CHA-AFT Zeolite Intergrowth Synthesis for Catalytic Stability
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Solution Overview
Problem
There is a need for the synthesis of new zeolitic materials with improved properties, particularly in the field of heterogeneous catalysis, as existing materials may have limitations in stability and performance in catalytic reactions such as methanol to olefin conversion.
Innovation Solution
A process for synthesizing zeolitic materials comprising one or more zeolite intergrowth phases of zeolites with CHA-type and AFT-type framework structures, specifically COE-10, through an organotemplate-free method involving the steaming of zeolitic materials to enhance catalytic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing zeolitic materials are used in heterogeneous catalysis, then catalytic activity is achieved, but stability and performance in catalytic reactions (such as methanol to olefin conversion) are limited
Solution Approach 1:
The patent applies composite materials by creating zeolitic intergrowth phases that combine multiple framework structures (CHA-type and AFT-type) within a single material system. This composite structure allows the material to exhibit both the catalytic activity needed for methanol to olefin conversion and the stability required for sustained performance, resolving the contradiction between reliability and productivity in catalytic applications
2Productivity
If conventional zeolite synthesis methods are used, then production is achieved, but the materials lack improved catalytic properties and extended time on stream
Solution Approach 1:
The patent employs parameter changes by modifying the synthesis conditions and thermal treatment parameters to achieve the formation of zeolitic intergrowth phases with enhanced catalytic properties. By controlling parameters such as temperature, time, and chemical composition during synthesis and steaming processes, the material achieves both extended time on stream and improved catalytic performance, simultaneously addressing productivity and reliability
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 synthesized zeolitic materials exhibit excellent catalytic properties, particularly in extending the time on stream in methanol to olefin (MTO) processes, indicating improved stability and performance compared to traditional materials.
Implementation Method 1
subjecting the zeolitic material obtained in (2) to a procedure for removing at least a portion of X, preferably tetrahedrally coordinated X, from the framework structure of the zeolitic material
Data Source
AI summary
A process for the production of a zeolitic material comprising one or more zeolite intergrowth phases of one or more zeolites having a CHA-type framework structure comprising SiO2 and X2O3, and one or more zeolites having an AFT-type framework structure comprising SiO2 and X2O3, wherein X is a trivalent element, and wherein said process comprises:(1) preparing a mixture comprising one or more sources for SiO2, one or more sources for X2O3, and seed crystals comprising a zeolitic material, said zeolitic material comprising SiO2 and X2O3 in its framework structure and having a CHA-type framework structure;(2) heating the mixture prepared in (1) for obtaining a zeolitic material comprising one or more zeolite intergrowth phases; and(R) subjecting the zeolitic material obtained in (2) to a procedure for removing at least a portion of X from the framework structure of the zeolitic material.