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AssigneeCorning Incorporated
InventorsShy-Hsien Wu, Kenneth E. Zaun
Estimating the term…
Zeolite based material and a method for making the zeolite, comprising a zeolite having a silica/alumina ratio of at least 300 and a surface area of 250 m2/g and no greater than about 20 parts, by weight, of a silica binder. The combination of properties this zeolite based material exhibits includes the following: (1) a modulus of rupture of at least 1500 psi; (2) a surface area of at least 100 m2/g; (3) a coefficient of thermal expansion of less than about +/−10 ppm/° C.; and, (4) a thermal shock resistance of at least 850° C. The zeolite-based material can include a third component, specifically a gamma alumina having a specific surface area of greater than 100 m2/g.
A zeolite composite exhibiting a modulus of rupture strength of at least 1500 psi, a surface area of at least 100m2/g, a coefficient of thermal expansion of less than about +/−10 ppm/° C. and a thermal shock resistance of at least 850° C., said composite being formed from a mixture comprising, in weight percent:
A zeolite body exhibiting a modulus of rupture strength of at least 1500 psi, a surface area of at least 100 m2/g, a coefficient of thermal expansion of less than about +/−10 ppm/° C. and a thermal shock resistance of at least 850° C., said body being formed from a mixture comprising:
Dependencies are inferred from the claim text.
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Shaped bodies; Monolithic structures: honeycomb or cellular structures; Solid foams or sponges
Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g.…: by…
Handling or mounting catalysts: devices in general for catalytic purification of waste gases
Comprising oxides or hydroxides of metals not provided for in group B01J20/04: comprising aluminium oxide or hydroxide; comprising bauxite
Term ended 14 May 2021 (estimated)
USPTO file history isn’t available for this patent, so only indexed dates are shown.
1. Field of the Invention
The present invention relates to a improved zeolite/silica/alumina material and a method for making such material. In particular it relates to a zeolite/silica/alumina composite material exhibiting a high strength and a high surface area.
2. Background and Discussion of the Related Art
To further illustrate the principles of the present invention, there will be described certain examples of zeolite and zeolite/alumina bodies formed according to the invention, as well as a comparative body. However, it is to be understood that the examples are given for illustrative purpose only, and the invention is not limited thereto, but various modifications and changes may be made in the invention, without departing from the spirit of the invention.
Both examples involved thoroughly mixing together in a Littleford mixer a batch mixture as provided Table I. The zeolite raw material comprised a ZSM-5 zeolite having an SiO2/Al2O3 ratio of 300 (CBV-3002 from PQ Corporation) and a silica binder comprising an amount of a concentrated silicone resin (6-2230 resin from Dow Corning) dissolved in a dibasic ester solution with the resin/solvent ratio reported in the Table; in each example the amount of resin resulted in the amount of silica permanent binder reported in the fired composition. The mixed batch was transferred to a muller and an amount of water, in as reported in Table I, was added to the batch and the batch was uniformly plasticized; the water listed as a superaddition weight percent based on the fired composition.
Honeycomb bodies with a wall thickness of about 8 mil and exhibiting 400 cells/in2 and rods suitable for testing MOR, exhibiting a diameter of 0.3125 in. were formed by extrusion through a ram extruder. Each of the two examples, green extruded honeycombs and the rods, were dried in the following manner: RT to 95° C. in a humidity oven (95-100% relative humidity) for a period of 4 days. After drying, the extruded honeycombs and rods were pre-fired in an N2 atmosphere at a rate of between 15-25° C./hr. to 500° C., where temperature was held for a period of 4 hours. The honeycombs were cooled to room temperature and then heated in air, at a rate of between 15-25° C./hr, to a temperature of 500° C., where again the temperature was held for a period of 4 hours. Following this hold, the firing involved heating the honeycombs, at a rate of between 25-50° C./hr, to a final temperature of 1100° C., where the honeycombs were held for a final period of 4 hours. The composition of the fired body is reported in Table I.