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US 5,492,883 AGranted
Molecular sieve structures using aqueous emulsions
AssigneeCorning Incorporated
InventorShy-Hsien Wu
Life of this patent
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Abstract
The invention relates to the use of aqueous emulsions of silicone resins in forming cellular zeolite substrates which can be dried rapidly without incurring blistering while still exhibiting good strength and zeolite activity.
Claims16
A method of producing an extruded honeycomb monolith having substantial strength comprising:
- (a) mixing and forming into a substantially homogeneous body, a mixture comprising (i) molecular sieve material selected from the group consisting of zeolites, metallosilicates, titanosilicates, metalloaluminates, germaniumaluminates, metallophosphates, aluminophosphates, silicoaluminophosphates, metalloaluminophosphates, gallogerminates, gallosilicates, chromosilicates, borosilicates, ferrisilicates and combinations of these, (ii) aqueous silicone resin emulsion, (iii) a temporary binder selected from the group consisting of methylcellulose, ethylcellulose, hydroxybutylcellulose, hydroxybutylmethylcellulose, hydroxyethylcellulose, hydroxymethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylmethylcellulose, and mixtures of these, and (iv) water;
- (b) drying the body;
- and
- (c) sintering the body to a temperature sufficient to form a catalyst support having substantial strength.
1 more element
A method of producing a an extruded honeycomb monolith having substantial strength and high surface area comprising:
- (a) mixing into a substantially homogeneous body
- (i) a zeolite having a surface area of at least 20 m.sup.2 /g;
- (ii) aqueous silicone resin emulsion;
- (iii) a temporary binder selected from the group consisting of methylcellulose, ethylcellulose, hydroxybutylcellulose, hydroxybutylmethylcellulose, hydroxyethylcellulose, hydroxymethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxyethylmethylcellulose, and mixtures of these;
- and
- (iv) water;
- (b) extruding the body to form a green honeycomb structure;
- (c) heating the structure in a dielectric oven for a duration in the range of 5 to 30 minutes to form a crack-free dry structure;
- and
- (d) heating or sintering the dried honeycomb structure to a temperature in the range of 500.degree. to 1000.degree. C. for a time period sufficient to form a sintered structure having substantial strength and high surface area.
7 more elements
Dependencies are inferred from the claim text.