METHODS OF CONTROLLING POLYMORPHISM IN ORGANIC-FREE SYNTHESIS OF NA-ZEOLITES AND ZEOLITE CRYSTALS FORMED THEREFROM
One of the major economic factors in commercial zeolite synthesis is the use of organic structure-directing agents (SDAs), which are molecules with commensurate size and shape of zeolite pores and channels. SDAs alter the kinetics of zeolite crystallization and guide the fonnation of framework structures; however, the organic becomes occluded within the internal pores and must be removed by post-treatment calcinations, which decomposes the SDA and prevents the possibility of recycling (i.e. a high economic cost considering the price of the organics). As such, commercial processes rely on organic-free (often tenned template-free) syntheses. The economic advantage of this approach is evident; however, there are two critical challenges that must be overcome: (1) there are only a handful of known zeolite crystal structures that can be synthesized in the absence of organic SDAs, and (2) syntheses often result in the fonnation of two or more crystal structures. Indeed, it is desirable to a priori set the conditions for zeolite growth that will produce a single (pure) crystal phase. To this end, this invention disclosed here provides a set of growth conditions that will lead to the fonnation of seven different zeolite framework structures, each in a pure crystal phase without any impurities. We have established a kinetic phase diagram using a ternary plot of three critical components of zeolite syntheses: the aluminum content (AI). the silica content (Si), and the mineralizing agent (NaOH). Here our preliminary studies have focused on aluminosilicate zeolite syntheses using Na+ as the counterion. We recognize, however, that substitution of sodium with other alkali metals, transition metals, or ions thereof can alter the phase diagram. It has been theoretically proposed that a ternary phase diagram (Al, Si, Na+) assuming pseudo equilibrium for the synthesis of zeolites LTA (zeolite A) and FAU (zeolites X and Y) exhibit three regions: (i) pure LTA, (ii) pure FAU, and (iii) binary mixture of both phases around a Si/ Al ratio of 1.0. It is known that as solutions of LT A are heated, there is a structural transformation to more thermodynamically favorable structures: sodalite (SOD) and cancrinite (CAN). It is also reported that heating solutions ofFAU lead to a transformation to gismondine (GIS, or zeolite P). Moreover, recent studies reveal that low temperature syntheses can yield zeolite EMT. We have performed zeolite synthesis using a composition ofX SiO2: Y AbO3: Z NaOH: 190 H2O (Z 6, 11, 37 and X/Y = 0.1 to 8.0). These studies were performed at three temperatures (65, 100, 180 °C) for times that varied from 6 hours to 3 weeks. Based on these studies, we have developed methods for achieving 7 pure phase zeolite crystals without the use of an organic SDA. The invention consists of the following methods (here we denote the Si/ Al ratio as the starting composition of the synthesis solution prior to zeolite nucleation and growth): (1) Low temperature syntheses (25 ST S 65 °C) result in the formation of LT A at Si/ Al < 1.0 and F AU at Si/ Al> 1.5. In the region 1.0 < Si/ Al < 1.5 there are binary mixtures of LTA and FAU. In addition, syntheses at Si/Al> 1.5 result in the initial formation of LT A, which transforms to F AU over the course of 2 - 7 days. Heating at 65 °C for 7 days provides enough time for the transformation to occur and yield pure FAU at Si/Al > 1.5. (2) Increasing the temperature to 100 °C results in the structural transformation of LT A to SOD and FAU to GIS. It is observed that pure SOD forms at Si/Al< 1.0, pure GIS forms at Si/ Al > 1.5, and a binary mixture exists in between these values. Syntheses reveal that the structural transformations are complete within 7 days. Moreover, analyses at lower temperatures (e.g. 95 °C) revealed traces ofFAU and LTA in the binary phase region, 1.0 3.0, and a binary mixture of the two phases is observed at intermediate Si/ Al ratios. (4) Claims 1 - 3 refer to syntheses using Z = 11 and were performed in regions of Si/OH< 1.0. It is observed that if Z = 6 (i.e. increase in solution pH), the size of the crystals increases. A similar effect is noted with increased time of heating (an effect attributed to Ostwald ripening). (5) Syntheses at Z 37 and low temperature (25 T 65 °C) result in EMT formation at Si/ Al > 1.5 and SOD formation at Si/ Al < 1.0. Preliminary studies suggest heating solutions of EMT leads to a structural transformation to F AU. (6) We expect that solutions of high pH (Z = 37) will generate smaller zeolite crystals. (7) Syntheses in Claims l - 5 reveal that nano-sized zeolites with sizes ranging from 10 to 150 nm are produced. Changes in conditions (time, temperature, Si/ Al ratio, Z, and compositions and conditions thereof) can tailor the size of zeolite crystals. (8) Our studies reveal that multiple silica sources can be used for these syntheses.