Co-crystallized MFI/MOR Zeolite Synthesis Using ODSO
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Solution Overview
Problem
There is a need for an efficient and economical method to treat large volumes of disulfide oil (DSO) by-products and their derivatives to modify their properties for environmentally acceptable disposal and to enhance their value to refiners.
Innovation Solution
A method for preparing co-crystallized MFI/MOR zeolites by forming a homogeneous aqueous mixture of a silica source, an aluminum source, an alkali metal source, a structure directing agent, and an effective amount of water-soluble oxidized disulfide oil (ODSO), and then heating the mixture to form a crystalline zeolite precipitate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional zeolite synthesis methods are used, then zeolite products can be manufactured, but the yield is limited and disposal of DSO by-products remains problematic
Solution Approach 1:
The patent converts DSO (disulfide oil), a harmful by-product from mercaptan oxidation, into a useful component for zeolite synthesis. By oxidizing DSO to form ODSO (oxidized disulfide oil), the method transforms this waste substance into a structure-directing agent that enhances zeolite yield and enables co-crystallization of MFI/MOR frameworks, thereby eliminating the disposal problem while improving productivity
Solution Approach 2:
The patent changes the chemical parameters of the synthesis system by introducing ODSO derived from DSO oxidation. This parameter change (adding oxidized disulfide oil to the synthesis mixture) fundamentally alters the crystallization process, enabling co-crystallization of pentasil zeolite with MFI framework and zeolite mordenite with MOR framework, thereby increasing zeolite yield and product quality
2Object-affected harmful factors
If DSO by-products are disposed of conventionally, then disposal requirements are met, but environmental impact and economic value are compromised
Solution Approach 1:
The patent transforms DSO from a harmful environmental pollutant into a valuable chemical reagent. By oxidizing DSO to ODSO and using it as a structure-directing agent in zeolite synthesis, the method eliminates the need for conventional disposal methods, thereby reducing environmental impact while creating economic value through zeolite production
Solution Approach 2:
The patent enables the DSO by-product stream to serve itself by converting it into a useful synthesis component. The ODSO derived from DSO automatically directs the formation of desired zeolite frameworks, eliminating the need for separate disposal operations and integrating the waste management function into the productive synthesis process
3Adaptability or versatility
If single zeolite framework synthesis is used, then specific application requirements are met, but versatility and co-crystallization options are limited
Solution Approach 1:
The patent creates a universal synthesis system where ODSO serves multiple functions: it acts as a structure-directing agent, a template for framework formation, and a controller for co-crystallization. This multi-functional approach enables the simultaneous production of different zeolite frameworks (MFI and MOR) from a single synthesis mixture, thereby increasing versatility without requiring multiple separate synthesis processes
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 method increases the yield of zeolite products and allows for the co-crystallization of pentasil zeolite with a MFI framework and zeolite mordenite with a MOR framework, effectively utilizing DSO by-products in an economically and environmentally friendly manner.
Implementation Method 1
heating the homogeneous aqueous mixture under conditions and for a time effective to form a crystalline zeolite as precipitate suspended in a supernatant
Implementation Method 2
forming a homogeneous aqueous mixture of a silica source, an aluminum source, an alkali metal source, a structure directing agent, and an effective amount of water-soluble oxidized disulfide oil (ODSO)
Data Source
AI summary
The present disclosure is directed to a method of manufacture of co-crystallized pentasil zeolite and zeolite mordenite (hereinafter “MFI/MOR zeolites”). This is accomplished by using an improved sol-gel formulation including a water-soluble fraction of ODSO as an additional component. The resulting products are, or contain, co-crystallized MFI/MOR zeolites, whereas in the absence of the ODSO, the resulting products are analcime, typically considered a zeolite impurity.