a d i l u t e n-propanol + water s o l u t i o n t h a n a m a t e r i a l which was p r e p a r e d i n a l k a l i n e medium. The complete o r p a r t i a l c a n c e l l i n g by F o f t h e n e g a t i v e c h a r g e s i n d u c e d by t h e i n c o r p o r a t i o n o f t r i v a l e n t elements such as A l i n f l u duced
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
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13.
GUTHETAK
Zeolite Synthesis with Fluoride Ions
189
A T O N 5 0 ° / . T O N 50·/.
2 0 d a y s (static) FERIOO'/.FERIOOV.FER+TON
T O N 20'/.
10 'FER
90V.
7
30
50
35
300
Si/AI(starting) •TON 100V.
• F E R 60*/.
T O N 100V.
10 d a y s ( a g i t a t e d )
T O N 95V.
(•in p r e s e n c e of s e e d s )
Ψ F i g u r e 4 : I n f l u e n c e of s t a r t i n g seeding on FER- and TON-type n - b u t y l a m i n e template.
S i / A l r a t i o , time, a g i t a t i o n and materials crystallization with
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
ZEOLITE SYNTHESIS
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190
F i g u r e 5. S c a n n i n g e l e c t r o n m i c r o g r a p h s o f (a) FER-, and (c) MTT-type m a t e r i a l s . C o n t i n u e d on next page.
(b)
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
TON-,
GUTHETAL.
191
Zeolite Synthesis with Fluoride Ions
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13.
Figure 5. Continued. Scanning electron micrographs of (d) (e) NUl-type materials, and (f) of a novel c l a t h r a s i l .
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
MTN-,
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192
ZEOLITE SYNTHESIS
F i g u r e 6 : n - p r o p a n o l a d s o r p t i o n ( from d i l u t e aqueous n-propanol solutions) o f HFI-type z e o l i t e s p r e p a r e d (a) i n a l k a l i n e medium and ( b) i n f l u o r i d e medium .
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
13. GUTHETAK
193
Zeolite Synthesis with Fluoride Ions
ences t h e a c i d c a t a l y s i s p r o p e r t i e s . I t was found, f o r example, t h a t methanol t o h y d r o c a r b o n c o n v e r s i o n was v e r y low on t h e above-men tioned Mg-MFI sample c o n t a i n i n g 3. 3 A l and 3 F p e r u n i t c e l l . The conversion reached however 100 % on t h e d e f l u o r i n a t e d r e c a l c i n e d sample. A FER-type sample which was p r e p a r e d by u s i n g conditions close t o t h e c o n d i t i o n s employed f o r t h e above FER-type sample (2.5A1 and 0. 3F p e r u n i t c e l l ) but c o n t a i n i n g C o + i n s t e a d o f Hg , showed a methanol c o n v e r s i o n y i e l d o f about 100 %, which d e c r e a s e d slowly w i t h i n c r e a s i n g time-on-stream (90 % c o n v e r s i o n after 26h, H. H. S. V. » 0 . 4 ) . The a c t i v i t y o f t h e same sample which was f i r s t defluorinated and r e c a l c i n e d , d e c r e a s e d more r a p i d l y owing t o s t r o n g and r a p i d c o k i n g on t h e a c i d s i t e s which were a v a i l a b l e from t h e outset. In c o n t r a s t , i n the case of the n o n - d e f l u o r i n a t e d sample, the f o r m a t i o n o f water d u r i n g t h e c o n v e r s i o n l e a d s t o t h e gradual e l i m i n a t i o n o f F and t h u s makes t h e a c i d s i t e s s l o w l y a v a i l a b l e .
