Systems and methods for the synthesizing zsm-22 zeolites

Patent metadata

Field	Value
Publication number	US-2022297098-A1
Application number	US-202117206938-A
Country	US
Kind code	A1
Filing date	Mar 19, 2021
Priority date	Mar 19, 2021
Publication date	Sep 22, 2022
Grant date	—

Abstract

According to one or more embodiments, non-agglomerated, nano-sized ZSM-22 zeolites may be synthesized by methods comprising operating a mechanical rotation drum unit at a first temperature of from 40° C. to 60° C. and a first speed of from 200 rpm to 1000 rpm for a first time period of from 1.3 hours to 2.7 hours; operating the mechanical rotation drum unit at a second speed of from 30 rpm to 90 rpm for a second time period of from 0.05 hours to 0.4 hours; heating the mechanical rotation drum unit at a ramping temperature of from 8° C./minute to 12° C./minute to a second temperature of from 115° C. to 185° C. at the second speed; operating the mechanical rotation drum unit at the second temperature and the second speed for a third time period of from 30 hours to 90 hours; and cooling the mechanical rotation drum unit at a fourth speed of 0 rpm.

First claim

What is claimed is:

1 . A method of synthesizing a non-agglomerated, nano-sized ZSM-22 zeolite, the method comprising:
passing a silica solution and an aluminate solution into a mechanical rotation drum unit; operating the mechanical rotation drum unit at a first temperature of from 40° C. to 60° C. and a first speed of from 200 rpm to 1000 rpm for a first time period of from 1.3 hours to 2.7 hours; operating the mechanical rotation drum unit at a second speed of from 30 rpm to 90 rpm for a second time period of from 0.05 hours to 0.4 hours; heating the mechanical rotation drum unit at a ramping temperature of from 8° C./minute to 12° C./minute to a second temperature of from 115° C. to 185° C. at the second speed of from 30 rpm to 90 rpm; operating the mechanical rotation drum unit at the second temperature of from 115° C. to 185° C. and the second speed of from 30 rpm to 90 rpm for a third time period of from 30 hours to 90 hours; and cooling the mechanical rotation drum unit at a fourth speed of 0 rpm to produce the non-agglomerated, nano-sized ZSM-22 zeolite; and wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 100 nanometers to 400 nanometers and a width within a range of from 50 nanometers to 250 nanometers.

2 . The method of claim 1 , wherein the mechanical rotation drum unit is cooled to a temperature of from 20° C. to 50° C.

3 . The method of claim 1 , further comprising drying the non-agglomerated, nano-sized ZSM-22 zeolite.

4 . The method of claim 1 , further comprising calcining the non-agglomerated, nano-sized ZSM-22 zeolite.

5 . The method of claim 1 , further comprising activating the non-agglomerated, nano-sized ZSM-22 zeolite to produce an active catalyst.

6 . The method of claim 1 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 100 nanometers to 200 nanometers and a width within a range of from 50 nanometers to 100 nanometers.

7 . The method of claim 1 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 150 nanometers to 400 nanometers and a width within a range of from 100 nanometers to 250 nanometers.

8 . The method of claim 1 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite has a silica/alumina ratio of from 25 to 100.

9 . A method of synthesizing a non-agglomerated, nano-sized ZSM-22 zeolite, the method comprising:
passing a silica solution and an aluminate solution into a mechanical rotation drum unit; and operating the mechanical rotation drum unit at five stages to produce the non-agglomerated, nano-sized ZSM-22 zeolite; wherein: the first stage operates at a first mixing speed of from 200 rpm to 1000 rpm and at a first time period of from 1.3 hours to 2.7 hours; the second stage operates at a second mixing speed of from 30 rpm to 90 rpm and at a second time period of from 0.05 hours to 0.4 hours; the third stage operates at a third mixing speed of from 30 rpm to 90 rpm and at a third time period of from 0.05 hours to 0.4 hours; the fourth stage operates at a fourth mixing speed of from 30 rpm to 90 rpm and at a first time period of from 30 hours to 90 hours; and the fifth stage operates at a fifth mixing speed of 0 rpm.

10 . The method of claim 9 , wherein the first stage operates at a temperature of from 40° C. to 60° C.

11 . The method of claim 9 , wherein the second stage operates at a temperature of from 40° C. to 60° C.

12 . The method of claim 9 , wherein the fourth stage operates at a temperature of from 115° C. to 185° C.

13 . The method of claim 9 , wherein the fifth stage operates at a temperature of from 20° C. to 50° C.

14 . The method of claim 9 , wherein the third stage operates a ramping temperature of from 8° C./minute to 12° C./minute.

15 . The method of claim 9 , further comprising producing the silica solution in a silicate unit;
producing the aluminate solution in an aluminate unit; and combining the silica solution and the aluminate solution prior to passing the silica solution and the aluminate solution into the mechanical rotation drum unit.

16 . The method of claim 9 , further comprising activating the non-agglomerated, nano-sized ZSM-22 zeolite to produce an active catalyst.

17 . The method of claim 9 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 100 nanometers to 400 nanometers and a width within a range of from 50 nanometers to 250 nanometers.

18 . The method of claim 17 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 100 nanometers to 200 nanometers and a width within a range of from 50 nanometers to 100 nanometers.

19 . The method of claim 17 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite comprises crystals each having a length within a range of from 150 nanometers to 400 nanometers and a width within a range of from 100 nanometers to 250 nanometers.

20 . The method of claim 9 , wherein the non-agglomerated, nano-sized ZSM-22 zeolite has a silica/alumina ratio of from 25 to 100.

Assignees

• Saudi Arabian Oil Co
• Univ King Fahd Pet & Minerals

Inventors

• Al-Shafei Emad
• Muraza Oki
• Jamil Anas Karrar
• Choi Ki-Hyouk
• Punetha Ashok K
• Yamani Zain Hassan

Classifications

• C01B39/46

  Other types characterised by their X-ray diffraction pattern and their defined composition {(C01B39/023, C01B39/026, C01B39/06 take precedence)} · CPC title

• C01B39/48 Primary

  using at least one organic template directing agent · CPC title

• C01B39/02

  Crystalline aluminosilicate zeolites; Isomorphous compounds thereof; Direct preparation thereof; Preparation thereof starting from a reaction mixture containing a crystalline zeolite of another type, or from preformed reactants; After-treatment thereof · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J2219/0009

  Coils · CPC title