Zirconium phosphate and method of making same

1. An amorphous zirconium phosphate compound having a P:Zr ratio of from about 1.8-2.0 to 1, which compound has an H-form which exhibits a single peak at −13.7±0.5 ppm in the 31 P NMR spectra.

2. A compound according to claim 1 which has a structure which exhibits x-ray diffraction peaks when intercalated with n-butylamine.

3. A compound according to claim 1 which has a sodium form which exhibits a single peak at −7.8±0.5 ppm in the 31 P NMR spectra.

4. A compound according to claim 1 wherein, when intercalated with n-butylamine, said intercalated product includes a d-spacing of 18.4±0.3 Å.

5. A compound according to claim 1 having the formula Zr(HPO 4 ) 2 . nMe x O.mH 2 O, wherein n=0-1.2, m=0.5−3.0, x=0.5-1 and Me is selected from the group consisting of NH 4 , Li, Na, K, Cs, Mg, Ca, Sr and Ba.

6. A compound according to claim 1 having the formula Zr(HPO 4 ) 2 . nNa 2 O.mH 2 O, wherein n=0-1.2 and m=0.5-3.0.

7. A compound according to claim 1 in granular form having an average particle size from about 50 microns to about 60 microns.

8. A compound according to claim 1 having the formula Zr(HPO 4 ) 2 .nMe x O.mH 2 O, wherein n=0-1.2, m=0.5-3.0, x=0.5-1 and Me is selected from the group consisting of NH 4 , Li, Na, K, Cs, Mg, Ca, Sr and Ba, in granular form having an average particle size of from about 50 microns to about 60 microns.

9. An ion exchange compound according to claim 1 . compound according to claim 1 .

10. A catalyst or catalyst support comprising a zirconium phosphate compound according to claim 1 .

11. An ion exchange media comprising a zirconium phosphate compound according to claim 1 having an average particle size of from about 50 microns to about 60 microns.

12. A method of removing cations from a fluid comprising contacting said fluid with a zirconium phosphate compound according to claim 1 .

13. A method of making an amorphous zirconium phosphate compound comprising mixing a water insoluble zirconium compounds, an aqueous solution of an acidic phosphorous containing reagent and an aqueous solution of an acidic sulfate containing reagent in a molar ratio of said acidic phosphorous containing reagent and said acidic sulfate containing reagent of 0.25-2.0:1 to produce a reaction mixture having a phosphorous to zirconium ratio of from about 2.0-2.5:1, and reacting said mixture at a temperature and time effective to produce said amorphous zirconium phosphate compound.

14. A method according to claim 13 comprising selecting said zirconium compound from a basic zirconium sulfate, a basic zirconium carbonate or a hydrous zirconium oxide.

15. A method according to claim 13 comprising selecting said zirconium compound to have an average particle size from about 50 microns to about 60 microns to produce said zirconium phosphate having an average particle size within said range.

16. A method according to claim 13 comprising forming said acidic phosphorous containing reagent from a phosphorous containing component selected from the group consisting of phosphoric acid, a mono-hydrogen phosphate of an alkali metal, a mono-hydrogen phosphate of ammonia mixtures thereof, and forming said acidic sulfate containing reagent from a sulfate containing component selected from sulfuric acid, a sulfate of an alkali metal, a sulfate of ammonia or mixtures thereof.

17. A method according to claim 13 comprising forming said acidic phosphorous containing reagent from a phosphorous containing component selected from the group consisting of phosphoric acid, a mono-hydrogen phosphate of an alkali metal, a mono-hydrogen phosphate of ammonia and mixtures thereof, and forming said acidic sulfate containing reagent from a sulfate containing component selected from sulfuric acid, a sulfate of an alkali metal, a sulfate of ammonia or mixtures thereof, and a pH less than about 4.

18. A method according to claim 13 wherein said acidic phosphorous containing reagent and said acidic sulfate containing reagent comprise phosphoric acid and sulfuric acid, respectively.

19. A method according to claim 13 wherein said temperature is from about 80° C. to boiling point.

20. A method according to claim 19 comprising reacting said mixture at said temperature for said time of from about 1 to about 3 hours.

