# US 2025/0145480 A1 · Methods for making zeolite-y particles

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- Number: US 2025/0145480 A1
- Document ID: US20250145480A1
- Status: Published application
- Kind: A1
- Application number: 18/502,495
- Filed: 2023-11-06
- Published: 2025-05-08
- Earliest claimed: 2023-11-06
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Hana Habboubi; Faisal Alotaibi; Lianhui Ding
- Web page: https://patentgrep.com/patent/US20250145480A1

## CPC

- C01B 39/24: Type Y {(C01B39/205 takes precedence)}
- B01J 6/001: {Calcining}
- B01J 29/084: {Y-type faujasite}
- B01J 37/06: Washing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- C01P 2004/60: Particles characterised by their size
- C01P 2006/12: Surface area
- C01P 2006/14: Pore volume
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS

## Abstract

A method for making zeolite-Y particles, the method may include forming a zeolite precursor solution including an alumina source material and a silica source material in a solvent. The method may include heating the zeolite precursor solution at a temperature of from 50° C. to 70° C. for a time period of from 12 hours to 24 hours to form an intermediate mixture. The method may include adding a structure directing agent and a swelling agent to the intermediate mixture; and following the adding of the structure directing agent and the swelling agent to the intermediate mixture, heating the intermediate mixture at a temperature of from 50° C. to 120° C. for a time period of from 12 hours to 24 hours to form the zeolite-Y particles.

## Claims

### Claim 1

A method for making zeolite-Y particles, the method comprising:
forming a zeolite precursor solution comprising an alumina source material and a silica source material in a solvent;
heating the zeolite precursor solution at a temperature of from 50° C. to 70° C. for a time period of from 12 hours to 24 hours to form an intermediate mixture;
adding a structure directing agent and a swelling agent to the intermediate mixture; and
following the adding of the structure directing agent and the swelling agent to the intermediate mixture, heating the intermediate mixture at a temperature of from 50° C. to 120° C. for a time period of from 12 hours to 24 hours to form the zeolite-Y particles.

### Claim 2 (depends on 1)

The method of claim 1, further comprising adding a second silica source material to the intermediate mixture prior to heating the intermediate mixture.

### Claim 3 (depends on 2)

The method of claim 2, wherein the second silica source material is tetraethyl orthosilicate.

### Claim 4 (depends on 1)

The method of claim 1, wherein the structure directing agent is one or more of cetyltrimethylammonium bromide, dodecyltrimethylammonium bromide, cetyltripropylammonium bromide, and tri-n-propylamine.

### Claim 5 (depends on 1)

The method of claim 1, wherein the swelling agent is one or more of 1,2,4-trimethylbenzene, 1,3,5-trimethylbenzene, xylene, and toluene.

### Claim 6 (depends on 1)

The method of claim 1, further comprising adding one or more of NaOH, KOH, or Mg(OH)2 to the intermediate mixture prior to heating the intermediate mixture.

### Claim 7 (depends on 1)

The method of claim 1, further comprising adding a co-solvent to the intermediate mixture prior to heating the intermediate mixture.

### Claim 8 (depends on 1)

The method of claim 1, wherein the alumina source material is chosen from one or more of NaAlO2, Al2(SO4)3, Al(NO3)3, AlCl3, or Al2O3.

### Claim 9 (depends on 1)

The method of claim 1, wherein the silica source material is chosen from one or more of colloidal silica, fumed silica, tetraethyl orthosilicate, or Na2SiO4.

### Claim 10 (depends on 1)

The method of claim 1, wherein forming zeolite precursor solution comprises:
mixing a basic compound, the silica source material, and the alumina source material into a solvent to form a mixture; and
aging the mixture by stirring the mixture for at least 10 hours.

### Claim 11 (depends on 10)

The method of claim 10, wherein the solvent is water.

### Claim 12 (depends on 10)

The method of claim 10, wherein aging the mixture comprises stirring the mixture at a temperature of from 20° C. to 40° C.

### Claim 13 (depends on 10)

The method of claim 10, wherein aging the mixture comprises stirring the mixture for from 10 hours to 30 hours.

### Claim 14 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have a ratio of mesopore surface area to total surface area of at least 38%.

### Claim 15 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have an average particle size of from 150 nm to 300 nm.

### Claim 16 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have an average pore size of from 2.5 to 4 nm.

### Claim 17 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have a total pore volume of from 0.4 ml/g to 0.7 ml/g.

### Claim 18 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have an average surface area of at least 650 m2/g.

### Claim 19 (depends on 1)

The method of claim 1, wherein the zeolite-Y particles have a relative crystallinity of greater than 60%.

### Claim 20 (depends on 1)

The method of claim 1, further comprising:
washing the zeolite-Y particles;
drying the zeolite-Y particles; and
calcinating the zeolite-Y particles.