A One-Step Method for the Synthesis of High Silica Content Zeolites in Organic-Free Media

Zeolite A (LTA) is extensively used commercially as an ion exchange material; however, its broader applicability to catalysis has been hindered by its acidity (high Al content), which leads to rapid deactivation and reduced hydrothermal stability. notably, LTA is prepared in Al-rich growth solutions, forming crystals with a Si-to-Al ratio (SAR) of approximately 1. Attempts to increase the SAR with the use of organic structure directing agents (Cl>SDAs) have been demonstrated; however, achieving similar ends by a single step organic-free route remains elusive. The invention disclosed here provides a process to prepare zeolite type A (LTA) material with a final product SAR(s) > 2, which to our knowledge is the highest value obtained by an OSDA-free method. We have utilized the Si-Al-NaOH ternary kinetic phase diagram as a guide and established regions to which high silica LTA are formed. Specific synthesis conditions to which a pure phase zeolite A are reported with details on the observed crystal phase transformation that occurs when specific parameters are varied. Our study is focused on structures that form using Na• as the extrafr1mework cation, colloidal silica (LUDOX) as the silica source, and sodium aluminate as the alumina source for all syntheses. We have explored the use of different growth conditions, which include (but are not limited to) the molar composition of reagents, the sources of silica and alumina, temperature, water content, and alkalinity. Based on these studies, we have synthesized zeolite type A material that would potentially expand its applicability to a wider range of operating conditions that materials prepared by more conventional OSDA-free routes. One aspect of the invention consists of the following methods: (1) Synthesis around 65 °C to 100 °C for a period of 1 to 7 days from an initial gel mixture with Si/OH ratio greater than 1.5 results to a pure LTA product with SAR> 2. Crystallization at 100 °C with an initial gel having an SAR of 4 yields zeolite Y /FAU) while an starting mixture with Si/OH < 1.5 yields zeolite P (GIS). (2) Product collected at synthesis temperature of 100 °C results in a mixed crystalline and amorphous component, with the latter being a minor fraction that is easily removed by filtration. (3) Crystallization at 100 °C for more than 7 days produced mixed zeolite A and zeolite P phases. (4) One week crystallization at 120 °C and 180 °C results to formation of zeolite P (GIS) and analcime (ANA) products, respectively. (5) Using a colloidal silica source with smaller particle size promotes the formation of an FAU type zeolite over an LTA type. I (6) High silica zeolite A could be prepared with high yield. For example, we prepared around 8 grams of crystalline product per 20 ml of growth solution. (7) Analyses at varying water content revealed that the viscosity of the growth solution can be varied from that of a gel to a solution.

App TypeCase No.CountryPatent/Publication No.
InquireNational Phase2014053United States10,407,312