MWW Zeolite Precursor Nanoparticles Without Layer Condensation
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Solution Overview
Problem
Direct synthesis of zeolite nanoparticles, particularly MWW zeolites, is challenging due to the need for specialized additives and high reaction temperatures that lead to scalability issues, yield reductions, and unwanted crystallographic changes.
Innovation Solution
Formation of MWW zeolite precursor nanoparticles at lower temperatures (60°C or below) using an aqueous base to fragment parent zeolites without inducing condensation between stacked layers, followed by calcination to produce pristine zeolite nanoparticles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high reaction temperatures are used to synthesize zeolite nanoparticles, then catalytic activity is improved, but scalability deteriorates and yield reductions occur
Solution Approach 1:
The patent applies parameter changes by utilizing lower reaction temperatures (60°C or below) compared to conventional high-temperature synthesis methods. This temperature parameter change enables the formation of zeolite precursor nanoparticles while maintaining catalytic activity and improving scalability, thereby resolving the contradiction between catalytic performance and production feasibility.
Solution Approach 2:
The patent employs preliminary action by first forming zeolite precursor nanoparticles at low temperatures through base treatment, and only subsequently performing calcination to achieve the final catalytically active zeolite structure. This two-step approach with preliminary nanoparticle formation at mild conditions avoids the need for high-temperature direct synthesis, thus improving scalability while maintaining catalytic activity.
2Length of moving object
If high reaction temperatures are used to fragment parent zeolites into nanoparticles, then nanoparticle size is reduced, but unwanted crystallographic changes occur
Solution Approach 1:
The patent utilizes parameter changes by conducting the fragmentation process at low temperatures (60°C or below) rather than high temperatures. This temperature parameter change enables effective nanoparticle formation while preserving the original crystallographic structure of the zeolite precursor, preventing unwanted phase transformations and maintaining structural stability.
Solution Approach 2:
The patent replaces thermal fragmentation mechanisms with a chemical base treatment approach. Instead of using high-temperature thermal energy to break down parent zeolites, the invention employs aqueous base treatment at mild temperatures to achieve nanoparticle fragmentation, thereby avoiding thermal-induced crystallographic changes while still achieving the desired nanoparticle size reduction.
3Productivity
If specialized additives are used in direct synthesis of MWW zeolites, then synthesis efficiency is improved, but device complexity increases
Solution Approach 1:
The patent applies the taking out principle by removing specialized additives from the synthesis process. Instead of using complex polymer additives or multiple structure directing agents, the invention employs a simple aqueous base treatment approach that achieves nanoparticle formation without requiring these specialized substances, thereby simplifying the process while maintaining synthesis efficiency.
Solution Approach 2:
The patent utilizes cheap short-living objects by employing common aqueous bases (such as NaOH or KOH) as temporary treatment agents that can be easily removed through washing. These simple, inexpensive bases serve as effective agents for nanoparticle formation and can be completely removed from the final product, eliminating the need for complex, difficult-to-remove specialized additives and simplifying the overall process.
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 method allows for the production of more pristine MWW zeolites with improved catalytic activity and reduced side reactions, facilitating scalable and efficient catalytic processes such as aromatic alkylation.
Implementation Method 1
contacting the parent zeolite precursor with an aqueous base under temperature conditions sufficient to fragment the parent zeolite precursor into a plurality of zeolite precursor nanoparticles
Implementation Method 2
followed by calcination to produce pristine zeolite nanoparticles
Data Source
AI summary
Zeolite precursor nanoparticles may be formed by contacting a parent zeolite precursor, such as MCM-22 zeolite precursor, MCM-56 zeolite precursor, or EMM-10 zeolite precursor, with an aqueous base under temperature conditions at which adjacent stacked layers in the MWW zeolite framework do not undergo substantial condensation with one another. The zeolite precursor nanoparticles may be converted to zeolite nanoparticles following calcination. The zeolite nanoparticles may optionally be formed into an extrudate using a binder. Unbound or extrudate forms of the zeolite nanoparticles may be utilized to promote alkylation of C6+ aromatic compounds.