Process for the Preparation of Organo-Template Free Supported Zeolite Layers

Simple SummaryContent extracted from patent full text and abstract with AI.

The patented invention describes a process for creating supported zeolite layers, especially BEA-type (beta) zeolite layers, without the use of organo-templates (organic molecules usually needed in zeolite synthesis for directing crystal structure). The method involves two main steps: first, zeolite seed crystals are coated onto a support material, and second, the zeolite layer is grown on this support using either hydrothermal treatment or steam-assisted conversion, all in the absence of additional organo-templates. This eliminates the need for high-temperature template removal, reducing potential defects and stress in the final product.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacture of zeolite membranes for gas separation and purification (e.g., CO2 or CH4 capture).
• Catalytic reactors, notably in chemical and petrochemical industries, where supported zeolite layers serve as catalysts.
• Development of sensors that use zeolite coatings for selective adsorption.
• Creation of ion-exchange materials for water treatment and softening.
• Membrane reactors that combine separation and reaction processes at high temperatures.
• Production of structured catalysts with improved heat and mass transfer inside reactors.

BenefitsContent extracted from patent full text and abstract with AI.

• Avoids the use of organo-templates, reducing cost and environmental impact associated with their use and removal.
• Eliminates the high-temperature calcination step for template removal, reducing risk of structural damage, cracking, and defects in the zeolite layer.
• Produces more robust, continuous and defect-free zeolite layers, which perform better in membrane and catalytic applications.
• Expands the choice of support materials, as lower synthesis temperatures and gentler procedures are possible without organics.
• Reduces production complexity and increases process scalability.
• Enables the fabrication of high-silica (BEA-type) zeolite layers that were previously not possible without templates.

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Inventors & Applicants

Patent Abstract

Provided is a process for the preparation of an organo-template free, supported zeolite layer, preferably a BEA-type zeolite layer, said process comprising at least two steps, with a first step (i) wherein seed crystals are coated onto a support, and a second step (ii) wherein the zeolite layer is prepared on the support in the absence of an organo-template via (iia) a hydrothermal treatment of the support having seed crystals deposited thereon, or via (iib) a steam-assisted conversion process on the support having seed crystals coated thereon.