Zeolite Beta Synthesis Using ODSO Waste Additive
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Solution Overview
Problem
There is a need for an efficient and economical method to produce zeolite beta using sulfur-containing refinery waste streams, specifically disulfide oil (DSO) by-products, in an environmentally friendly manner, as existing methods do not effectively utilize these by-products for zeolite synthesis.
Innovation Solution
A method involving the use of water-soluble oxidized disulfide oil (ODSO) as an additional component in a sol-gel formulation to enhance the synthesis of beta zeolites, where ODSO is derived from refinery waste streams, forming a homogeneous aqueous mixture with silica, aluminum, and alkali metal sources, and heating it under specific conditions to increase zeolite yield and modify properties for easier disposal and utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional zeolite synthesis methods are used without ODSO, then the synthesis process is simple, but the zeolite yield is lower and refinery waste cannot be utilized
Solution Approach 1:
The patent converts harmful refinery waste (disulfide oil) into a beneficial component that enhances zeolite synthesis. ODSO derived from DSO acts as a structure-directing agent and template, increasing zeolite beta yield by up to 14% while simultaneously solving the waste disposal problem. This transforms an environmental liability into a valuable synthetic additive.
Solution Approach 2:
The patent modifies the synthesis system by introducing ODSO at controlled concentrations (0.1-10 wt% of total gel composition) and adjusting related parameters such as silica-to-alkali metal ratio and water content. These parameter changes optimize crystal growth kinetics and thermodynamics, enabling higher yields without compromising zeolite structural quality.
2Quantity of substance
If ODSO is added to enhance zeolite yield, then zeolite beta yield increases by up to 14%, but the synthesis process becomes more complex
Solution Approach 1:
ODSO serves multiple functions simultaneously: it acts as a structure-directing agent, a template for crystal formation, and a yield-enhancing additive. This multi-functionality means that a single addition achieves multiple objectives (directing beta-phase formation, increasing yield, and utilizing waste), simplifying the overall process despite the added component.
Solution Approach 2:
ODSO acts as an intermediary substance that mediates between the inorganic precursors (silica, alumina, alkali metals) and the desired zeolite beta product. It facilitates the complex self-assembly process by providing a molecular template that guides crystal growth, making the synthesis more controllable and efficient.
3Object-generated harmful factors
If DSO is disposed of through conventional methods (fuel oil pool or hydrotreating), then disposal is achieved, but environmental impact remains and valuable material is lost
Solution Approach 1:
The patent transforms the harmful sulfur-containing waste stream (DSO) into a valuable synthetic additive (ODSO). Instead of disposing of DSO through conventional methods that merely transfer the problem, the process converts it into a functional component that enhances zeolite synthesis, thereby eliminating environmental harm and recovering valuable materials simultaneously.
Solution Approach 2:
The patent implements a recovery strategy where DSO that would otherwise be discarded is instead processed into ODSO and reused in zeolite synthesis. This closes the material loop, preventing loss of sulfur-containing compounds and converting waste into a resource that adds economic and environmental value to the refinery operation.
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 inclusion of ODSO in the synthesis process increases zeolite beta yield by up to 14% compared to conventional methods, allowing for the effective utilization of refinery waste and potentially reducing environmental impact by valorizing DSO by-products.
Implementation Method 1
heating the homogeneous aqueous mixture under conditions and for a time effective for hydrolysis and to form a crystalline zeolite as precipitate
Implementation Method 2
form a crystalline zeolite as precipitate suspended in a supernatant, wherein the precipitate contains beta zeolite
Data Source
AI summary
The present disclosure is directed to a method of manufacture of beta zeolites. This is accomplished by using an improved sol-gel formulation including a water-soluble fraction of ODSO as an additional component. The resulting products are, or contain, beta zeolites, with increased yield.