Mesostructured Zeolite Synthesis via Surfactant Mediation
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Solution Overview
Problem
Existing mesostructured zeolitic materials lack long-range crystallinity, resulting in weaker acidity and lower catalytic activity compared to zeolites, and previous attempts have been ineffective in synthesizing zeolite single crystals with ordered mesoporosity due to surface tension issues.
Innovation Solution
A method involving adding a zeolite to a pH-controlled medium with a surfactant, followed by hydrothermal treatment and calcination, to create fully crystalline mesostructured zeolites with controlled mesopore arrangements, such as hexagonal, cubic, or lamellar structures, which maintain zeolitic crystallinity and enhance catalytic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If MCM-41-type materials are used to provide mesopores, then pore size is improved (2-10 nm), but crystallinity and acidity are lost
Solution Approach 1:
The patent merges the mesoporous structure of MCM-41 with the crystalline framework of zeolites to create a hybrid material that possesses both large mesopores (2-10 nm) and long-range crystalline order. This combination allows the material to maintain zeolitic crystallinity and acidity while providing the beneficial mesopore size for enhanced mass transport.
Solution Approach 2:
The invention creates a composite material integrating zeolite nanocrystals within an ordered mesoporous matrix. The zeolite component provides crystallinity, acidity, and hydrothermal stability, while the mesoporous structure provides large pore openings. This composite approach resolves the contradiction by combining materials with complementary properties.
2Shape
If zeolite nanoclusters are aggregated to form mesoporous structures, then mesoporosity is achieved, but long-range crystallinity is lost
Solution Approach 1:
The patent introduces long-range order in the mesoscale dimension while maintaining nanoscale zeolite crystallinity. The zeolite nanoclusters are arranged in an ordered three-dimensional mesoporous framework, creating hierarchy from nanoscale (zeolite crystals) to microscale (mesoporous structure), thus achieving both mesoporosity and long-range crystallinity.
3Ease of manufacture
If surface tension is not addressed during synthesis, then synthesis is simpler, but zeolite single crystals with ordered mesoporosity cannot form
Solution Approach 1:
The patent uses surfactants as intermediary agents during synthesis to mediate the assembly of zeolite nanoclusters into ordered mesoporous single crystals. The surfactants reduce surface tension and guide the self-assembly process, enabling the formation of well-defined mesoporous structures with long-range order while maintaining synthesis feasibility.
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 approach results in zeolites with improved acidity and catalytic activity, specifically increasing gasoline production and light olefin yield in Fluid Catalytic Cracking Units, while maintaining the structural integrity of zeolites with controlled mesoporosity.
Implementation Method 1
a method involving adding a zeolite to a pH-controlled medium with a surfactant, followed by hydrothermal treatment and calcination, to create fully crystalline mesostructured zeolites with controlled mesopore arrangements
Implementation Method 2
exposing a solution of one or more inorganic compounds to a basic medium under a first set of time and temperature conditions to form a fully crystalline inorganic material
Implementation Method 3
previous attempts have been ineffective in synthesizing zeolite single crystals with ordered mesoporosity due to surface tension issues
Data Source
AI summary
One aspect of the present invention relates to mesostructured zeolites. The invention also relates to a method of preparing mesostructured zeolites, as well as using them as cracking catalysts for organic compounds and degradation catalysts for polymers.