Zeolite Beta Synthesis Using PDADMA Template

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Solution Overview

Problem

The synthesis of zeolite beta with a composite pore structure is complex and costly due to the need for combined organic templates, limiting its industrial feasibility, and existing methods do not efficiently produce zeolites with improved mass transfer efficiency and catalytic activity for hydrocarbon conversions.

Innovation Solution

A method using polymeric compound PDADMA as the sole template for hydrothermal synthesis of zeolite beta, with specific molar ratios and processing conditions, simplifies the synthesis and reduces costs while maintaining improved porosity and catalytic activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If combined organic templates (TEAOH and polyquaternium-6) are used to synthesize zeolite beta with composite pore structure, then the zeolite achieves improved mass transfer efficiency and catalytic activity, but the synthesis process becomes complex and costly

Engineering Contradiction:

Improvecatalytic activityVSAvoidsynthesis process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of two separate templates (TEAOH for micropores and polyquaternium-6 for mesopores) into a single polymeric template PDADMA that can direct the formation of both microporous and mesoporous structures simultaneously. This consolidation simplifies the synthesis process while maintaining the composite pore structure necessary for high catalytic activity and mass transfer efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

PDADMA serves multiple functions: it acts as both the micropore template and mesopore template, provides structural direction for zeolite beta formation, and enables cost-effective synthesis. This multi-functional template replaces the need for multiple specialized templates, reducing process complexity while achieving the desired composite pore structure

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If combined organic templates are used to form both microporosity and mesoporosity, then zeolite beta with composite pore structure is achieved, but the cost of synthesis increases

Engineering Contradiction:

Improvecomposite pore structureVSAvoidsynthesis cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent employs PDADMA, a cost-effective polymeric template, to replace expensive commercial templates like TEAOH. PDADMA can be readily synthesized or obtained at lower cost, and its temporary role during synthesis (as a sacrificial template removed during calcination) aligns with the principle of using economical disposable materials to achieve the desired structural outcome

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If combined templates are used for synthesis, then mesoporosity and microporosity are both formed, but the synthesis procedure becomes complicated requiring precise template matching

Engineering Contradiction:

Improvepore structure controlVSAvoidsynthesis procedure simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent utilizes the ability of PDADMA to self-adjust and form different pore structures by changing synthesis parameters such as pH, temperature, and aging time. The polymeric template's conformation and pore-forming capability respond to these parameter changes, enabling control over both microporous and mesoporous structure formation through a single template system rather than requiring precise matching of multiple templates

Inventive Principle:

Principle #35Parameter changes

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 results in zeolite beta with enhanced BET surface area, pore volume, and hydrothermal stability, making it suitable for extensive industrial applications, particularly in hydrocarbon conversion catalysts, achieving higher catalytic activity and conversion efficiency compared to conventional zeolites.

Implementation Method 1

A method using polymeric compound PDADMA as the sole template for hydrothermal synthesis of zeolite beta

Methodology Applied

Scientific EffectHydrothermal synthesis:

Implementation Method 2

using polymeric compound PDADMA as the sole template for hydrothermal synthesis of zeolite beta, with specific molar ratios and processing conditions

Methodology Applied

Scientific EffectTemplating effect:

Implementation Method 3

zeolite beta has varied pore structure and improved porosity as well as varied mass transfer ability and catalytic activity

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 4

zeolite beta has improved mass transfer efficiency and catalytic activity for hydrocarbon conversions

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentEP2928827B1Process for preparing zeolite beta

Publication Date: 2019.02.20 SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ BV

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AI summary

Method for preparing zeolite beta which method comprises crystallization of zeolite beta from a solution comprising a template, a silicon source and an aluminum source in which the template is polymeric compound comprising ionizable polydiallyldimethylammonium (PDADMA) cationcrystallization. Furthermore, the present invention provides the use of thus prepared zeolite beta in catalysts for hydrocarbon conversions.