Zeolite Production From Acid-Refractory Minerals With Impurity Separation
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Solution Overview
Problem
Existing methods for producing zeolite from acid-refractory mineral compositions, such as lithium leach residues, face challenges in selective production, contamination by refractory impurities, and high energy costs due to high temperature processing.
Innovation Solution
A method involving alkaline treatment to dissolve silicon and acid treatment to dissolve aluminum, followed by combining the solutions to precipitate zeolite, allowing control over zeolite composition and purity without high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high temperature fusion with caustic soda is used to produce zeolite, then zeolite formation is achieved, but energy costs increase significantly
Solution Approach 1:
The patent changes the temperature parameter from high temperature fusion to low temperature hydrothermal conditions (e.g., 100-200°C), and changes the chemical environment from dry fusion with caustic soda to aqueous alkaline solution treatment, thereby achieving zeolite formation with significantly reduced energy consumption
Solution Approach 2:
The patent introduces aqueous alkaline solution treatment instead of dry fusion, using liquid-phase chemistry to dissolve aluminosilicate and form zeolite precursors, which then crystallize under hydrothermal conditions, replacing the need for high-temperature thermal processing
2Manufacturing precision
If dissolution-reprecipitation mechanism is used to convert acid-refractory aluminosilicate into zeolites, then zeolite production is achieved, but selective production of desired zeolite products is constrained
Solution Approach 1:
The patent systematically varies multiple parameters including Si:Al ratio, alkaline solution concentration, temperature, pressure, and addition of structure-directing agents to control which specific zeolite phase crystallizes, enabling selective production of different zeolite types (e.g., Zeolite A, X, P, or chabazite) from the same aluminosilicate feedstock
Solution Approach 2:
The patent uses aqueous alkaline solution as an intermediary medium to dissolve aluminosilicate and form soluble silicate and aluminate species, which then serve as precursors for controlled zeolite crystallization, allowing better control over product selectivity compared to direct solid-state conversion
3Manufacturing precision
If fusion with caustic soda is used to produce zeolite, then zeolite formation is achieved, but refractory impurities such as quartz contaminate the product
Solution Approach 1:
The patent uses milder alkaline treatment conditions (lower temperature, aqueous phase) that selectively dissolve aluminosilicate components while leaving refractory impurities like quartz undissolved, enabling separation by filtration before zeolite crystallization, thereby producing higher purity zeolite products
Solution Approach 2:
The patent extracts dissolved silicate and aluminate species from the alkaline solution through controlled crystallization, separating them from undissolved refractory impurities that remain as solid residue, thereby purifying the zeolite product
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 approach enables the production of high-purity zeolites with controlled selectivity, reducing energy costs and avoiding contamination, while allowing recovery of valuable metal components.
Implementation Method 1
treating an acid-refractory mineral composition comprising aluminosilicate with an alkaline solution to dissolve silicon from the aluminosilicate into the alkaline solution
Implementation Method 2
contacting at least a portion of the aluminium-bearing mineral residue with an acid solution to dissolve aluminium from the aluminium-bearing mineral residue into the acid solution
Implementation Method 3
combining at least a portion of the alkaline silicate solution and at least a portion of the aluminium salt solution to form a zeolite precursor solution and precipitating a zeolite from the zeolite precursor solution
Data Source
AI summary
The invention provides a method of producing zeolite from an acid-refractory mineral composition, the method comprising: (a) treating an acid-refractory mineral composition comprising aluminosilicate with an alkaline solution to dissolve silicon from the aluminosilicate into the alkaline solution, thereby producing an alkaline silicate solution and an aluminium-bearing mineral residue; (b) separating the alkaline silicate solution from the aluminium-bearing mineral residue; (c) contacting the aluminium-bearing mineral residue with an acid solution to dissolve aluminium from the aluminium-bearing mineral residue into the acid solution, thereby producing an aluminium salt solution and an aluminium-lean solid residue; (d) separating the aluminium salt solution from the aluminium-lean solid residue; (e) combining at least a portion of the alkaline silicate solution and at least a portion of the aluminium salt solution to form a zeolite precursor solution; and (f) precipitating a zeolite from the zeolite precursor solution.