Ultrasmall MTT Molecular Sieve Crystallization Without Liquid Phase
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Solution Overview
Problem
Conventional methods for producing molecular sieves with the MTT framework topology often require excessive water, leading to the formation of a separate liquid phase and additional processing steps, which complicates the crystallization process and increases the need for water removal post-crystallization.
Innovation Solution
A method involving a reaction mixture with a controlled water content, specifically a mole ratio of H2O/YO2 between 1.9 to 5.0, is used to crystallize molecular sieves with MTT framework topology, allowing crystallization in the absence of an external liquid phase and minimizing water usage, thereby avoiding the need for separate liquid phase removal and maintaining a self-supporting reaction mixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods use excessive water in the reaction mixture, then the molecular sieve can crystallize, but a separate liquid phase forms requiring additional processing steps and water removal
Solution Approach 1:
The patent applies parameter changes by precisely controlling the water content in the reaction mixture to a specific range (H2O/YO2 mole ratio of 1.9 to 5.0). This parameter optimization allows crystallization to proceed reliably while preventing excess water from forming a separate liquid phase, thereby eliminating the need for additional water removal steps and simplifying the overall process
Solution Approach 2:
The patent uses partial action by providing only the sufficient amount of water needed for crystallization rather than excessive water. The water content is carefully controlled to be not substantially in excess of what is required to cause and maintain crystallization, which prevents the formation of a separate liquid phase while still ensuring reliable crystallization occurs
2Reliability
If excessive water is used in the reaction mixture, then crystallization can proceed, but additional processing steps are required for water removal post-crystallization
Solution Approach 1:
The patent optimizes the water content parameter (H2O/YO2 mole ratio between 1.9 and 5.0) to achieve a balance where crystallization succeeds reliably without requiring subsequent water removal steps. This precise parameter control eliminates unnecessary processing steps and improves overall processing efficiency
Solution Approach 2:
The patent applies partial action by providing only the sufficient amount of water needed for crystallization rather than excessive water. This approach ensures crystallization proceeds successfully while avoiding the need for additional water removal operations, thereby improving productivity
3Reliability
If the reaction mixture contains sufficient water for crystallization, then the molecular sieve forms, but the mixture may collapse or melt under its own weight
Solution Approach 1:
The patent optimizes the water content parameter to a specific range (H2O/YO2 mole ratio of 1.9 to 5.0) that provides enough water for crystallization while maintaining the mixture's structural integrity. This precise parameter control prevents the mixture from collapsing or melting under its own weight
Solution Approach 2:
The patent uses partial action by providing only the sufficient amount of water needed for crystallization rather than excessive water. This controlled water content maintains the self-supporting nature of the reaction mixture while still enabling successful crystallization to occur
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
This approach enables the production of ultrasmall crystallites with sizes ranging from 150 to 600 Angstroms, reducing processing complexity and water usage while maintaining the integrity of the crystallized material, and accelerating the crystallization process.
Implementation Method 1
heating said reaction mixture at crystallization conditions and in the absence of an external liquid phase for sufficient time to form a crystallized material containing crystals of a molecular sieve having MTT framework topology
Data Source
AI summary
A method for preparing a crystalline molecular sieve having MTT framework topology and crystallite sizes of about 150 to about 600 Angstroms, comprising:a. preparing a reaction mixture comprising, in terms of mole ratios, the following.YO2/W2O330-40R+/YO20.06-0.12OH−/YO20.20-0.26K+/YO20.09-0.15and an amount of water not substantially in excess of the amount required to cause and maintain crystallization, wherein Y is silicon, germanium or mixtures thereof; W is aluminum, boron, gallium, iron or mixtures thereof; and R+ is a diisopropylimidazolium cation, andb. heating said reaction mixture at crystallization conditions and in the absence of an external liquid phase for sufficient time to form a crystallized material containing crystals of the molecular sieve.Also, a method to make the shaped ultrasmall crystal MTT molecular sieve, and a method to form the molecular sieve using a particular order of addition of components.