Synthesis of zeolite using hydrous kaolin
AssigneeBASF SE
InventorsXingtao GAO, Christopher John GILBERT, Qi FU, Mukta RAI, Vijay KOBETIC
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Abstract
Described herein is a process for preparing a zeolite including mixing an aluminum source, a sodium source and water to form a mixture. After mixing, a silicon source is added and mixed. Then, a zeolite crystal or zeolite seed is added to form a gel mixture, which is then crystallized at a temperature of about 100° C. to about 200° C. for about 10 to about 108 hours to obtain zeolite crystals.
Claims50
A process for preparing a zeolite comprising:
- mixing an aluminum source, a sodium source, and water to form a first mixture;
- after mixing, adding a silicon source to the first mixture and mixing;
- adding a zeolite crystal or zeolite seed to form a gel mixture;
- crystallizing the gel mixture at a temperature from about 150° C. to about 200° C. for about 12 to about 48 hours to obtain product zeolite crystals,
- wherein the aluminum source is hydrous kaolin.
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A zeolite crystal comprising ZSM-5 having a SAR from about 24 to about 40 and a sodium content of less than about 0.4%.
A process for preparing a chabazite (CHA) zeolite:
- preparing an aqueous mixture comprising a silica source, a sole alumina source, a base agent, and an organic structure directing agent (OSDA) to form an gel mixture;
- crystallizing the gel mixture at a temperature from about 100° C. to about 200° C. for about 10 to about 108 hours to obtain zeolite crystals,
- wherein the sole aluminum source is hydrous kaolin.
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A method of producing a catalytic article comprising:
- coating a substrate with a catalytic coating using a washcoat process;
- and
- drying and calcining the coated substrate at a temperature of about 550° C. for about 1 hour;
- wherein the catalytic coating comprises a chabazite, about 3.0 wt % to about 6.0 wt % copper oxide, about 5 wt % zirconium oxide, and about 5 wt % pseudoboehmite (PB-250) binder.
Dependencies are inferred from the claim text.