Zeolite SSZ-52 Synthesis Cost Reduction via Alternative OSDAs
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Solution Overview
Problem
The commercial development of zeolite SSZ-52 is hindered by the high cost of the organic structure directing agent required for its synthesis, necessitating the search for alternative, less expensive structure directing agents.
Innovation Solution
A process for preparing zeolite SSZ-52 using a reaction mixture containing silicon, oxides of trivalent or pentavalent elements, an organic structure directing agent, an auxiliary structure directing agent such as N-cyclohexylmethyl-N-ethylpiperidinium cation, hydroxide ions, and water, subjected to crystallization conditions to form zeolite crystals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional organic structure directing agent (N,N-diethyl-5,8-dimethyl-azonium bicyclo[3.2.2.]nonane cation) is used for SSZ-52 synthesis, then the zeolite structure is successfully formed, but the synthesis cost becomes excessively high
Solution Approach 1:
The patent replaces the expensive conventional organic structure directing agent with cheaper alternative OSDAs such as N-ethyl-N-(2,4,4-trimethylcyclopentyl)pyrrolidinium cation or N-ethyl-N-(3,3,5-trimethylcycloheptyl)pyrrolidinium cation. These alternative OSDAs perform the same structural directing function but at significantly lower cost, enabling economical commercial production of SSZ-52 zeolite while maintaining the desired crystal structure and catalytic properties
Solution Approach 2:
The patent modifies the chemical structure parameters of the organic structure directing agent by changing the cationic core from azonium bicyclo[3.2.2.]nonane to pyrrolidinium or piperidinium derivatives with specific alkyl substituents. This parameter change in the OSDA molecular structure maintains its ability to direct SSZ-52 formation while reducing the overall cost of the synthesis process
2Ease of manufacture
If alternative less expensive structure directing agents are used, then the synthesis cost is reduced, but the ability to form the correct SSZ-52 structure may be compromised
Solution Approach 1:
The patent identifies alternative OSDAs that replicate the essential structural directing function of the conventional expensive agent. The N-ethyl-N-(2,4,4-trimethylcyclopentyl)pyrrolidinium and N-ethyl-N-(3,3,5-trimethylcycloheptyl)pyrrolidinium cations copy the key molecular features necessary for directing SSZ-52 formation, including the cationic nitrogen center and appropriate hydrophobic alkyl groups, thereby achieving the same structural outcome at lower cost
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 approach allows for the synthesis of zeolite SSZ-52 with a reduced cost, maintaining its structural integrity and catalytic properties, as evidenced by XRD patterns and SEM images, and demonstrating effective NO conversion capabilities.
Implementation Method 1
subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the zeolite
Data Source
AI summary
A method is disclosed for synthesizing zeolite SSZ-52 in the presence of an organic structure directing agent having the following structure (1):wherein R1, R2, R3 and R4 are independently selected from the group consisting of alkyl groups having from 1 to 3 carbon atoms and n has a value of 0, 1 or 2.