Preparation of mesoporous zeolites with reduced processing
AssigneeRive Technology, Inc.
InventorsR. Samuel Boorse, Kunhao Li
Life of this patent
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Abstract
Methods for introducing mesoporosity into zeolitic materials are described herein that employ an acid treatment, an optional surfactant treatment, and a base treatment without filtration or purification steps between the steps. In particular, the process generally involves subjecting a zeolitic material to an acid treatment followed by a surfactant treatment and base treatment. The methods can efficiently introduce mesoporosity into various zeolitic materials, such as zeolites.
Claims53
A method for producing a material comprising a mesoporous zeolite, said method comprising:
- (a) contacting an initial zeolitic material with an acid to produce an acid-treated zeolitic material, wherein said contacting of step (a) is carried out in a first slurry comprising a first solid phase and a first liquid phase;
- and
- (b) subsequent to step (a), contacting said acid-treated zeolitic material with a base to thereby provide a base-treated zeolitic material, wherein said contacting of step (b) is carried out in a second slurry comprising a second solid phase and a second liquid phase, wherein at least 30 weight percent of said first liquid phase is also present in said second liquid phase,
- wherein the 20 to 80 Å diameter mesopore volume of said base-treated zeolitic material is greater than the mesopore volume of said initial zeolitic material,
- wherein the pH of said second liquid phase is higher than the pH of said first liquid phase.
A method for forming a mesoporous zeolitic material, said method comprising:
- (a) contacting an initial zeolitic material with an acid to thereby form a first mixture comprising at least a portion of said acid, an acid-treated zeolitic material, and a liquid, wherein said contacting is carried out in the substantial absence of hydrofluoric acid;
- (b) contacting said first mixture with a surfactant to thereby form a second mixture comprising at least a portion of said surfactant, at least a portion of said acid, at least 30 weight percent of said liquid from said first mixture, and a surfactant-treated zeolitic material;
- (c) contacting said second mixture with a base to thereby form a third mixture comprising at least a portion of said acid, at least a portion of said surfactant, at least a portion of said base, at least 30 weight percent of said liquid from said first mixture, and a base-treated zeolitic material;
- and
- (d) recovering at least a portion of said base-treated zeolitic material from said third mixture to thereby form said mesoporous zeolitic material.
A method for producing a material comprising a mesoporous zeolite, said method comprising:
- (a) contacting an initial zeolite with an acid to produce an acid-treated zeolite, wherein said contacting of step (a) is carried out in a first slurry comprising a first solid phase and a first liquid phase;
- and
- (b) subsequent to step (a), contacting said acid-treated zeolite with a base and a surfactant to thereby provide a base-treated zeolite, wherein said contacting of step (b) is carried out in a second slurry comprising a second solid phase and a second liquid phase, wherein at least 30 weight percent of said first liquid phase is also present in said second liquid phase,
- wherein the 20 to 80 Å diameter mesopore volume of said base-treated zeolite is greater than the mesopore volume of said initial zeolite,
- wherein the pH of said second liquid phase is higher than the pH of said first liquid phase.
Dependencies are inferred from the claim text.