FER/MOR Composite Molecular Sieve Synthesis Without Organic Templates
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Solution Overview
Problem
The industrial synthesis of composite molecular sieves requires organic templates, increasing production costs and causing environmental pollution, and the catalytic activity of these sieves is heavily dependent on the ratio of their crystal phases, which can vary by reaction type.
Innovation Solution
A method for synthesizing FER/MOR composite molecular sieves without organic templates by adjusting the ratio of seed crystal phases and acidity/alkalinity in the synthesis system, using silicon and aluminum sources, and controlling the pH to produce a dual-phase sieve with adjustable crystalline properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic templates are used in the synthesis of FER/MOR composite molecular sieves, then the crystalline structure and phase ratio can be controlled, but production costs increase and environmental pollution occurs
Solution Approach 1:
The patent removes organic templates from the synthesis system entirely, replacing them with inorganic base catalysts (NaOH, KOH, Ca(OH)2). This extraction of the harmful organic component eliminates environmental pollution while maintaining control over crystalline phase formation through inorganic alternatives.
Solution Approach 2:
The patent changes the chemical parameters of the synthesis system by using inorganic bases with different strengths (NaOH, KOH, Ca(OH)2) and controlling pH levels (9-14) to achieve phase ratio control without organic templates. The base-to-silicon ratio is precisely controlled to direct crystallization toward desired phase compositions.
2Manufacturing precision
If organic templates are used in the synthesis of FER/MOR composite molecular sieves, then the crystalline structure can be controlled, but production costs increase
Solution Approach 1:
The patent extracts organic templates from the synthesis process and replaces them with inexpensive inorganic bases. This eliminates the need to purchase, handle, and remove expensive organic structure-directing agents, significantly reducing production costs while maintaining manufacturing precision through controlled base addition.
Solution Approach 2:
The patent uses cheap inorganic bases (NaOH, KOH, Ca(OH)2) that can be easily added and neutralized without requiring expensive recovery or disposal procedures. These inorganic catalysts are much more economical than organic templates and can be removed through simple washing and calcination.
3Adaptability or versatility
If different catalytic reactions are performed, then various optimum phase ratios are required, but adjusting the synthesis system becomes more complex
Solution Approach 1:
The patent creates a dynamic synthesis system where the base type and concentration can be adjusted to produce different phase ratios on demand. By varying the inorganic base (NaOH, KOH, Ca(OH)2) and their ratios, the system can be tuned for different catalytic applications without requiring completely different synthesis protocols.
Solution Approach 2:
The patent uses parameter changes in the inorganic base system (type of base, concentration, addition rate, pH level) to achieve different phase ratios suitable for various catalytic reactions. This provides versatility while maintaining relatively simple synthesis procedures compared to organic template systems.
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 method reduces manufacturing costs, eliminates environmental pollution, and allows for the production of sieves with controlled crystalline properties, enhancing their catalytic performance and versatility in applications like skeletal isomerization of butene.
Implementation Method 1
causing that reaction mixture to undergo a crystallization reaction, in order to obtain the FER/MOR composite molecular sieve
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
This application consists of a method for the synthesis of a type of FER/MOR composite molecular sieve. That method consisting of mixing FER seed crystals, MOR seed crystals, a silicon source, water and an acid or alkali, thus yielding a reaction mixture; by adjusting the proportions of the seed crystals added, the silicon-aluminium proportion, acidity/alkalinity and other reaction conditions, it is possible to obtain a dual phase composite molecular sieve within which the proportions of the crystal phases may be adjusted. In the synthesis process to which the method of this application relates, there is no need to add any organic template, thus reducing the cost of the reaction, in addition to reducing likely environmental pollution, thus having major potential applications.