SSZ-41 Synthesis Using FAU Zeolite Precursor
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Solution Overview
Problem
Current methods for synthesizing zincoaluminosilicate molecular sieve SSZ-41 are limited in achieving high aluminum content and efficient catalytic properties, particularly in hydrocarbon conversion reactions.
Innovation Solution
A method involving a reaction mixture with a combined source of silicon oxide and aluminum oxide from a FAU framework type zeolite, zinc, a Group 1 or Group 2 metal, 1,1'-(1,4-butanediyl)bis-4-aza-1-azoniabicyclo[2.2.2]octane dication as a structure directing agent, hydroxide ions, and water, subjected to crystallization conditions to form crystals of the molecular sieve, which can include seeds and specific molar ratios to enhance crystal formation and catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional synthesis methods using separate silicon and aluminum sources are used, then the synthesis process is straightforward, but the aluminum content in the resulting SSZ-41 molecular sieve is limited and catalytic properties are insufficient
Solution Approach 1:
The patent combines separate silicon and aluminum sources into a single aluminosilicate precursor material that contains both elements in a predetermined ratio. This precursor is then used in the synthesis reaction mixture along with zinc salt and structure-directing agent to produce SSZ-41 molecular sieve with high aluminum content (Si/Al ratio of 3-10), thereby improving catalytic properties while simplifying the manufacturing process.
2Reliability
If high aluminum content is achieved in SSZ-41, then catalytic performance in hydrocarbon conversion is improved, but the synthesis requires specific combined sources of silicon and aluminum oxide
Solution Approach 1:
The patent prepares the aluminosilicate precursor material in advance with the desired silicon-to-aluminum ratio before using it in the SSZ-41 synthesis. This preliminary preparation ensures that the correct stoichiometry is achieved, leading to consistent high aluminum content in the final product and reliable catalytic performance in hydrocarbon conversion reactions.
3Quantity of substance
If argon adsorption capacity is increased, then the molecular sieve performance is enhanced, but conventional methods cannot achieve the required aluminum incorporation
Solution Approach 1:
The patent changes the silicon-to-aluminum ratio parameter in the aluminosilicate precursor to achieve high aluminum content (Si/Al ratio of 3-10) in the SSZ-41 molecular sieve. This parameter optimization directly increases argon adsorption capacity (up to three times that of VPI-8) while maintaining precise control over aluminum incorporation through the controlled synthesis conditions.
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 method effectively synthesizes zincoaluminosilicate SSZ-41 with high aluminum content, demonstrating improved argon adsorption capacity and catalytic performance in hydrocarbon conversion processes, such as selective hydroconversion of n-decane, with enhanced aluminum incorporation and catalytic activity.
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
a combined source of silicon oxide and aluminum oxide which is a FAU framework type zeolite
Data Source
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AI summary
A method is disclosed for synthesizing zincoaluminosilicate molecular sieve SSZ-41 having high aluminum content from a combined source of silicon oxide and aluminum oxide selected from one or more a FAU framework type zeolite and a colloidal aluminosilicate.