TON Molecular Sieve Synthesis for Small Crystals and Faster Crystallization
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Solution Overview
Problem
Existing methods for synthesizing TON framework type molecular sieves are complex and time-consuming, limiting the production of molecular sieves with unique morphologies and physico-chemical properties, and the ability to produce small crystal sizes.
Innovation Solution
A method involving a reaction mixture with 1,3,4-trimethylimidazolium cations, alumina-coated silica, aluminosilicate zeolites, and seeds of TON framework type molecular sieves, subjected to crystallization conditions with specific molar ratios and thermal treatment to form TON-type molecular sieves with controlled crystal size and morphology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional synthesis methods are used for TON framework type molecular sieves, then the molecular sieves can be produced, but the synthesis process is complex and time-consuming
Solution Approach 1:
The patent changes the chemical composition parameters of the reaction mixture by introducing 1,3,4-trimethylimidazolium cations as a structure-directing agent and using specific aluminosilicate starting materials. This parameter change transforms the synthesis process into a simpler, faster procedure that produces TON-type molecular sieves with unique morphologies and small crystal sizes, directly resolving the contradiction between productivity and process complexity
Solution Approach 2:
The patent uses 1,3,4-trimethylimidazolium cations as an intermediary structure-directing agent that mediates the formation of TON framework type molecular sieves. This intermediary substance guides the self-assembly of the molecular sieve structure, enabling the synthesis to proceed under simpler conditions with shorter heating periods while maintaining high productivity
2Shape
If conventional synthesis methods are used, then molecular sieves can be produced, but they lack unique morphologies and small crystal sizes
Solution Approach 1:
The patent incorporates seeds comprising TON framework type molecular sieve into the reaction mixture before crystallization. This preliminary action provides nucleation sites that guide the growth of new crystals, enabling the formation of small crystal sizes and unique morphologies while significantly reducing the crystallization time required
Solution Approach 2:
By adjusting the composition parameters including the use of 1,3,4-trimethylimidazolium cations, water content, and heating conditions, the patent achieves control over crystal growth kinetics. This enables the production of TON-type molecular sieves with unique morphologies and small crystal sizes in shorter crystallization periods, resolving the contradiction between shape control and time loss
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 enables the synthesis of TON-type molecular sieves with improved selectivity and reduced crystallization time, allowing for the production of small crystal sizes and unique morphologies, enhancing their catalytic performance in hydrocarbon conversion processes.
Implementation Method 1
subjecting the reaction mixture to crystallization conditions sufficient to form crystals of the molecular sieve
Data Source
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AI summary
A method is disclosed making a molecular of TON framework type having unique properties. The method uses 1,3,4-trimethylimidazolium cations as a structure directing agent and a combined source of silicon and aluminum selected from alumina-coated silica and aluminosilicate zeolites. The obtained molecular sieve can be used in processes for dewaxing paraffinic hydrocarbon feedstocks.