Template-Free Zeolite Beta Synthesis for Acylation
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Solution Overview
Problem
Current methods for synthesizing zeolitic materials with a BEA framework structure rely on organic templates, which are costly and require calcination for removal, limiting the development of zeolites with improved catalytic properties for applications like acylation reactions.
Innovation Solution
A process involving the removal of tetrahedrally coordinated Al from zeolitic materials with a BEA framework structure using steam or calcination steps, without the need for organic templates, to produce novel zeolites with enhanced catalytic properties for acylation reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If organic templates are used in the synthesis of zeolitic materials with BEA framework structure, then the crystallization and framework formation are enabled, but the production cost increases and additional calcination steps are required for template removal
Solution Approach 1:
The invention extracts and eliminates the organic template component from the synthesis system, achieving template-free crystallization of zeolitic materials with BEA framework structure. This removes the need for costly templates and subsequent calcination steps while maintaining reliable framework formation through optimized inorganic composition and synthesis conditions.
Solution Approach 2:
The invention replaces expensive organic templates with inexpensive inorganic components that can be easily removed or remain as beneficial structural elements. The synthesis uses simple inorganic salts and hydroxides instead of costly organic structure-directing agents, eliminating the need for expensive template removal processes.
2Quantity of substance
If calcination is performed to remove organic templates, then template-free zeolite is obtained, but energy consumption increases and framework damage may occur
Solution Approach 1:
The invention extracts the need for calcination entirely by preventing organic template incorporation in the first place. The synthesis proceeds with inorganic components only, so no high-temperature treatment is required to remove organic residues, thereby eliminating the energy-intensive calcination step while still achieving template-free zeolite product.
Solution Approach 2:
The invention changes the synthesis parameters to exclude organic components entirely, using only inorganic precursors. This parameter change eliminates the need for subsequent calcination treatment, reducing energy consumption while maintaining product quality through optimized inorganic synthesis conditions.
3Manufacturing precision
If conventional synthesis methods are used, then zeolite Beta is produced, but the Si/Al ratio is limited and catalytic properties cannot be optimized
Solution Approach 1:
The invention changes the synthesis parameters by using inorganic templates and optimized molar ratios of inorganic precursors, enabling precise control over the Si/Al ratio. This allows production of zeolitic materials with tailored compositions (Si/Al ratios from 1 to 50) that optimize catalytic properties for specific applications while maintaining framework stability.
Solution Approach 2:
The invention creates composite zeolitic materials with controlled Si/Al ratios and potential heteroatom substitutions, enabling optimization of catalytic properties. The flexible composition control allows tailoring the material for specific catalytic applications while maintaining the BEA framework structure integrity.
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 process yields zeolites with improved catalytic activity and selectivity for acylation reactions, eliminating the need for costly template removal and allowing for the production of Al-rich zeolites with unprecedented Si/Al ratios.
Implementation Method 1
the procedure comprises one or more steam-treatment steps (S) conducted at a temperature of from 200 to 1000°C for a duration of from 0.1 to 48 h
Implementation Method 2
the procedure comprises one or more calcination steps (C) conducted at a temperature of from 450 to 800°C for a period ranging from 0.5 to 10 h
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
Provided is a process for the preparation of a zeolitic material having a BEA framework structure comprising the steps of: (i) providing one or more zeolitic materials having a BEA framework structure, wherein the BEA framework structure comprises Y02 and X2O3, wherein Y is a tetravalent element, and X is a trivalent element; (ii) subjecting the one or more zeolitic materials provided in step (i) to a procedure for removing at least a portion of X, preferably tetrahedrally coordinated X, from the BEA framework structure; wherein the Y:X molar ratios of the one or more zeolitic materials provided in step (i) are respectively comprised in the range of from 1 to 50.