SSZ-105 Molecular Sieve Synthesis via ERI-LEV Intergrowth
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Solution Overview
Problem
There is a need for new molecular sieves with novel internal pore architectures to enhance selectivities in industrial processes such as gas separation and organic conversion reactions, as existing molecular sieves lack desirable properties for these applications.
Innovation Solution
A disordered aluminosilicate molecular sieve, SSZ-105, is developed by intergrowing phases of ERI and LEV framework types, using N,N-dimethylpiperidinium cations as a structure directing agent, and a specific reaction mixture composition, followed by calcination to remove the template, resulting in a material suitable for various industrial processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If new molecular sieves with novel internal pore architectures are developed, then selectivity in gas separation and organic conversion reactions is enhanced, but the complexity of the synthesis process increases
Solution Approach 1:
The patent creates a composite molecular sieve material SSZ-105 that combines ERI and LEV framework types in a disordered intergrowth structure. This composite approach enables the material to exhibit enhanced selectivity properties that are superior to individual framework types, while the use of a single structure-directing agent (N,N-dimethylpiperidinium cation) simplifies the synthesis process compared to attempting to create ordered intergrowths or multiple-phase mixtures
Solution Approach 2:
The patent achieves novel pore architectures by modifying the chemical composition parameters of the reaction mixture, specifically using a SiO2/Al2O3 ratio of 15-40 and incorporating N,N-dimethylpiperidinium cations at controlled concentrations. By adjusting these compositional parameters, the synthesis produces a disordered intergrowth structure with enhanced selectivity without requiring complex multi-step synthesis procedures
2Reliability
If disordered intergrowth structures are created from multiple framework types, then catalytic properties are significantly different and enhanced, but the manufacturing precision required to achieve the desired intergrowth increases
Solution Approach 1:
The patent uses N,N-dimethylpiperidinium cations as an intermediary structure-directing agent that mediates the formation of the disordered ERI/LEV intergrowth structure. This single intermediary component guides the self-assembly of the complex intergrowth architecture during crystallization, achieving the desired catalytic performance without requiring precise control over the relative amounts or sequences of individual framework types
Solution Approach 2:
The patent controls the intergrowth structure by optimizing reaction parameters including temperature (100-200°C), time (1-30 days), and chemical composition (SiO2/Al2O3 ratio of 15-40, metal cation ratios). These parameter adjustments enable the spontaneous formation of disordered intergrowths with enhanced catalytic properties without requiring high manufacturing precision for controlled phase mixing
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
SSZ-105 exhibits unique properties making it useful for separation processes and as a catalyst in organic conversion reactions, offering enhanced selectivities and performance compared to individual ERI and LEV framework materials.
Implementation Method 1
subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve
Implementation Method 2
Because the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions
Implementation Method 3
Molecular sieve materials, both natural and synthetic, have been demonstrated in the past to be useful as adsorbents and to have catalytic properties for various types of organic conversion reactions
Data Source
AI summary
A method for making a new crystalline molecular sieve designated SSZ-105 is disclosed. SSZ-105 is synthesized using N,N-dimethylpiperidinium cations as a structure directing agent. SSZ-105 is a disordered aluminosilicate molecular sieve comprising at least one intergrown phase of an ERI framework type molecular sieve and an LEV framework type molecular sieve.