EMM-10-P Molecular Sieve Morphology Control for Catalyst Stability
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Solution Overview
Problem
There is a need for novel crystalline molecular sieve compositions with specific morphologies and properties to enhance catalyst behavior and stability in hydrocarbon conversion processes, as existing molecular sieves may have limitations in crystal morphology, size, and aggregation/agglomeration affecting their activity and stability.
Innovation Solution
A crystalline molecular sieve, EMM-10-P, is developed, which is an MCM-22 family molecular sieve with a unique X-ray diffraction pattern and morphology, including tabular habit with specific crystal dimensions, and a method for its synthesis involving specific molar ratios of reactants and crystallization conditions to achieve enhanced surface area and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional molecular sieves are used, then catalytic activity is achieved, but crystal morphology and aggregation/agglomeration affect stability and performance
Solution Approach 1:
The patent changes the crystallization parameters including temperature (100-200°C), time (1-400 hours), and composition ratios (OH−:SiO2, M+:SiO2, R:SiO2) to control crystal morphology and prevent aggregation, thereby improving catalyst stability while maintaining activity
Solution Approach 2:
The patent uses organic directing agents (R) as intermediaries during synthesis to control crystal growth and morphology. These directing agents mediate the formation of EMM-10-P with specific tabular habits, preventing unwanted aggregation and improving catalyst performance
2Productivity
If molecular sieves with larger crystal size are used, then catalyst activity increases, but aggregation/agglomeration decreases stability
Solution Approach 1:
The patent optimizes crystallization temperature and time parameters to produce crystals of optimal size that maintain high catalytic activity while preventing aggregation. The specific parameter ranges (100-200°C, 1-400 hours) are tuned to achieve this balance
Solution Approach 2:
Organic directing agents serve as intermediaries that control crystal growth at the molecular level, enabling the formation of larger crystals with controlled morphology that do not aggregate, thus maintaining both activity and stability
3Manufacturing precision
If existing synthesis methods are used, then molecular sieve production is achieved, but specific morphology and surface area properties are not optimized
Solution Approach 1:
The patent establishes specific parameter ranges for synthesis (OH−:SiO2 ratio of 0.001-2, M+:SiO2 ratio of 0.001-2, R:SiO2 ratio of 0.001-2, temperature 100-200°C, time 1-400 hours) that achieve precise morphological control while remaining practically implementable
Solution Approach 2:
The patent achieves local quality control in crystal formation by using organic directing agents that selectively influence specific crystal faces and growth directions, producing tabular habits with controlled dimensions and high surface area while maintaining ease of manufacture
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 EMM-10-P molecular sieve exhibits a total surface area greater than 450 m2/g and a favorable ratio of external to total surface area, demonstrating improved catalyst activity and stability, particularly in hydrocarbon conversion processes.
Implementation Method 1
Molecular sieve materials, both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion. Certain molecular sieves, zeolites, AlPOs, mesoporous materials, are ordered, porous crystalline materials having a definite crystalline structure
Data Source
AI summary
This invention relates to a crystalline molecular sieve having, in its as-synthesized form, an X-ray diffraction pattern including d-spacing maxima at 13.18±0.25 and 12.33±0.23 Angstroms, wherein the peak intensity of the d-spacing maximum at 13.18±0.25 Angstroms is at least as great as 90% of the peak intensity of the d-spacing maximum at 12.33±0.23 Angstroms. This invention also relates to a method of making thereof.