Facile synthesis of tin-containing zeolites

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 and Fe-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, the gel is then heated to form a solid, then filtered, washed, dried, and finally calcined.

Specific methods disclosed in this patent include one as short as 2 days, as well as 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 syntheses.

•       Can synthesize Sn-Beta, Si-Beta, Ti-Beta, Zr-Beta, and Fe-Beta zeolite catalysts

•       Cuts synthesis time from several weeks as little as 2 days

•       Catalyst yields from method >85%

•       Includes a fluorine-free synthesis method that is much safer than the traditional utilization of hydrofluoric acid

•       Performs sugar isomerization and dehydration reactions together, which eases catalyst separation and process engineering design and reduces corrosion, compared to liquid acids

•       Petrochemical processing

•       Chemicals and fuels from cellulosic biomass

•       One-pot HMF synthesis

•       Isomerization of triose, pentose, and hexose sugars

•       Selective oxidation reactions

Dr. Wei Fan is an Associate Professor of Chemical Engineering focusing on the rational synthesis of nanoporous materials for the catalysts of biorefinery and drug delivery carriers.