Faujasite Zeolite Synthesis Using ODSO to Raise Zeolite Y Yield
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Solution Overview
Problem
There is a need for improved methods to produce zeolite materials, particularly using disulfide oil (DSO) by-products in an economically and environmentally friendly manner, as existing methods face challenges in efficiently treating large volumes of DSO by-products and their derivatives for disposal and utilization.
Innovation Solution
A method involving the use of water-soluble oxidized disulfide oil (ODSO) as an additional component in the synthesis of faujasite zeolites, such as zeolite Y, by forming a homogeneous aqueous mixture with silica, aluminum, and an alkali metal source, and heating under specific conditions to enhance zeolite yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional zeolite synthesis methods are used, then the synthesis process is simple, but the zeolite yield is lower and DSO by-products cannot be utilized
Solution Approach 1:
The patent converts DSO by-products, which are harmful waste materials requiring disposal, into beneficial components of the zeolite synthesis process. By oxidizing DSO to ODSO and using it as an additive in the synthesis gel, the process transforms a environmental liability into a value-added ingredient that enhances zeolite yield and provides sulfur doping benefits.
Solution Approach 2:
The patent modifies the synthesis gel composition by introducing ODSO at controlled concentrations (0.1-5 wt% of total gel mass) and adjusting its oxidation state. This parameter change enables the system to achieve higher zeolite yields while maintaining processability and crystallization behavior.
2Loss of substance
If DSO by-products are disposed of through conventional methods, then disposal is achieved, but economic value is lost and environmental impact remains
Solution Approach 1:
Instead of disposing of DSO through incineration or landfill, the patent oxidizes it to ODSO and incorporates it into the zeolite synthesis gel. This converts a waste disposal problem into a value-creation opportunity, where the by-product becomes a functional component that enhances zeolite performance through sulfur doping and structural modification.
Solution Approach 2:
The zeolite synthesis process itself serves the dual function of producing zeolite while simultaneously consuming and utilizing DSO by-products. The system is self-sufficient in terms of sulfur content, as the ODSO derived from DSO provides the necessary sulfur for sulfur-doped zeolite synthesis, eliminating the need for external sulfur sources.
3Productivity
If water-soluble ODSO is added to the synthesis mixture, then zeolite yield increases, but the synthesis process becomes more complex
Solution Approach 1:
The patent optimizes the concentration of water-soluble ODSO in the synthesis gel to specific ranges (0.1-5 wt% of total gel mass) to maximize zeolite yield while avoiding excessive complexity. This parameter optimization ensures that the additive enhances crystallization without causing uncontrolled side reactions or requiring complex process controls.
Solution Approach 2:
Water-soluble ODSO acts as an intermediary substance that facilitates the formation of zeolite crystals by modifying the gel structure and providing sulfur sources. It mediates between the inorganic precursors and the final zeolite product, enabling higher yields through improved crystallization kinetics and phase 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 method increases the overall zeolite yield by 0.5-15% compared to conventional synthesis, providing a more efficient and cost-effective process for producing faujasite zeolites using refinery waste streams, thereby enhancing the value of DSO by-products.
Implementation Method 1
heating the homogeneous aqueous mixture under conditions and for a time effective to form a precipitate suspended in a supernatant as an intermediate suspension, wherein the precipitate comprises faujasite zeolite
Implementation Method 2
The by-product DSO compounds from the mercaptan oxidation process can be oxidized, preferably in the presence of a catalyst. The oxidation reaction products constitute an abundant source of ODSO compounds, sulfoxides, sulfonates, sulfinates and sulfones.
Data Source
AI summary
The present disclosure is directed to a method of manufacture of faujasite zeolite including zeolite Y. A sol-gel formulation includes a water-soluble fraction of ODSO as an additional component. The resulting products include faujasite zeolite, and yields can be increased relative to comparable sol-gel formulations without ODSO.