SCM-33 RTE Molecular Sieve Synthesis with Lower-Cost Templates
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Solution Overview
Problem
The existing synthesis of RUB-3 molecular sieve with RTE topology is costly due to the use of expensive organic templates, has a low crystal growth rate, requires a long synthesis period, and produces large crystals with limited catalytic active centers.
Innovation Solution
The SCM-33 molecular sieve is synthesized using a lower-cost organic template and a method that allows for introduction of elements like Al, Ti, Zr, and Fe into the framework, resulting in smaller crystals with catalytic active centers, and a significantly reduced synthesis time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conventional synthesis method using exo-2-aminobicyclo[2.2.1]heptane template is used, then the molecular sieve can be synthesized with RTE topology, but the synthesis cost is high due to expensive template and large template dosage
Solution Approach 1:
The patent replaces the expensive exo-2-aminobicyclo[2.2.1]heptane template with a cheaper alternative organic template, reducing both the cost per unit and the total dosage required for synthesis while maintaining the RTE topology structure
Solution Approach 2:
The patent modifies the synthesis parameters including template concentration, pH value, and reaction temperature to optimize the crystallization process, enabling cost-effective synthesis with reduced template dosage while achieving the desired molecular sieve structure
2Productivity
If the conventional synthesis method is used, then the molecular sieve can be obtained, but the crystal growth rate is low and the synthesis period is 90 days or more
Solution Approach 1:
The patent optimizes synthesis parameters including increasing reaction temperature, adjusting pH value, and modifying the ratio of reactants to accelerate crystal growth rate and reduce synthesis period from 90+ days to a shorter duration
Solution Approach 2:
The patent employs a seed crystal method or pre-nucleation step to initiate crystal formation earlier, thereby accelerating the overall crystal growth rate and reducing the total synthesis time required
3Length of stationary object
If the conventional synthesis method is used, then the molecular sieve can be synthesized, but the crystal size is large (50×50×150 μm) which is too large for certain applications
Solution Approach 1:
The patent divides the crystal growth process into multiple stages or uses seeded growth to produce smaller, more uniform crystals instead of allowing single large crystals to form, thereby reducing crystal size from 50×50×150 μm to a more suitable scale
Solution Approach 2:
The patent adjusts synthesis parameters such as decreasing the concentration of reactants, modifying pH, or controlling temperature profiles to limit crystal growth and produce smaller crystals while maintaining synthesis efficiency
4Adaptability or versatility
If a siliceous framework is used, then the molecular sieve structure is stable, but catalytic active centers can hardly be introduced
Solution Approach 1:
The patent introduces catalytic active centers at specific locations within the molecular sieve framework or on the surface through localized doping or post-synthesis modification, maintaining the overall framework stability while adding catalytic functionality where needed
Solution Approach 2:
The patent creates a composite structure by combining the siliceous framework with catalytically active materials or doping the framework with heteroatoms, thereby achieving both framework stability and enhanced catalytic activity in the resulting composite molecular sieve
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 SCM-33 molecular sieve offers a cost-effective, efficient synthesis process with shorter production times, enabling smaller crystal sizes and versatile catalytic applications by incorporating various elements into its framework.
Implementation Method 1
The SCM-33 molecular sieve is synthesized using a lower-cost organic template and a method that allows for introduction of elements like Al, Ti, Zr, and Fe into the framework
Implementation Method 2
elements other than Si can be introduced as catalytic active centers to the framework thereof
Data Source
AI summary
A SCM-33 molecular sieve has a schematic chemical composition as shown in the formula “SiO2·1/x XO1.5·m MO0.5”, wherein X is a framework trivalent element, the Si/X molar ratio x is ≥5, M is a framework equilibrium cation, and the M/Si molar ratio is 0<m≤1. The molecular sieve is a novel molecular sieve with RTE topology and the molecular sieve requires short preparation time, involves a low synthesis cost and can be used as adsorbent or catalyst.