Tunable Mesoporous BEA Zeolite Synthesis via Dual Organosilane Templates
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Solution Overview
Problem
Existing methods for producing mesoporous zeolites are limited by the need for specific organosilane templates to achieve desired pore width distributions, restricting the range of mesopore sizes that can be achieved and limiting catalytic activity.
Innovation Solution
A method involving a combination of two or more distinct organosilane mesopore templates, with varying ratios, to produce mesoporous zeolites with tunable pore widths, allowing for a continuous range of mesopore sizes and enhanced catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single organosilane template is used to functionalize the growing seed crystal, then the zeolite structure is simplified and easier to manufacture, but the range of achievable pore width distributions is limited to specific values corresponding to each template
Solution Approach 1:
The patent combines multiple distinct organosilane templates (specifically Template A and Template B) in the zeolite precursor solution to achieve a continuous range of pore width distributions. By merging the functions of different templates, the invention overcomes the limitation of single templates that can only produce discrete pore sizes, enabling tunable mesopore structures with center of pore width distribution ranging from 24 Å to 48 Å.
Solution Approach 2:
The invention changes the parameter of template composition by using varying ratios of different organosilane templates. By adjusting the molar ratio of Template A to Template B (from 100:0 to 0:100 and intermediate ratios), the center of pore width distribution can be continuously tuned across a wide range, transforming the discrete pore size limitation into a continuous可调 parameter.
2Adaptability or versatility
If multiple distinct organosilane templates are combined in varying ratios, then the range of achievable mesopore sizes expands to a continuous spectrum, but the complexity of the synthesis process increases
Solution Approach 1:
The patent employs two distinct organosilane templates (Template A and Template B) that serve multiple functions: Template A produces mesopores with center of pore width distribution of 24 Å, Template B produces 48 Å mesopores, and their combinations continuously tune the pore size. This multi-functionality allows a single synthesis system to achieve a continuous range of pore sizes without requiring separate synthesis protocols for each pore size.
Solution Approach 2:
The invention simplifies the management of multiple templates by systematically varying their molar ratios as a controlled parameter. The synthesis process manages complexity by establishing clear relationships between template ratios and resulting pore sizes, making the tunable system predictable and controllable despite using multiple templates.
3Adaptability or versatility
If a single organosilane template is used, then the catalytic activity is limited to specific hydrocarbon feeds or desired products, but the catalyst design and selection process is simpler
Solution Approach 1:
The patent establishes a direct relationship between template composition parameters and catalytic performance by enabling continuous tuning of pore width distribution. This allows catalysts to be optimized for different hydrocarbon cracking applications by adjusting the Template A:Template B ratio, creating a systematic approach to catalyst design that balances versatility with manageable complexity.
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 enables the production of mesoporous zeolites with a center of pore width distribution that can be tailored to any value within a continuous spectrum, optimizing catalytic activity and expanding the range of achievable mesopore sizes without the need for multiple templates.
Implementation Method 1
mixing a silicon-containing material, an aluminum-containing material, and at least a quaternary amine to produce a zeolite precursor solution, wherein the quaternary amine comprises tetraethylammonium hydroxide
Implementation Method 2
pre-crystallizing the zeolite precursor solution at a pre-crystallization temperature of greater than 125 °C and autogenous pressure to form a pre-crystallized zeolite precursor solution
Implementation Method 3
combining two or more distinct organosilane mesopore templates with the pre-crystallized zeolite precursor solution to produce a zeolite precursor gel
Implementation Method 4
crystallizing the zeolite precursor gel to produce a crystalline zeolite intermediate
Implementation Method 5
calcining the crystalline zeolite intermediate to produce the mesoporous zeolite
Data Source
Figure 1~2B
Figure 3~4
Figure 5A~5C
AI summary
Methods of forming mesoporous zeolites with tunable pore widths are provided. In some embodiments, the method includes mixing a silicon-containing material, an aluminum-containing material, and at least a quaternary amine to produce a zeolite precursor solution. The zeolite precursor solution is pre-crystallized at a pre-crystallization temperature of greater than 125°C and autogenous pressure to form a pre-crystallized zeolite precursor solution and combined with two or more distinct organosilane mesopore templates to produce a zeolite precursor gel. The zeolite precursor gel is crystallized to produce a crystalline zeolite intermediate and the crystalline zeolite intermediate is calcined to produce the mesoporous zeolite.