KL Zeolite Extrudates with High Mechanical Strength
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Solution Overview
Problem
Existing methods struggle to shape zeolitic materials with high KL zeolite content while maintaining good mechanical strength, as evidenced by the lack of data on mechanical strength in prior art patents.
Innovation Solution
A process involving shaping KL zeolite with a zeolitizable binder, followed by zeolitization in the presence of potassium hydroxide, to achieve extrudates, tablets, or beads with at least 90% KL zeolite and a mechanical crush strength of greater than or equal to 0.7 daN/mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If KL zeolite is shaped with high content (≥90%) using conventional methods, then the zeolite content is improved, but the mechanical strength deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the binder system. Specifically, it uses a binder containing both silica and alumina in controlled ratios, and introduces potassium hydroxide as a chemical modifier. These parameter changes enable the binder to undergo zeolitization and form a mechanically strong matrix that can support high KL zeolite content (≥90%) while maintaining structural integrity and mechanical strength ≥0.7 daN/mm.
Solution Approach 2:
The patent employs composite materials by creating a binder system that combines silica and alumina in specific proportions, and potentially includes other additives. This composite binder structure undergoes zeolitization to form a strong matrix material that works synergistically with the KL zeolite crystals, enabling the formulation of shaped materials with ≥90% KL zeolite content while achieving the required mechanical strength through the composite binder matrix.
2Ease of manufacture
If conventional binders are used for shaping, then the shaping process is simple, but the mechanical strength of the extrudates is insufficient
Solution Approach 1:
The patent transforms the binder system through parameter changes by introducing potassium hydroxide and controlling the silica-alumina ratio. These changes enable the binder to undergo chemical transformation (zeolitization) that significantly enhances mechanical strength while maintaining ease of shaping during the extrusion process. The modified binder parameters allow the extrudates to achieve ≥0.7 daN/mm strength after treatment.
Solution Approach 2:
The patent utilizes phase transitions by inducing zeolitization of the binder system through chemical and thermal treatment. The binder containing silica and alumina undergoes phase transformation in the presence of potassium hydroxide and heat, forming a zeolitic matrix structure. This phase transition creates a mechanically strong material that maintains the shaped form and achieves the required strength specifications.
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 successfully produces microporous zeolitic materials with high KL zeolite content and improved mechanical strength, suitable for use as catalyst supports, adsorbents, or separating agents.
Implementation Method 1
at least one stage of zeolitization of said shaped partially zeolitic material of stage i) by bringing into contact with water or with an aqueous potassium hydroxide solution in vapor or liquid form
Data Source
AI summary
The present invention relates to a method for the preparation of a microporous material shaped in the form of extrudates, tablets or beads having good mechanical crush strength and containing at least 90% by weight of KL zeolite (structural type LTL). This method comprises a stage of shaping a KL zeolite with at least one zeolitizable binder and at least one stage of zeolitization, in the presence of potassium hydroxide in one and/or the other of the stages, in order to obtain a material shaped in the form of extrudates, tablets or beads containing at least 90% by weight of KL zeolite and good mechanical crush strength.