Cubic Hierarchical Zeolites for Mesopore Ordering and Diffusion
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Solution Overview
Problem
Existing methods for producing hierarchically ordered zeolites lack control over the long-range ordering and size of mesopores, leading to poor interconnectivity and diffusion limitations, which hinder their performance in applications requiring larger species diffusion and are susceptible to coking.
Innovation Solution
A composition and method involving supramolecular templating with controlled base-mediated reassembly of zeolites, using supramolecular templates and ionic co-solutes to induce well-defined long-range mesoporous ordering of cubic symmetry, minimizing diffusion into micropores and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to produce hierarchically ordered zeolites, then mesopores can be formed, but long-range ordering and interconnectivity are poor due to lack of control
Solution Approach 1:
The patent applies parameter changes by precisely controlling pH levels and hydrothermal conditions during synthesis. By adjusting these parameters, the method achieves well-defined long-range mesoporous ordering with cubic symmetry while ensuring proper interconnectivity, resolving the contradiction between manufacturing precision and reliability.
Solution Approach 2:
The patent uses supramolecular templates as intermediaries to mediate the formation of mesopores. These templates direct the self-assembly process to create ordered cubic mesoporous structures with controlled interconnectivity, eliminating the randomness present in conventional methods and simultaneously improving both ordering precision and structural reliability.
2Length of moving object
If mesopore size is increased to accommodate larger species, then diffusion limitations are reduced, but control over size and ordering is lost
Solution Approach 1:
The patent employs parameter changes by adjusting pH and hydrothermal conditions to precisely control mesopore size while maintaining cubic symmetry and long-range ordering. This allows tailoring pore dimensions for specific applications without sacrificing the precision of size control or the overall structural order.
3Manufacturing precision
If base-mediated reassembly is used to improve ordering, then amorphization may occur, but controlled conditions minimize this effect
Solution Approach 1:
The patent carefully controls pH and hydrothermal parameters during base-mediated reassembly to achieve long-range mesoporous ordering while minimizing amorphization. By optimizing these conditions, the method preserves the crystalline nature of the zeolite framework while introducing ordered mesopores, thus maintaining compositional stability.
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 approach results in hierarchically ordered zeolites with improved mass transfer, reduced coke formation, and enhanced catalytic performance, particularly in hydrocracking processes, by ensuring well-defined mesoporous structures and cubic symmetry.
Implementation Method 1
base-mediated reassembly of zeolites using supramolecular templates and ionic co-solutes to induce well-defined long-range mesoporous ordering of cubic symmetry
Implementation Method 2
controlled by pH and hydrothermal conditions, minimizing amorphization and ensuring mesopores are constrained by template dimensions
Implementation Method 3
The approach results in hierarchically ordered zeolites with improved mass transfer
Implementation Method 4
enhanced catalytic performance, particularly in hydrocracking processes
Data Source
AI summary
A composition of matter is provided comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of cubic symmetry. The composition possesses mesopores having walls of crystalline microporous material and a mass of mesostructure between mesopores of crystalline microporous material. Long-range ordering is defined by presence of secondary peaks in an X-ray diffraction (XRD) pattern and/or cubic symmetry observable by microscopy.