Heteroatom containing zeolite catalysts have shown excellent catalytic activity and thermal stability in petrochemical processes as well as for converting biomass into biofuels and high-value chemicals. However, their synthesis is difficult, requiring harsh chemicals and long synthesis times.
This patented technology is several rapid, high-yield synthesis methods for heteroatom containing zeolites, such as Sn-Beta. The method begins with adding zeolite seeds to a solution comprising a heteroatom source and a structure-directing agent. By directly adding the seeds to the solution without calcination or drying, the seeds do not agglomerate and as a result, crystallization time is shortened. To complete catalyst synthesis from the resulting gel, it is then heated to form a solid, filtered, washed, dried, and finally calcined.
Specific methods disclosed in this patent include one as short as 2 days and the first fluorine-free synthesis route. The catalysts were demonstrated to be active for both sugar isomerization and dehydration reactions, necessary in fuel and chemical synthesis.
