USY Seed Crystal Zeolite Membrane for Solvent Water Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional FAU zeolite separation membranes are ineffective in separating water from organic solvent mixtures, necessitating a process that can achieve satisfactory separation performance.
Innovation Solution
A process involving a porous alumina support with USY zeolite crystals attached as seed crystals, followed by hydrothermal synthesis to form a dense FAU zeolite layer with a high Si/Al ratio, ensuring effective separation of organic solvent and water mixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional FAU zeolite crystals (NaY or NaX) with Si/Al ratio less than 3 are used as seed crystals, then the hydrothermal synthesis can proceed, but the Si/Al ratio in the reaction solution changes near the porous support surface, preventing formation of zeolite layer with desired compositional ratio
Solution Approach 1:
The patent changes the key parameter of the seed crystals by selecting USY zeolite crystals with Si/Al ratio of 3 or greater, rather than conventional NaY or NaX crystals with Si/Al ratio less than 3. This parameter change ensures that during hydrothermal synthesis, both aluminum from the porous support and silicon from the seed crystals elute into the reaction solution, maintaining a relatively constant Si/Al ratio and enabling formation of zeolite layer with desired compositional ratio
Solution Approach 2:
The USY zeolite crystals serve as an intermediary that mediates the interaction between the porous support and the reaction solution. By having Si/Al ratio of 3 or greater, these seed crystals control the elution of aluminum and silicon into the reaction solution, acting as a buffer that maintains compositional stability during the hydrothermal synthesis process
2Reliability
If conventional processes are used to produce FAU zeolite separation membranes, then the membranes can be manufactured, but they are not capable of satisfactorily separating water from organic solvent mixtures
Solution Approach 1:
The patent achieves satisfactory separation performance by changing the Si/Al ratio parameter of the seed crystals to 3 or greater. This parameter change results in formation of a dense zeolite layer with high crystallinity and uniform composition, which provides the necessary separation performance for water-organic solvent mixtures while maintaining a relatively simple hydrothermal synthesis process
3Manufacturing precision
If a dense zeolite layer with high crystallinity is formed, then separation performance improves, but the process requires precise control of Si/Al ratio in reaction solution
Solution Approach 1:
The patent simplifies process control by changing the Si/Al ratio of seed crystals to 3 or greater. This single parameter change simultaneously achieves dense zeolite layer formation with high crystallinity while maintaining constant Si/Al ratio in the reaction solution, reducing the need for complex process control measures
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 resulting FAU zeolite separation membrane exhibits high separation performance, durability, heat resistance, and resistance to acid and water contamination, enabling efficient separation of liquid mixtures at elevated temperatures and high water proportions.
Implementation Method 1
the porous support is contacted with a reaction solution containing silicon and aluminum, and the reaction solution is heated to form a crude product of the zeolite separation membrane
Implementation Method 2
a seed crystal-attaching step in which USY zeolite crystals are attached as seed crystals to the surface of, and inside the pores of, the porous support
Implementation Method 3
FAU zeolite separation membranes...can be used for separation of a mixture of different organic solvents
Implementation Method 4
separation of water from a mixture of organic solvent and water
Data Source
AI summary
A process for producing a zeolite separation membrane having a porous support containing alumina as a main component and, provided on a surface and within pores of the porous support, a zeolite layer, comprising the seed crystal adhering step of adhering USY zeolite crystal as a seed crystal on a surface and within pores of the porous support; the basis material forming step of bringing a reactant liquid containing silicon and aluminum into contact with the porous support and heating the reactant liquid to thereby obtain a zeolite separation membrane basis material; and the basis material separating step of separating the zeolite separation membrane basis material from the reactant liquid to thereby obtain a zeolite separation membrane. By this process for producing a zeolite separation membrane, there can be produced an FAU zeolite separation membrane capable of satisfactory separation of a mixture of organic solvent and water.