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2
2 +
CONCLUSIONS By using f l u o r i d e anions i n z e o l i t e synthesis, i t i s p o s s i b l e t o e x t e n d t h e u s u a l a l k a l i n e pH range t o a n e u t r a l o r a c i d i c one. The r e p l a c e m e n t o f OH" by F" f o r t h e f o r m a t i o n o f s o l u b l e fra mework b u i l d i n g s p e c i e s f a c i l i t a t e s the i n c o r p o r a t i o n of Τ elements which are s p a r i n g l y s o l u b l e (e.g., F e , T i ) o r do n o t polycondensate e a s i l y ( e . g . , G e ) i n a l k a l i n e medium. The n a t u r e of the soluble species i s s t i l l n o t w e l l known, i . e . , c o o r d i n a t i o n and type o f t h e o t h e r l i g a n d s b e s i d e F~( e. g., H 0, OH). Particularly, the F/( o t h e r l i g a n d s ) r a t i o seems t o be c r i t i c a l . A compromise has to be found, a low f l u o r i d e c o n t e n t h i n d e r s s o l u b i l i z a t i o n and a high content p r e v e n t s p o l y c o n d e n s a t i o n . The compromise leads to systems which a r e l e s s s u p e r s a t u r a t e d t h a n f o r a l k a l i n e media. Hen ce, f e w e r m e t a s t a b l e phases a r e o b t a i n e d . T h i s i s however also an advantage s i n c e b e t t e r c o n t r o l l e d n u c l e a t i o n and s l o w e r growth rate yield crystals w i t h fewer d e f e c t s and w i t h controlled size. The relative stability of the fluoro-complexes o f the elements which were studied, i s strongly i n favour of s i l i c o n incorporation. This F~ route i s therefore well s u i t e d f o r obtaining s i l i c a - r i c h mater i a l s , i . e., o f t h e p e n t a s i l type. But t h e s m a l l number o f framework negative c h a r g e s l e a d s t o fewer t e m p l a t i n g c a t i o n - f r a m e w o r k inter actions. This, and t h e l o w e r s u p e r s a t u r a t i o n , make t h e s y n t h e s i s more c r i t i c a l and enhance the r o l e of the template f o r the s t a b i l i z a t i o n o f t h e z e o l i t e s t u c t u r e . C h o i c e o f t h e t e m p l a t e becomes thus more c r i t i c a l . A good s t e r i c and c h e m i c a l f i t t o t h e framework has to be r e a c h e d i n o r d e r t o i n c r e a s e t h e f a v o u r a b l e i n t e r a c t i o n s and also t h o s e between t h e s p e c i e s which a r e p r e s e n t i n t h e pores. It should be mentioned f u r t h e r t h a t many o r g a n i c s p e c i e s such as t h e q u a t e r n a r y ammonium i o n s a r e more s t a b l e i n a n e u t r a l medium t h a n i n an a l k a l i n e one. Neutral or a c i d i c pH v a l u e s make i t p o s s i b l e t o s t a r t w i t h c a t i o n s which a r e s p a r i n g l y s o l u b l e i n a l k a l i n e medium ( e . g . divalent c a t i o n s ) o r do n o t e x i s t i n s u c h a medium ( e. g. N H 4 ) . Hhen t h e NH4' ' c a t i o n s r e p l a c e the usual a l k a l i cations, the m a t e r i a l s obtained are therefore alkali-free and a s i m p l e c a l c i n a t i o n y i e l d s the a c i d i c form o f t h e z e o l i t e . The c a t i o n exchange s t e p i s t h u s bypassed. 1 1 1
I V
I V
2
+
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.
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ZEOLITE SYNTHESIS
Finally a m o d i f i c a t i o n o f exchange, a d s o r p t i o n and catalytic p r o p e r t i e s has been found (e. g., i n c r e a s e d h y d o p h o b i c i t y , cancelling of framework c h a r g e s ) . He thank Dr Ζ. GABELICA from Namur u n i v e r s i t y f o r h i s c o n t r i b u t i o n t o t h e s t u d y o f t h e germanium i n c o r p o r a t i o n and Miss A. C. FAUST f o r t h e s y n t h e s i s and t h e a n a l y s i s o f many samples.
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RECEIVED December 22, 1988
In Zeolite Synthesis; Occelli, M., et al.; ACS Symposium Series; American Chemical Society: Washington, DC, 1989.