CHA Framework Crystallization Using Water-Soluble ODSO for Lower SDA Use

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Solution Overview

Problem

The production of CHA framework crystalline materials is hindered by the high cost and limited availability of structure directing agents (SDAs), and there is a need for an efficient and economical method to utilize refinery by-products like oxidized disulfide oil (ODSO) to reduce SDA usage and enhance the value of these materials.

Innovation Solution

A method is developed to synthesize CHA framework crystalline materials using a water-soluble fraction of ODSO as an additional component in the sol-gel formulation, reducing the amount of structure directing agent required and increasing the yield of CHA framework crystalline materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If structure directing agents (SDAs) are used in typical synthesis techniques to form CHA framework crystalline materials, then the crystallization process can be achieved, but the manufacturing cost increases and availability becomes limited

Engineering Contradiction:

Improvecrystallization processVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Oxidized disulfide oil (ODSO) is introduced as an intermediary substance that mediates between the available refinery by-products and the CHA framework formation process. The ODSO acts as a bridging agent that enables crystallization while using cheaper, more available materials than traditional SDAs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The synthesis approach changes the chemical composition parameters of the reaction mixture by incorporating ODSO compounds (such as dimethyldisulfide, diethyldisulfide, and methylethyldisulfide) to replace or supplement conventional SDAs, thereby altering the cost and availability parameters while maintaining crystallization capability.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If higher content of structure directing agents is used in the reaction mixture, then the CHA framework crystalline material can be formed, but the manufacturing cost increases and handling of mother liquor becomes more difficult

Engineering Contradiction:

ImproveCHA framework formationVSAvoidhandling of mother liquor

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention converts the harmful or waste sulfur-containing by-products from the MEROX process into beneficial ODSO compounds that serve functional roles in the synthesis. What was previously waste material causing handling difficulties is now transformed into a useful reagent that reduces the need for expensive SDAs and simplifies mother liquor management.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The refinery's own sulfur-containing by-products from the MEROX process are utilized to serve the synthesis process, creating a self-sufficient system where waste materials from one process become resources for another, thereby reducing external dependencies and simplifying overall material handling.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If oxidized disulfide oil (ODSO) is used to reduce structure directing agent content, then manufacturing costs are lowered, but the synthesis process requires new formulation approaches

Engineering Contradiction:

Improvemanufacturing costVSAvoidsynthesis formulation

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The ODSO compounds serve multiple functions simultaneously: they act as structure-directing agents, modify the reaction medium properties, and utilize existing refinery by-products. This multi-functionality reduces the need for separate additives and simplifies the overall formulation despite the novel approach.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach allows for the production of CHA framework crystalline materials with reduced SDA usage and increased yield, utilizing refinery by-products like ODSO in an environmentally friendly manner, thereby lowering manufacturing costs and facilitating handling of sulfur-containing by-products.

Implementation Method 1

A method is developed to synthesize CHA framework crystalline materials using a water-soluble fraction of ODSO as an additional component in the sol-gel formulation

Methodology Applied

Scientific EffectSol-gel process: Sol

Implementation Method 2

The CHA framework crystalline material uptakes structure directing agent into pores of the CHA framework crystalline material during formation

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS12391561B2Method to lower structure directing agent content requirement for manufacture of crystalline material having a CHA framework

Publication Date: 2025.08.19 SAUDI ARABIAN OIL CO

AI summary

The present disclosure is directed to a method of manufacture of CHA framework crystalline materials of silica and a framework metal oxide, with the ability to reduce the amount of structure directing agent needed for synthesis. This is accomplished by using an improved sol-gel formulation including a water-soluble fraction of ODSO as an additional component. The resulting products include CHA framework crystalline materials of silica and a framework metal oxide, whereby a framework metal oxide can be an oxide of Al, Fe, B or Ga.