21. An amorphous zirconium phosphate compound prepared by the method of claim 13 .

22. A method of making an amorphous zirconium phosphate compound comprising forming an acidic phosphorous and sulfate containing reagent from a phosphorous containing component selected from the group consisting of phosphoric acid, a mono-hydrogen phosphate of an alkali metal, a mono-hydrogen phosphate of ammonia and mixtures thereof, and a sulfate containing component selected from the group consisting of sulfuric acid, a sulfate of an alkali metal, a sulfate of ammonia and mixtures thereof, mixing a water insoluble zirconium compound with an aqueous solution of said acidic phosphorous and sulfate containing reagent comprising phosuhoric acid and sulfuric acid in a molar ratio of 0.25-2.0:1 to produce a reaction mixture having a phosphorous to zirconium ratio of from about 2.0-2.5:1 and reacting said mixture at a temperature and time effective to produce said amorphous zirconium phosphate compound.

23. A method according to claim 22 comprising forming said acidic phosphorous and sulfate containing reagent at a pH of less than about 4.

24. A method according to claim 22 wherein said acidic phosphorous and sulfate containing reagent comprises phosphoric acid and sulfuric acid.

25. A method according to claim 22 wherein said temperature is from about 80° C. to boiling point.

26. A method according to claim 25 comprising reacting said mixture at said temperature for said time of from about 1 to about 3 hours.

27. An amorphous zirconium phosphate compound prepared by the method of claim 22 .

28. An amorphous zirconium phosphate compound having an H-form that exhibits a peak at −13.7±0.5 ppm in the 31 P NMR spectra.

29. A compound according to claim 28 which exhibits an affinity for Co +2 ions characterized by Kd≧500 mL/g at LOD 18%, based on a simulant solution of 0.5 M NaNO 3 +0.001 M Co(NO 3 ) 2 +0.001 M Ni(NO3) 2 .

30. A compound according to claim 29 wherein said affinity for Co +2 ions is characterized by Kd<1000 mL/g at said LOD and based on said simulant solution.

31. A compound according to claim 28 which exhibits an affinity for Ni +2 ions characterized by Kd≧400 mL/g at LOD 18%, based on a simulant solution of 0.5 M NaNO 3 +0.001 M Co(NO 3 ) 2 0.001 M Ni(NO 3 ) 2 .

32. A compound according to claim 31 wherein said affinity for Ni +2 ions is characterized by Kd≧800 mL/g at said LOD and based on said simulant solution.

33. A method of removing Co +2 ions from a fluid comprising contacting said fluid with a zirconium phosphate compound according to claim 28 .

34. A method of removing Ni +2 ions from a fluid comprising contacting said fluid with a zirconium phosphate compound according to claim 28 .

35. An amorphous zirconium phosphate compound having the formula Zr(HPO 4 ) 2 .nMe x O.mH 2 O, wherein n=0-1.2, m=0.5-3.0, x 0.5-1 and Me is selected from the group consisting of NH 4, Li, Na, K, Cs, Mg, Ca, Sr and Ba which exhibits an affinity for Co +2 ions characterized by Kd≧500 mL/g at LOD 18%, based on a simulant solution of 0.5 M NaNO 3 +0.00 1 M Co(NO 3 ) 2 +0.001 M Ni(NO 3 ) 2 .

36. A compound according to claim 35 wherein said affinity far Co +2 ions is characterized by Kd≧1000 mL/g at said LOD and based on said simulant solution.

37. An amorphous zirconium phosphate compound having the formula Zr(HPO 4 ) 2 .nMe x O.mH 2 O, wherein n=0-1.2, m=0.5-3.0, x=0.5-1 and Me is selected from the group consisting of NH 4, Li, Na, K, Cs, Mg, Ca, Sr and Ba which exhibits an affinity for Ni +2 ions characterized by Kd≧400 mL/g at LOD 18%, based on a simulant solution of 0.5 M NaNO 3 +0.00 1 M Co(NO 3 ) 2 +0.001 M Ni(NO 3 ) 2 .

38. A compound according to claim 37 wherein said affinity for Ni +2 ions is characterized by Kd≧800 mL/g at said LOD and based on said simulant solution.