SFE Molecular Sieve Crystallization via Parameter Optimization
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Solution Overview
Problem
The existing processes for producing molecular sieves with the SFE structure are inefficient, requiring long crystallization durations, high water and organic template consumption, and complex procedures, which lead to high energy consumption, production costs, and environmental impact.
Innovation Solution
A novel process involving the crystallization of a mixture containing a first oxide source, a second oxide source, an organic template, and water under specific conditions, significantly reducing crystallization duration, water usage, and organic template requirements, while allowing for direct production of hetero-atom containing molecular sieves with the SFE structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional crystallization processes are used to produce SFE structure molecular sieves, then the molecular sieve can be obtained with the desired structure, but the crystallization duration is excessively long (42-60 days)
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the crystallization system. Specifically, it uses a novel gel composition with SiO2/B2O3 ratio of 40-60 and incorporates specific amounts of aluminum oxide (0.5-5 wt%) and titanium oxide (0.1-1 wt%). These compositional parameter changes enable the crystallization to proceed much faster (1-7 days vs. 42-60 days) while maintaining the SFE structure integrity.
2Quantity of substance
If conventional processes are used, then molecular sieve production is achieved, but water consumption is excessively high
Solution Approach 1:
The patent reduces water consumption by optimizing the gel composition parameters. The crystallization is performed with water-to-silica ratio controlled at 20-40, which is significantly lower than conventional processes. This parameter optimization reduces the total water required while ensuring complete crystallization of the SFE structure molecular sieve.
3Quantity of substance
If conventional processes are used, then molecular sieve production is achieved, but organic template consumption is excessively high
Solution Approach 1:
The patent optimizes organic template consumption by adjusting the gel composition parameters. The specific SiO2/B2O3 ratio (40-60) and the controlled water-to-silica ratio (20-40) enable efficient template utilization. This results in reduced organic template consumption while maintaining high production efficiency and complete crystallization.
4Ease of manufacture
If conventional processes are used, then molecular sieve production is achieved, but the procedure is complex
Solution Approach 1:
The patent simplifies the manufacturing procedure by merging multiple steps into a single crystallization process. The novel gel composition allows simultaneous formation of the SFE structure with controlled incorporation of heteroatoms (Al, Ti), eliminating the need for separate synthesis and modification steps. This single-step process reduces procedure complexity while maintaining high production efficiency.
5Use of energy by moving object
If conventional processes are used, then molecular sieve production is achieved, but energy consumption is high
Solution Approach 1:
The patent reduces energy consumption by optimizing crystallization parameters. The controlled water-to-silica ratio (20-40) and temperature regime enable efficient crystallization at moderate temperatures over shorter periods (1-7 days). This parameter optimization reduces the total energy input required while maintaining high production efficiency.
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 process simplifies the production of molecular sieves with the SFE structure, reducing energy consumption, production costs, and environmental impact, while enabling faster and more efficient production of hetero-atom containing molecular sieves with improved efficiency and reduced waste.
Implementation Method 1
a step of crystallizing a mixture comprising a first oxide source, a second oxide source, an organic template and water to obtain a molecular sieve having the SFE structure
Data Source
Figure 1
AI summary
The present invention relates to a molecular sieve having the SFE structure, a process for producing same and use thereof. The process includes a step of crystallizing a mixture comprising a first oxide source, a second oxide source, an organic template and water to obtain a molecular sieve having the SFE structure, wherein the organic template is preferably 4-dimethylamino pyridine. As compared with the prior art, the process exhibits such merits as significantly reduced crystallization duration.