Accelerated Aluminosilicate Zeolite Crystallization via Segmented Addition
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Solution Overview
Problem
The standard industrial process for producing crystalline aluminosilicate zeolite materials is inefficient, requiring longer times to achieve similar properties, and there is a need for accelerated synthesis approaches that enhance throughput and efficiency.
Innovation Solution
The process involves adding an alumina source to a heated mixture comprising a silica source, a mineralizing agent, and an organic structure directing agent, with the alumina source being consumed during crystallization, often under elevated pressure, to achieve faster crystallization times while maintaining desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the standard industrial process is used to produce crystalline aluminosilicate zeolite materials, then the desired crystalline properties are achieved, but the production time is long and throughput is low
Solution Approach 1:
The patent applies preliminary action by pre-heating the mixture of silica source, mineralizing agent, and organic structure directing agent before adding the alumina source. This preliminary heating step prepares the reaction environment to facilitate faster crystallization once alumina is introduced, reducing the overall crystallization time while maintaining desired zeolite properties
Solution Approach 2:
The patent segments the crystallization process into distinct stages: first mixing and heating the silica source, mineralizing agent, and organic structure directing agent; then separately adding the alumina source. This segmentation allows each component to be optimized independently and enables controlled crystallization that reduces total process time
2Ease of manufacture
If all materials are mixed together upfront in a pressure vessel, then the crystallization process can proceed, but the process efficiency and throughput are reduced
Solution Approach 1:
The patent segments the mixing process into two distinct steps: first combining the silica source, mineralizing agent, and organic structure directing agent; then adding the alumina source separately. This segmentation improves process efficiency by allowing optimized mixing of each component group before combination, reducing overall process time and increasing throughput
Solution Approach 2:
The patent performs preliminary mixing and heating of the silica source, mineralizing agent, and organic structure directing agent before adding alumina. This preliminary action ensures that the reaction environment is prepared optimally, improving process efficiency and enabling faster crystallization without compromising zeolite quality
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
This method significantly reduces the time required to achieve high crystallinity of aluminosilicate zeolite crystals, typically by 1.5 to 3 times faster than traditional methods, while maintaining or exceeding the quality and properties of standard products.
Implementation Method 1
adding an alumina source to a heated mixture such that the added alumina source is consumed to form an intermediate product over a second duration
Implementation Method 2
heating the mixture to form a heated mixture
Implementation Method 3
The pressure vessel is then subjected to hydrothermal conditions in batch mode
Data Source
AI summary
A method for crystallizing aluminosilicate zeolites, including the steps of preparing a mixture containing a silica source, a mineralizing agent, an organic structure directing agent; heating the mixture to form a heated mixture; and adding an alumina source to the heated mixture. The method steps described herein can provide an accelerated aluminosilicate zeolite crystallization process as compared to conventional processes.