ITQ-27 Microporous Material for Hydrocarbon Conversion
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Solution Overview
Problem
There is a need for new microporous framework structures with unique properties to enhance the performance of hydrocarbon processes, as existing materials like faujasite, mordenite, and ZSM-5 have limitations in catalytic performance and pore dimensions.
Innovation Solution
The development of a new crystalline microporous material, ITQ-27, with a tetrahedral atom framework, which is stable to calcination, absorbs hydrocarbons, and exhibits catalytic activity for hydrocarbon conversion, featuring a unique diffraction pattern and a composition of mR:aX2O3:YO2.nH2O, where R is an organic compound and X includes metals capable of tetrahedral coordination, synthesized by mixing silica, an organic structure directing agent, and optional metal under controlled heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing microporous materials like faujasite, mordenite, and ZSM-5 are used, then they provide known catalytic activity and pore structure, but they have limitations in catalytic performance and pore dimensions that prevent optimization for new hydrocarbon processes
Solution Approach 1:
The patent changes the fundamental parameters of pore dimension and framework structure by introducing a new crystalline microporous material (ITQ-27) with unique 2-dimensional channel systems and specific pore sizes (e.g., 7.4 Å × 7.1 Å) that differ from conventional materials. This allows optimization for specific hydrocarbon conversion processes while maintaining catalytic activity.
Solution Approach 2:
The invention creates a composite microporous material combining specific metal elements (Al, P, Si, and optional metals like B, Ga, Fe, Li, Be, Zn, Cr, Mg, Co, Ni, Mn, As, In, Sn, Sb, Ti, Zr) in a unique framework structure. This composite approach enables tailored catalytic properties and pore characteristics that neither component alone could achieve.
2Reliability
If a new crystalline microporous material with unique framework structure is synthesized, then improved catalytic performance and separation capabilities are achieved, but the synthesis process requires controlled heating and specific composition ratios
Solution Approach 1:
The synthesis process utilizes controlled parameter changes (temperature, time, composition ratios) to achieve crystallization of the new microporous material. By optimizing these parameters, the material achieves desired catalytic properties while maintaining a manageable synthesis process.
Solution Approach 2:
The patent employs an organic structure directing agent (SDA) as an intermediary during synthesis. This SDA template guides the formation of the unique framework structure and pore architecture, enabling controlled crystallization and simplifying the synthesis process by providing a directional template for material formation.
3Productivity
If the material is subjected to calcination to remove organic compounds, then hydrocarbon absorption and catalytic activity are enhanced, but crystallinity must be maintained to preserve structural integrity
Solution Approach 1:
The calcination process, which could potentially damage the framework, is converted into a beneficial treatment that removes organic SDA templates and activates the material's catalytic sites. The unique framework structure of ITQ-27 is designed to withstand this thermal treatment while maintaining crystallinity, transforming a potentially harmful process into a beneficial activation step.
Solution Approach 2:
The material's crystallinity and structural stability are preserved through controlled calcination parameters (temperature, atmosphere, duration). By optimizing these parameters, the organic content is removed and catalytic activity is enhanced while the framework structure remains intact, maintaining crystallinity and structural integrity.
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
ITQ-27 demonstrates improved catalytic performance and hydrocarbon separation capabilities, offering a unique 2-dimensional channel system and high acid activity, making it suitable for various hydrocarbon conversion processes without losing crystallinity upon calcination.
Implementation Method 1
ITQ-27 is stable to calcination in air, absorbs hydrocarbons, and is catalytically active for hydrocarbon conversion
Implementation Method 2
ITQ-27 is stable to calcination in air... The invention also includes the use of ITQ-27 as a hydrocarbon conversion catalyst
Data Source
AI summary
ITQ-27 (INSTITUTO DE TECNOLOGÍA QUÍMICA number 27) is a new crystalline microporous material with a framework of tetrahedral atoms connected by atoms capable of bridging the tetrahedral atoms, the tetrahedral atom framework being defined by the interconnections between the tetrahedrally coordinated atoms in its framework. ITQ-27 can be prepared in silicate compositions with a organic structure directing agent. It has a unique X-ray diffraction pattern, which identifies it as a new material. ITQ-27 is stable to calcination in air, absorbs hydrocarbons, and is catalytically active for hydrocarbon conversion.