ODSO Co-Synthesis of Zeolite and Amorphous Binder Phases
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Solution Overview
Problem
There is a need for an efficient and economical process to treat large volumes of disulfide oil (DSO) by-products and their derivatives to facilitate environmentally acceptable disposal and enhance their value, particularly in the context of zeolite catalyst production.
Innovation Solution
A method is developed to co-synthesize amorphous and crystalline materials using a homogeneous aqueous mixture that includes water-soluble oxidized disulfide oil (ODSO) as a component, which forms a precipitate comprising both phases under controlled heating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If DSO by-products are disposed of through traditional methods (incineration, landfill), then environmental compliance is achieved, but resource waste occurs and disposal costs increase
Solution Approach 1:
The patent converts the harmful DSO by-product into a beneficial synthesis reagent. ODSO is used as a sulfur source and structure-directing agent in zeolite synthesis, transforming a waste disposal problem into a value-added material production process. This eliminates the need for separate disposal operations while recovering valuable materials.
Solution Approach 2:
Instead of discarding DSO through incineration or landfill, the patent recovers and utilizes ODSO in the zeolite synthesis process. The sulfur-containing compounds are recovered and incorporated into the catalyst structure, achieving both waste reduction and resource recovery simultaneously.
2Productivity
If separate synthesis processes are used for crystalline zeolite and amorphous binder, then process control is simplified, but production time and energy consumption increase
Solution Approach 1:
The patent merges the synthesis of crystalline zeolite and amorphous binder into a single co-synthesis process. Both materials are formed simultaneously in one reactor using the same ODSO-containing gel, eliminating the need for separate synthesis steps and reducing overall production time and energy consumption.
Solution Approach 2:
The ODSO-containing gel serves multiple functions simultaneously: it acts as a sulfur source, a structure-directing agent for crystalline zeolite formation, and a precursor for amorphous binder formation. This multi-functionality enables co-synthesis of both materials in a single process step.
3Strength
If traditional binder materials are used separately, then catalyst formulation flexibility is maintained, but adhesion and mechanical strength are insufficient
Solution Approach 1:
The patent creates a composite catalyst structure where crystalline zeolite and amorphous binder are co-synthesized in intimate contact. The amorphous material formed from ODSO serves as an effective binder that provides strong adhesion and mechanical strength while maintaining the catalytic functionality of the zeolite component.
Solution Approach 2:
The ODSO-containing gel is prepared in advance with the appropriate composition and structure to simultaneously generate both crystalline and amorphous phases upon heating. This preliminary preparation ensures that the binder and catalyst are formed together with optimal adhesion properties from the start.
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 enhances the efficiency of catalyst production by incorporating ODSO into the synthesis process, allowing for the production of tailored amorphous and crystalline materials, thereby improving the handling and utilization of DSO by-products.
Implementation Method 1
heating the homogeneous aqueous mixture under conditions and for a time effective to form a precipitate suspended in a supernatant as an intermediate suspension, wherein the precipitate comprises crystalline material and amorphous material
Implementation Method 2
forming a precipitate comprising crystalline material and amorphous material
Data Source
AI summary
The present disclosure is directed to a method to co-synthesize amorphous and crystalline porous materials, including a phase of crystalline solids possessing well-defined structures and uniform pore sizes, and an amorphous phase. A sol-gel formulation which includes a water-soluble fraction of ODSO as an additional component is provided that precipitates multiple solid phases.