Al-SSZ-63 Zeolite Direct Synthesis Without Boron
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Solution Overview
Problem
There is a need for a direct and more economical method to prepare aluminosilicate SSZ-63 zeolite, as existing methods require boron and involve complex post-treatment processes, limiting its catalytic efficiency and industrial applicability.
Innovation Solution
A direct synthesis method using N-cyclodecyl-N-methyl-pyrrolidinium cation as a structure directing agent, involving sources of fumed silicon oxide and aluminum oxide, which eliminates the need for boron and simplifies the synthesis process, resulting in a more active and economically viable Al-SSZ-63 zeolite with unique morphology and catalytic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conventional method using boron and post-treatment is employed to prepare Al-SSZ-63, then the zeolite can be synthesized, but the process becomes complex and less economical
Solution Approach 1:
The invention extracts and eliminates boron from the synthesis system entirely. By using a direct aluminosilicate synthesis approach with N-cyclodecyl-N-methyl-pyrrolidinium cation as structure-directing agent, the complex post-treatment step required to replace boron with aluminum is removed, simplifying the overall manufacturing process
Solution Approach 2:
The invention performs preliminary action by directly incorporating aluminum into the zeolite framework during the initial synthesis step, rather than requiring a subsequent post-treatment step to introduce aluminum after boron-based synthesis. This preliminary incorporation of the correct elements eliminates unnecessary subsequent processing steps
2Reliability
If the conventional boron-based synthesis method is used, then SSZ-63 can be formed, but catalytic efficiency is limited
Solution Approach 1:
The invention changes the compositional parameter by using a SiO2/Al2O3 ratio greater than 15 in the direct synthesis gel, which is higher than conventional methods. This parameter change results in enhanced catalytic efficiency while maintaining structural integrity of the SSZ-63 zeolite framework
Solution Approach 2:
The invention achieves local quality by creating a more aluminum-deficient, silica-rich framework structure that provides optimal catalytic sites. The specific local arrangement of aluminum atoms in the framework, controlled by the direct synthesis method, enhances catalytic activity for hydrocarbon conversion reactions
3Ease of manufacture
If post-treatment with aluminum nitrate is performed to convert borosilicate to aluminosilicate, then Al-SSZ-63 is obtained, but the process becomes less economical
Solution Approach 1:
The invention merges the synthesis of the zeolite framework and the incorporation of aluminum into a single simultaneous process. By using aluminum oxide or aluminum hydroxide as starting materials in the gel preparation, the aluminum is incorporated during the primary crystallization step, eliminating the need for separate post-treatment operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The direct synthesis method produces Al-SSZ-63 with enhanced catalytic activity in hydroprocessing and unique morphology, offering improved catalytic performance and economic benefits by eliminating the need for boron and simplifying the synthesis process.
Implementation Method 1
Crystalline aluminosilicates are usually prepared from aqueous reaction mixtures containing alkali or alkaline earth metal oxides, silica, and alumina. By varying the synthesis conditions and the composition of the reaction mixture, different zeolites can often be formed.
Implementation Method 2
SSZ-63 is synthesized in U.S. Pat. No. 6,733,742 using 1-cyclodecyl-1-methylpyrrolidinium cation as the structure directing agent (SDA).
Implementation Method 3
the thus-prepared zeolite having the X-ray diffraction lines of Table IV. This thus-prepared molecular sieve is predominantly, i.e., mostly, in the hydrogen form, which hydrogen form is prepared by ion exchanging with an acid or with a solution of an ammonium salt followed by a second calcination.
Implementation Method 4
which hydrogen form is prepared by ion exchanging with an acid or with a solution of an ammonium salt followed by a second calcination.
Data Source
AI summary
Described herein is a new crystalline molecular sieve Al-SSZ-63 prepared by a direct synthesis. The synthesis uses N-cyclodecyl-N-methyl-pyrrolidinium cation as a structure-directing agent. A method for directly synthesizing the Al-SSZ-63 is also provided, as are processes employing the Al-SSZ-63 in a catalyst.