MCM-22 Molecular Sieve Crystallization Control
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Solution Overview
Problem
There is a need for novel crystalline molecular sieve compositions and methods of making them, as existing materials' crystal morphology, size, and aggregation/agglomeration affect catalyst behavior, particularly regarding activity and stability.
Innovation Solution
A crystalline MCM-22 family molecular sieve with specific X-ray diffraction patterns and a method of making it involving a mixture with defined molar ratios of tetravalent and alkali or alkali earth metal elements, directing agents, and water, subjected to controlled crystallization conditions to produce a sieve with improved catalytic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional molecular sieve synthesis methods are used, then existing MCM-22 family materials can be produced, but the crystal morphology, size, and aggregation/agglomeration affect catalyst behavior, particularly regarding activity and stability
Solution Approach 1:
The patent applies parameter changes by modifying the synthesis conditions including temperature (100-250°C), time (1-400 hours), and stirring speed (150-5000 RPM) to control crystal morphology and prevent agglomeration. The molar ratios of reactants are also optimized to achieve desired crystal characteristics that improve catalyst stability while maintaining activity
Solution Approach 2:
The patent introduces dynamic control through variable stirring speeds (150-5000 RPM) during crystallization to prevent crystal aggregation and control morphology. This dynamic parameter allows adjustment during the synthesis process to optimize both crystal shape and catalytic performance
2Reliability
If conventional molecular sieve synthesis methods are used, then existing MCM-22 family materials can be produced, but the crystal morphology, size, and aggregation/agglomeration affect catalyst behavior, particularly regarding activity and stability
Solution Approach 1:
The patent uses parameter changes including temperature (100-250°C), time (1-400 hours), and molar ratios of reactants to precisely control crystal size and morphology. These parameter optimizations enable manufacturing of molecular sieves with specific size ranges that enhance catalytic activity while maintaining consistent quality
Solution Approach 2:
The patent implements dynamic control through variable stirring speeds (150-5000 RPM) and extended crystallization times (1-400 hours) to achieve precise crystal size control. This dynamic approach allows real-time adjustment to prevent aggregation and ensure uniform crystal dimensions for optimal catalytic performance
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 resulting molecular sieve exhibits enhanced catalytic activity and stability, with a distinct XRD pattern and morphology that distinguishes it from other MCM-22 family materials, making it suitable for hydrocarbon conversion processes.
Implementation Method 1
submitting the mixture at crystallization conditions to form a product comprising the desired crystalline molecular sieve
Implementation Method 2
a reaction mixture for hydrothermal reaction containing hexamethyleneimine, an organic compound which acts as directing agent for synthesis of the MCM-56
Implementation Method 3
Molecular sieve materials, both natural and synthetic, have been demonstrated in the past to have catalytic properties for various types of hydrocarbon conversion
Implementation Method 4
hexamethyleneimine, an organic compound which acts as directing agent for synthesis of the MCM-56
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
This disclosure relates to a crystalline MCM-22 family molecular sieve composition having, in its as-synthesized form, an X-ray diffraction pattern including a peak at d-spacing maximum of 12.33.fcO.23 Angstroms, a distinguishable peak at a d-spacing maximum between 12.57 to about 14.17 Angstroms and a non-discrete peak at a d-spacing maximum between 8.8 to 11. Angstroms, wherein the peak intensity of the d-spacing maximum between 12.57 to about 14.17 Angstroms is less than 90% of the peak intensity of the d-spacing maximum at 12.33±0.23 Angstroms. This disclosure also relates to methods of making the crystalline MCM-22 family molecular sieve composition.