Mesoporous Zeolite Beta Calcination Without Crystallinity Loss
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Solution Overview
Problem
Conventional methods for producing nano-sized mesoporous zeolite Beta involve heating in air, which reduces crystallinity, leading to decreased efficiency in catalytic cracking processes.
Innovation Solution
A two-stage heating process is employed, first in an inert gas environment (99 mol.% or greater) followed by heating in an oxygen-rich environment, to preserve crystallinity and effectively remove organic templating agents without dealumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If heating in air is used to remove organic templating agents, then organic removal is achieved, but crystallinity is reduced
Solution Approach 1:
The patent applies inert atmosphere by conducting the heating treatment in nitrogen gas instead of air. This prevents oxidation reactions that would otherwise occur in air, thereby removing organic templating agents while preserving the crystalline structure of zeolite Beta. The inert nitrogen environment eliminates oxygen from the system, avoiding dealumination and crystallinity loss.
2Productivity
If heating temperature is increased to improve organic removal efficiency, then organic removal is enhanced, but crystallinity degradation increases
Solution Approach 1:
By using nitrogen atmosphere, the patent enables effective organic removal at lower temperatures compared to air heating. The inert environment prevents harmful oxidation reactions, allowing sufficient organic templating agent removal while maintaining crystallinity that would otherwise be degraded at equivalent temperatures in air.
3Loss of substance
If conventional calcination in air is performed, then organic removal is achieved, but dealumination occurs reducing catalytic activity
Solution Approach 1:
The patent uses nitrogen atmosphere to prevent dealumination of the zeolite framework during organic templating agent removal. By excluding oxygen, the inert atmosphere eliminates oxidation reactions that would remove aluminum from the framework, thereby preserving the catalytic active sites and maintaining high catalytic activity for heavy oil conversion.
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 maintains high crystallinity and enhances catalytic activity by preserving the zeolite's structure, allowing for efficient conversion of heavy oils with increased pore size and surface area.
Implementation Method 1
heating, in an environment comprising 99 mol. % or greater inert gas, a precursor nano-sized zeolite Beta to form an inert gas-treated nano-sized mesoporous zeolite Beta intermediate material
Implementation Method 2
heating, in an environment comprising 10 mol. % or greater oxygen gas, the inert gas-treated nano-sized mesoporous zeolite Beta intermediate material to form the nano-sized mesoporous zeolite Beta
Data Source
AI summary
A method for making nano-sized mesoporous zeolite Beta may include heating, in an environment including 99 mol. % or greater inert gas, a precursor nano-sized zeolite Beta to form an inert gas-treated nano-sized mesoporous zeolite Beta intermediate material. The inert gas may be chosen from nitrogen, helium, argon, or combinations thereof. The method may further include heating, in an environment including 10 mol. % or greater oxygen gas, the inert gas-treated nano-sized mesoporous zeolite Beta intermediate material to form the nano-sized mesoporous zeolite Beta.