Process for the flash calcination of a zeolitic material

Patent metadata

Field	Value
Publication number	US-11542170-B2
Application number	US-202117218959-A
Country	US
Kind code	B2
Filing date	Mar 31, 2021
Priority date	Mar 30, 2016
Publication date	Jan 3, 2023
Grant date	Jan 3, 2023

Abstract

The present invention relates to a process for the calcination of a zeolitic material, wherein said process comprises the steps of
(i) providing a zeolitic material comprising YO 2 and optionally further comprising X 2 O 3 in its framework structure in the form of a powder and/or of a suspension of the zeolitic material in a liquid, wherein Y stands for a tetravalent element and X stands for a trivalent element; (ii) atomization of the powder and/or of the suspension of the zeolitic material provided in (i) in a gas stream for obtaining an aerosol; (iii) calcination of the aerosol obtained in (ii) for obtaining a calcined powder; as well as to a zeolitic material obtainable and/or obtained according the inventive process, and to its use as a molecular sieve, as an adsorbent, for ion-exchange, as a catalyst, and/or as a catalyst support.

First claim

What is claimed is:

1. A process for the calcination of a zeolitic material, comprising:
(i) providing a zeolitic material comprising YO 2 in its framework structure in the form of at least one of a powder or a suspension of the zeolitic material in a liquid, wherein Y is a tetravalent element;
(ii) atomizing the zeolitic material in a gas stream to obtain an aerosol; and
(iii) calcining the aerosol to obtain a calcined powder,
wherein the temperature of the calcination in (iii) is in the range of from 500 K to 1500 K (227° C. to 1227° C.), and
wherein the duration of the calcination in (iii) is in the range from 5 ms to 30 s.

2. The process of claim 1 , wherein the providing comprises:
(i.a) preparing a mixture comprising a source for YO 2 and a solvent system; and
(i.b) crystallizing the mixture to obtain a suspension of a zeolitic material in a mother liquor as the suspension of the zeolitic material in a liquid.

3. The process of claim 2 , wherein the providing further comprises:
(i.c) separating the zeolitic material from the mother liquor;
(i.d) optionally washing the zeolitic material obtained in (i.b) and/or (i.c) with at least one solvent; and
(i.e) optionally drying the zeolitic material obtained in at least one of (i.b), (i.c) or (i.d).

4. The process of claim 2 , wherein for providing the zeolitic material in the zeolitic material in a mother liquor is spray-dried.

5. The process of claim 3 , wherein the providing further comprises:
(i.f) providing a solvent system; and
(i.g) suspending the zeolitic material in the form of a powder as obtained according to (i.c), (i.d) or (i.e) in the solvent system.

6. The process of claim 2 , wherein the mixture provided in (i.a) further comprises an organotemplate.

7. The process of claim 2 , wherein the solvent system comprises at least one of water or one or more organic solvents.

8. The process of claim 1 , wherein Y is selected from the group consisting of Si, Sn, Ti, Zr, Ge, and mixtures of two or more thereof.

9. The process of claim 1 , wherein the average particle size D50 of the powder particles and/or of the droplets from the suspension in the aerosol as determined according to ISO 13320:2009 is from 0.5 to 500 um.

10. The process of claim 1 , wherein the calcining is conducted in an oxygen containing atmosphere.

11. A zeolitic material obtained according to the process of claim 1 .

12. The zeolitic material of claim 11 , wherein an average particle size D50 of the zeolitic material determined according to ISO 13320:2009 is 0.5 um to 500 pm.

13. The process of claim 5 , wherein the solvent system comprises at least one of water or one or more organic solvent.

14. The process of claim 1 , wherein Y comprises Si or Ti.

15. The process of claim 1 , wherein the zeolitic material comprises at least one of Si, Ti or a silicate.

16. The process of claim 1 , wherein the zeolitic material provided in (i) has the framework structure MFI.

17. The zeolitic material of claim 11 , wherein the zeolitic material comprises at least one of Si, Ti or a silicate.

18. The zeolitic material of claim 11 , wherein the zeolitic material has the framework structure MFI.

19. The process of claim 1 , wherein the zeolitic material provided in (i) is a molecular sieve comprising at least one of Si, Ti or silicate.

20. The process of claim 1 , wherein the zeolitic material provided in (i) comprises a silicate.

21. The process of claim 1 , wherein the calcining (iii) is performed in a reactor at a temperature of 900 K to 1100 K.

22. The process of claim 21 , wherein the calcining (iii) is performed in the reactor for 1.5 s to 2.5 s.

23. The process of claim 1 , wherein the calcined powder comprises a crystallinity of 30% to 100%.

24. The process of claim 1 , wherein the calcined powder comprises 30% to 100% less carbon than the zeolitic material in (i) or (ii).

Assignees

• Basf Se

Inventors

• Kalo Benedikt
• Geiger Thomas
• Koenig Rene
• Mueller Ulrich
• Maurer Stefan

Classifications

• C01B39/48

  using at least one organic template directing agent · CPC title

• B01J29/70

  of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• C01P2004/61

  Micrometer sized, i.e. from 1-100 micrometer · CPC title

• B01J6/001

  Calcining · CPC title