Methods of preparing dry gel zeolites with hydrogel drying

Patent metadata

Field	Value
Publication number	US-2026028237-A1
Application number	US-202418782709-A
Country	US
Kind code	A1
Filing date	Jul 24, 2024
Priority date	Jul 24, 2024
Publication date	Jan 29, 2026
Grant date	—

Abstract

This disclosure relates to methods of preparing a dry gel zeolite including drying the zeolite hydrogel under reduced pressure to form a dry gel zeolite.

First claim

What is claimed is:

1 . A method of preparing a dry gel zeolite comprising:
combining zeolite precursor materials; stirring the zeolite precursor materials to form a zeolite hydrogel; and drying the zeolite hydrogel at a pressure of about 0.001 mbar to about 250 mbar and a temperature of about 20° C. to about 100° C. to form the dry gel zeolite.

2 . The method of claim 1 , wherein the method further comprises:
crystallizing the dry gel zeolite.

3 . The method of claim 1 , wherein the method further comprises:
heating the dry gel zeolite.

4 . The method of claim 1 , wherein the method further comprises:
calcinating the dry gel zeolite.

5 . The method of claim 1 , wherein the zeolite precursor materials comprise an aluminum source, a silica source, and a template source.

6 . The method of claim 5 , wherein the aluminum source is selected from NaAlO 2 , aluminum isopropoxide (AIP), Al 2 (SO 4 ) 3 , Al(NO 3 ) 3 , AlCl 3 , aluminum powder, Al(OH) 3 , and Al 2 O 3 .

7 . The method of claim 5 , wherein the silicon source is selected from tetraethylorthosilicate (TEOS), colloidal silica, Na 2 SiO 3 , and fumed silica.

8 . The method of claim 5 , wherein the template source is selected from tetrapropylammonium hydroxide (TPAOH) and tetraethylammonium hydroxide (TEAOH).

9 . The method of claim 5 , wherein:
the aluminum source is selected from NaAlO 2 , aluminum isopropoxide (AIP), Al 2 (SO 4 ) 3 , Al(NO 3 ) 3 , AlCl 3 , aluminum powder, Al(OH) 3 , and Al 2 O 3 ; the silica source is selected from tetraethylorthosilicate (TEOS), colloidal silica, Na 2 SiO 3 , and fumed silica; and the template source is selected from tetrapropylammonium hydroxide (TPAOH) and tetraethylammonium hydroxide (TEAOH).

10 . The method of claim 1 , wherein the dry gel zeolite is ZSM-5 or zeolite beta.

11 . The method of claim 1 , wherein drying the zeolite hydrogel is performed at a pressure of about 0.005 mbar to about 15 mbar.

12 . The method of claim 1 , wherein drying the zeolite hydrogel is performed at a temperature of about 40° C. to about 80° C.

13 . The method of claim 1 , wherein drying the zeolite hydrogel is performed for about 2 h to about 10 h.

14 . The method of claim 1 , wherein drying the zeolite hydrogel is performed for about 4 h to about 8 h.

15 . The method of claim 1 , wherein drying the zeolite hydrogel is performed at a pressure of about 0.005 mbar to about 15 mbar, a temperature of about 30° C. to about 90° C. for about 2 h to about 10 h.

16 . The method of claim 1 , wherein drying the zeolite hydrogel is performed at a pressure of about 0.01 mbar to about 10 mbar, a temperature of about 40° C. to about 80° C. for about 4 h to about 8 h.

17 . The method of claim 1 , wherein the dry gel zeolite has a relative crystallinity of 90% or greater.

18 . The method of claim 1 , wherein drying the zeolite hydrogel takes less time than a method of preparing a dry gel zeolite wherein drying the zeolite hydrogel is not performed at a pressure of about 0.001 mbar to about 25 mbar and a temperature of about 20° C. to about 100° C. to form the dry gel zeolite.

19 . The method of claim 1 , wherein the method uses less template source than a method of preparing a dry gel zeolite wherein drying the zeolite hydrogel is not performed at a pressure of about 0.001 mbar to about 25 mbar and a temperature of about 20° C. to about 100° C. to form the dry gel zeolite.

20 . A method of preparing a dry gel zeolite comprising:
combining zeolite precursor materials; stirring the zeolite precursor materials to form a zeolite hydrogel; drying the zeolite hydrogel at a pressure of about 0.001 mbar to about 250 mbar and a temperature of about 20° C. to about 100° C. to form the dry gel zeolite; grinding the dry gel zeolite; crystallizing the dry gel zeolite; isolating the dry gel zeolite; washing the dry gel zeolite; heating the dry gel zeolite; and calcinating the dry gel zeolite.

Assignees

• Saudi Arabian Oil Co

Inventors

• Ding Lianhui
• Aljishi Mohammad F
• Alotaibi Faisal

Classifications

• C01P2006/16

  Pore diameter · CPC title

• C01P2006/14

  Pore volume · CPC title

• C01P2006/12

  Surface area · CPC title

• C01P2004/64

  Nanometer sized, i.e. from 1-100 nanometer · CPC title

• C01P2002/04

  Compounds with a limited amount of crystallinty, e.g. as indicated by a crystallinity index · CPC title