Faujasite Y Zeolite Modification via Polyol Hydrothermal Treatment
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Solution Overview
Problem
Current methods for modifying Faujasite Y-type zeolites to reduce sodium content and enhance mesoporous properties for use in the Fluid Catalytic Cracking (FCC) process are inefficient, requiring multiple stages and leading to partial destruction of the crystalline structure and increased manufacturing costs.
Innovation Solution
A single-stage process involving the use of a short-chain polyol like glycerol and ammonium salts, followed by hydrothermal treatment and thermal treatment, to produce a modified Faujasite Y-type zeolite with reduced sodium content and associated mesoporous material, achieving a bimodal or multimodal pore size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple successive washing and thermal treatment stages are used to reduce sodium content and create mesoporous structure, then the zeolite can be modified for FCC catalyst use, but the manufacturing process becomes complex and costly, and the crystalline structure is partially destroyed
Solution Approach 1:
The patent combines multiple separate modification stages (washing with ammonia solutions, thermal treatment, dealumination) into a single hydrothermal treatment stage using ammonium salts in polyol solution. This single stage simultaneously achieves sodium removal, mesoporous structure creation, and crystalline structure preservation, resolving the contradiction between process complexity and modification effectiveness.
Solution Approach 2:
The patent uses polyols (glycerol, ethylene glycol) as structure-directing agents before the hydrothermal treatment. These polyols pre-organize the zeolite surface and control the formation of mesoporous structures during the subsequent treatment, ensuring that the desired pore structure forms while maintaining crystalline integrity, thus avoiding the need for multiple corrective stages.
2Quantity of substance
If traditional multi-stage modification methods are used, then sodium content can be reduced, but the process requires successive operations resulting in high manufacturing costs
Solution Approach 1:
The patent merges sodium removal, dealumination, and mesoporous structure formation into a single hydrothermal treatment step using ammonium salts in polyol solution. This eliminates the need for successive washing and thermal treatment stages, significantly reducing manufacturing complexity and cost while achieving the same sodium content reduction.
Solution Approach 2:
The patent changes the chemical parameters of the treatment medium by using polyols (glycerol, ethylene glycol) as solvents instead of water, and ammonium salts instead of ammonia solutions. This parameter change enables simultaneous achievement of sodium removal, aluminum extraction, and mesoporous structure formation in one step, reducing the number of operations and associated costs.
3Stability of the object's composition
If conventional modification treatments are applied, then zeolite can be stabilized, but these treatments frequently produce partial destruction of the crystalline structure thus reducing the intracrystalline zeolite area
Solution Approach 1:
The patent introduces polyols (glycerol, ethylene glycol) as intermediary substances that mediate between the ammonium salts and the zeolite structure during hydrothermal treatment. These polyols act as structure-directing agents that protect the crystalline framework while allowing controlled removal of sodium and aluminum, preventing partial destruction of the crystalline structure that occurs in conventional treatments.
Solution Approach 2:
The patent changes the physical-chemical parameters of the treatment environment by using polyol solutions instead of aqueous solutions, and by controlling pH and temperature within specific ranges. These parameter changes create milder treatment conditions that stabilize the crystalline structure while still achieving the desired sodium removal and mesoporous structure formation.
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 process effectively reduces sodium content by up to 75% and creates a mesoporous material with controlled pore size distribution, enhancing the zeolite's stability and catalytic properties while simplifying the manufacturing process and reducing costs.
Implementation Method 1
The presence of aluminum with tetrahedral coordination generates an excess of negative charge in the structure, which is neutralized by the presence of cations (called compensation cations) commonly alkyl or alkyl earth cations, which are interchangeable.
Implementation Method 2
subjecting the mixture to hydrothermal treatment at 95-250° C., for from 5 to 40 hours
Implementation Method 3
submitting the dried solid to a thermal treatment at 350 to 550° C., for 2 to 8 hours to obtain a product comprising a modified Faujasite Y-type zeolite
Data Source
AI summary
The present invention relates to a process for modifying the physical and chemical properties of Faujasite Y-type zeolites (FAU), mainly used as a base material of catalyst used in the Fluid Catalytic Cracking (FCC) process, for the interest of the oil refining industry, in which the conversion of oil heavy fractions into lighter fractions, with a higher commercial value, is carried out. The process produces a modified Faujasite Y-type zeolite, with lower sodium content, as low as 75%, than that of the starting Faujasite Y-type zeolite. A mesoporous material associated with the modified Faujasite Y-type zeolite has an average pore size ranging from 2 to 100 nm, having a bimodal or multimodal pore size distribution. The proportion of modified Faujasite Y-type zeolite with respect to the meso-porous material associated to the Faujasite Y type Zeolite can be regulated through the process operation conditions.