Process for Preparing Nano Size Zeolites

Abstract

A process has been developed to synthesize various zeolites with nano size crystals. The process involves forming an aluminosilicate initiator which exhibits the Tyndall effect. This initiator is then mixed with a clear solution comprising reactive sources of Al, Si, M and R plus water. M is an alkali or alkaline earth metal while R is an organoammonium compound. The resultant reaction mixture is reacted at a temperature and for a time sufficient to produce a zeolite such as zeolite Y with average crystallite size less than 500 nm.

Description

Claims

1. A process for preparing zeolites having an average crystallite size of less than 500 nm, the zeolite having an empirical formula of: (AlxSi1-x)O2

2. The process of claim 1 where M is selected from the group consisting of lithium, sodium, and potassium.

3. The process of claim 1 where the zeolite has an average crystallite size of less than 300 nm.

4. The process of claim 1 where the zeolite has the structure type BEA, FAV, MFI, MEL, MTW, MOR, LTL, LTA, EMT, ERI, FER, MAZ, MEI, TON and MWW.

5. The process of claim 4 where the zeolite has the structure of zeolite Y or zeolite X.

6. The process of claim 1 where the aluminum source is selected from the group consisting of aluminum alkoxides, precipitated alumina, aluminum hydroxide, aluminum salts, aluminum metal and mixtures thereof.

7. The process of claim 1 where the silica source is selected from the group consisting of tetra-ethylorthosilicate, fumed silicas, precipitated silicas, colloidal silica and mixtures thereof.

8. The process of claim 1 where the aging time of the initiator varies from about 1 hour to about 14 days.

9. The process of claim 1 where the source of the M metals is selected from the group consisting of the halide salts, nitrate salts, acetate salts, hydroxides and mixtures thereof.