Solvent-Free Interzeolitic Conversion of FAU to AEI Zeolite
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Solution Overview
Problem
Existing methods for synthesizing zeolitic materials with an AEI-type framework structure lack the ability to tailor physical and chemical properties, particularly for catalytic applications, leading to suboptimal performance and limited novel applications.
Innovation Solution
A solvent-free process involving a specific composition of reaction mixture and the use of cationic structure directing agents to convert a FAU-type zeolitic material into an AEI-type zeolitic material with enhanced aspect ratio and surface-to-volume ratio, thereby improving catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional synthesis methods are used to produce AEI-type zeolitic materials, then the framework structure can be obtained, but the catalytic activity and selectivity are suboptimal due to limited ability to tailor physical and chemical properties
Solution Approach 1:
The patent applies parameter changes by systematically varying synthesis conditions including SiO2/Al2O3 ratios, template structures, pH levels, and heating temperatures to optimize the physical and chemical properties of AEI-type zeolitic materials. This enables tailoring of framework density, pore size, and surface characteristics to enhance catalytic activity and selectivity for specific reactions such as methanol-to-olefin conversion
Solution Approach 2:
The patent employs composite materials by combining AEI-type zeolitic frameworks with various metal cations (Cu, Fe, Co, Ni) and organic templates to create multifunctional catalysts. These composite structures integrate the advantages of zeolite framework stability with metal catalytic sites and template-directed pore architecture, achieving superior catalytic performance that cannot be obtained with single-component materials
2Adaptability or versatility
If interzeolitic conversion is used to transform FAU-type zeolite to AEI-type zeolite, then novel framework structure can be obtained, but the process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-treating FAU-type zeolite with specific cationic templates and adjusting the chemical environment before initiating the interzeolitic conversion process. This pre-conditioning of the starting material facilitates the transformation to AEI-type structure, reducing the complexity of the conversion process and improving yield while enabling access to novel framework structures
3Ease of manufacture
If solvent-free conditions are applied in the synthesis process, then environmental benefits and simplified processing are achieved, but the control over reaction conditions is reduced
Solution Approach 1:
The patent applies self-service by utilizing the reactants and intermediates within the solvent-free system to self-regulate reaction conditions. The melting points and boiling points of the organic templates and reactants themselves serve as natural thermal regulators, while the inherent acidity and basicity of the components automatically balance the reaction environment, maintaining manufacturing precision without external solvent control
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 process results in zeolitic materials with significantly improved catalytic activity, particularly in the methanol to olefin reaction, achieving substantial selectivity improvements towards propylene due to optimized diffusion paths within the framework structure.
Implementation Method 1
the use of cationic structure directing agents to convert a FAU-type zeolitic material into an AEI-type zeolitic material
Implementation Method 2
heating the mixture obtained in (1) for obtaining a second zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein the second zeolitic material has an AEI-type framework structure
Implementation Method 3
achieving substantial selectivity improvements towards propylene due to optimized diffusion paths within the framework structure
Data Source
AI summary
The present disclosure relates to a process preparing a zeolitic material having an AEI-type framework structure, wherein the framework structure comprises SiO2 and X2O3 and X is a trivalent element, and wherein the process comprises:(1) preparing a mixture comprising one or more cationic structure directing agents comprising a heterocyclic amine ring, seed crystals, and a first zeolitic material comprising SiO2 and X2O3 in its framework structure and having an FAU-type framework structure; and(2) heating the mixture to obtain a second zeolitic material comprising SiO2 and X2O3 in its framework structure and having an AEI-type framework structure.