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US 5,895,769 AGranted
In-situ crystallized zeolite containing composition (LAI-ISC)
AssigneeExxon Research & Engineering Co.
InventorWenyih Frank Lai
Life of this patent
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AssigneeExxon Research & Engineering Co.
InventorWenyih Frank Lai
Estimating the term…
Applicant has discovered a new zeolite containing composition and a process for preparing the same. The composition is unique in that the zeolite crystals making up one layer of the composition pack in a manner such that the composition is essentially continuous with no large scale voids even when the zeolite layer is <10 .mu.m thick. Thus, the present invention is directed toward a composition comprised of a porous substrate and a layer of zeolite crystals wherein said layer of zeolite crystals is a polycrystalline layer with at least 99% of said zeolite crystals having at least one point between adjacent crystals that is .ltoreq.20 .ANG. and wherein at least 90% of said crystals have widths of from about 0.2 to about 100 microns (preferably about 2 to about 50 microns) and wherein at least 75% of said crystals have a thickness of within 20% of the average crystal thickness. Preferably the composition has at most 1 Volume % voids in the zeolite layer. Use of the composition is also described.
A method for preparing a composition comprising the steps of:
A separation process comprising contacting a feedstock derived from petroleum, natural gas, air or hydrocarbons, comprising at least two molecular species with a composition comprising a substrate and a layer of polycrystalline zeolite crystals wherein at least 99% of said zeolite crystals have at least one point between adjacent crystals that is .ltoreq.20 .ANG. and wherein at least 90% of said crystals have widths of from about 0.2 to about 100 microns and wherein at least 75% of said crystals have a thickness within 20% of the average crystal thickness wherein at least one molecular species of said feedstock is separated from said feedstock by said composition, and wherein said hydrocarbon feedstocks are selected from the group consisting of coal, bitumen, kerogen and mixtures thereof.
A process for catalyzing a chemical reaction comprising contacting a reaction stream under catalytic conversion conditions with a composition comprising a substrate and a polycrystalline layer of zeolite crystals wherein at least 99% of said zeolite crystals have at least one point between adjacent crystals that is .ltoreq.20 .ANG. and wherein at least 90% of said crystals have widths of from about 0.2 to about 100 microns and wherein at least 75% of said crystals have a thickness within 20% of the average crystal thickness.
A process for catalyzing a chemical reaction which comprises contacting one reactant of a bimolecular reaction mixture with one face of a composition comprising a substrate and a polycrystalline layer of zeolite crystals wherein at least 99% of said zeolite crystals have at least one point between adjacent crystals that is .ltoreq.20 .ANG. and wherein at least 90% of said crystals have widths of from about 0.2 to about 100 microns and wherein at least 75% of said crystals have a thickness within 20% of the average crystal thickness that is in active catalytic form, under catalytic conversion conditions, and controlling the addition of a second reactant by diffusion from the opposite face of the structure, thereby catalyzing the chemical reaction between said reactants.
Dependencies are inferred from the claim text.