Multi-Reactor Zeolite Synthesis for Controlled Particle Size
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Solution Overview
Problem
Current zeolite synthesis processes struggle to produce zeolite crystals with controlled, modulated, and reproducible multimodal particle size distributions, particularly between tens of nanometers and tens of micrometers, which is essential for various industrial applications requiring specific compactness and density characteristics.
Innovation Solution
The process involves producing zeolite crystals of different particle sizes in parallel synthesis reactors and mixing the reaction media from these reactors in specific proportions during or at the end of the crystallization reaction to achieve a stable and homogeneous multimodal particle size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical mixtures of dry powders with different crystal sizes are produced, then zeolite crystals of different sizes can be obtained, but homogeneous mixing is very difficult and the particle size distribution cannot be well controlled
Solution Approach 1:
The patent uses liquid suspension as an intermediary medium to facilitate mixing of crystals of different sizes. Instead of directly mixing dry powders which segregate due to size differences, the crystals are suspended in liquid where they can be homogeneously distributed before being introduced to the reaction medium, thus achieving controlled multimodal particle size distribution
Solution Approach 2:
The patent changes the physical state of the crystal mixture from dry powder to liquid suspension. This parameter change enables effective mixing by utilizing fluid dynamics and suspension stability, allowing crystals of different sizes to remain homogeneously distributed throughout the liquid medium during the mixing process
2Adaptability or versatility
If batch syntheses are performed to achieve identical particle size characteristics, then monomodal distributions can be obtained, but reproduction of several identical successive syntheses is difficult and multimodal distributions cannot be achieved
Solution Approach 1:
The patent segments the synthesis process into multiple parallel reactors, each producing crystals of a specific size range under optimized conditions. By dividing the overall synthesis into separate segments (different reactors with different parameters), the system can reliably produce consistent monomodal distributions from each reactor and combine them to achieve controlled multimodal distributions
Solution Approach 2:
The patent creates a universal process that can produce both monomodal and multimodal particle size distributions using the same overall methodology. The multi-functional system can adjust the number of reactors and their operating parameters to achieve either single-mode or multi-mode crystal size distributions as needed
3Adaptability or versatility
If conventional batch reactors are used for zeolite synthesis, then the process is simple to operate, but it is difficult to obtain zeolites with modulated and reproducible multimodal particle size distributions
Solution Approach 1:
The conventional single batch reactor is segmented into multiple parallel reactors, each optimized for producing crystals of a specific size range. This segmentation allows independent control of synthesis parameters in each reactor while maintaining the simplicity of batch operation, enabling the production of multimodal particle size distributions through controlled combination of outputs from different segments
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 allows for the reproducible and economical industrial production of zeolite crystals with adjustable and modulated multimodal particle size distributions, enhancing their compactness and adsorption performance, suitable for diverse applications such as gas and liquid separation and purification.
Implementation Method 1
carrying out a crystallization reaction, in parallel, in each of the at least two reactors
Data Source
AI summary
The present invention relates to a process for preparing zeolite crystals having a multimodal particle size distribution, and the sizes of which are between 0.02 μm and 20 μm, said process comprising feeding at least two reactors each with a synthesis gel capable of forming zeolite crystals, carrying out a crystallization reaction, in parallel, in each of the at least two reactors, and mixing the reaction media of the at least two reactors, after the start of at least one of the crystallization reactions.