Method of making silver-silicalite coated substrate

Patent metadata

Field	Value
Publication number	US-12110419-B2
Application number	US-202217962071-A
Country	US
Kind code	B2
Filing date	Oct 7, 2022
Priority date	Oct 7, 2022
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

A method of making a silver-silicalite coating on a surface of a stainless-steel substrate is provided. The method includes mixing metakaolin with an aqueous solution of NaOH to form a first mixture. The method further includes mixing silica gel and silver nitrate with the first mixture to form a second mixture. Furthermore, the method includes mixing Zeolites Socony Mobil-5 (ZSM-5) with the second mixture to form a third mixture. The method further includes hydrothermally treating the stainless-steel substrate with the third mixture to form the silver-silicalite coating on the surface of the stainless-steel substrate. The hydrothermal treatment is carried out in the absence of an organic template. The stainless-steel substrate coated with the silver-silicalite coating, prepared by the method of the present disclosure, has lower corrosion in comparison to the same stainless-steel substrate without the silver-silicalite coating.

First claim

The invention claimed is:

1. A method of making a silver-silicalite coating on a surface of a stainless-steel substrate, comprising:
mixing metakaolin with an aqueous solution of NaOH to form a first mixture;
mixing silica gel and silver nitrate with the first mixture to form a second mixture;
mixing ZSM-5 zeolite with the second mixture to form a third mixture; and
hydrothermally treating the stainless-steel substrate with the third mixture to form the silver-silicalite coating on the surface of the stainless-steel substrate,
wherein the silver-silicalite coating comprises rhombohedral cuboidal particles having an average length of 2 to 5 μm, an average width of 1 to 2 μm and an average height of 0.5 to 2 μm,
wherein the hydrothermal treatment is carried out in the absence of an organic template.

2. The method of claim 1 , wherein the hydrothermal treatment includes submerging the substrate in the third mixture in a vessel and sequentially pressuring to a pressure of up to 5 MPa and depressuring to ambient pressure, wherein the pressuring and depressuring is carried out for at least 5 cycles.

3. The method of claim 1 , wherein the silver-silicalite coating has a SiO 2 :Ag molar ratio of 25:1 to 100:1,
the silver-silicalite coating is in direct and continuous contact with substantially the entire exposed outside surface of the substrate, and
silver particles are formed at an outer surface of the silver-silicalite coating and substantially no silver particles are in contact with the surface of the substrate.

4. The method of claim 1 , wherein the silver-silicalite coating has a SiO 2 :Al 2 O 3 molar ratio of 30:1 to 100:1.

5. The method of claim 1 , wherein the silver-silicalite coating has a SiO 2 :Al 2 O 3 molar ratio of 50:1 to 80:1.

6. The method of claim 1 , wherein the hydrothermal treatment is carried out at a temperature range of 120 to 220° C. for 20 to 55 hours.

7. The method of claim 1 , wherein the hydrothermal treatment is carried out at a temperature range of 160 to 190° C. for 40 to 50 hours.

8. The method of claim 1 , wherein the silver-silicalite coating comprises silver nanoparticles having an average particle diameter of 10-200 nm.

9. The method of claim 8 , wherein the silver-silicalite coating further comprises rhombohedral crystals of the ZSM-5 zeolite decorated with the silver nanoparticles.

10. The method of claim 8 , wherein the silver-silicalite coating further comprises hexagonal lattice crystals of the ZSM-5 zeolite decorated with the silver nanoparticles.

11. The method of claim 1 , wherein the silver-silicalite coating comprises 35 to 45 wt. % O, 0.5 to 5 wt. % Al, 20 to 35 wt. % Si, 1 to 8 wt. % Cr, 10 to 25 wt. % Fe, 0.5 to 5 wt. % Ni, 0.5 to 5 wt. % Cu, and 1 to 10 wt. % Ag, wherein wt. % is based on a total weight of the silver-silicalite coating.

12. The method of claim 1 , wherein the silver-silicalite coating is at least partially enfolded by a polymer.

13. The method of claim 12 , wherein the polymer is at least one selected from the group consisting of a polyethylene glycol, a poly (ethylenimine), a poly (N-isopropyl acrylamide), a poly (2-hydroxyethyl methacrylate), a dendritic polymer, a polysaccharide, a poly (glycolic acid), and a poly (lactic acid).

14. The method of claim 13 , wherein the polymer is a polyethylene glycol.

15. The method of claim 1 , wherein the silver-silicalite coating further comprises coffin-shaped particles an average length in a range of 2 to 5 μm, an average width in a range of 0.5 to 2 μm, and an average height in a range of 0.5 to 2 μm, the coffin-shaped particles form agglomerates having an average diameter in a range of 4 to 10 μm.

16. The method of claim 1 , wherein the silver-silicalite coating is porous with a pore volume of 0.1 to 0.4 cm 3 /g.

17. The method of claim 1 , wherein the silver-silicalite coating is porous with a pore size distribution of 1 to 5 nm.

18. The method of claim 1 , wherein the coated stainless-steel substrate has a corrosion current from 0.04 to 0.1 ampere per square centimeter (A/cm 2 ) to 0.01-0.025 A/cm 2 lower in comparison to the same stainless-steel substrate without the silver-silicalite coating.

Assignees

• Univ Imam Abdulrahman Bin Faisal

Inventors

• Jermy B Rabindran
• Ravinayagam Vijaya

Classifications

• C09D7/61

  inorganic · CPC title

• C23C18/127

  Preformed particles · CPC title

• C23C18/1241

  Metallic substrates · CPC title

• C09D171/02

  Polyalkylene oxides · CPC title

• C09D7/63

  organic · CPC title