Systems and methods for synthesis of zsm-22 zeolite

Abstract

Systems and methods for production of consistently-sized ZSM- 22 zeolite catalyst crystals, a method including preparing an aluminate solution; preparing a silica solution; mixing the aluminate solution and the silica solution to form a zeolite-forming solution; heating the zeolite solution with microwave irradiation in a first, a second, a third, and a fourth distinct isothermal stage to produce the consistently-sized ZSM- 22 zeolite catalyst crystals within a pre-selected crystal size range using a non-ionic surfactant.

That claimed is: 
     
         1 . A system for producing consistently-sized ZSM-22 zeolite catalyst crystals, the system comprising:
 an aluminate solution mixing chamber;   a silica solution mixing chamber; and   a microwave-application mixing unit, the microwave-application mixing unit in fluid communication with both the aluminate solution mixing chamber and the silica solution mixing chamber, wherein the microwave-application mixing unit mixes and heats a zeolite-forming solution from the aluminate solution mixing chamber and the silica solution mixing chamber with microwave irradiation in a first, a second, a third, and a fourth distinct isothermal stage to produce the consistently-sized ZSM-22 zeolite catalyst crystals within a pre-selected nano-scale crystal size range using a non-ionic surfactant.   
     
     
         2 . The system according to  claim 1 , wherein the aluminate solution mixing chamber prepares an aluminate solution for the zeolite-forming solution and the silica solution mixing chamber prepares a silica solution for the zeolite-forming solution. 
     
     
         3 . The system according to  claim 1 , where the system comprises controllable stirring means in the aluminate solution mixing chamber, the silica solution mixing chamber, and the microwave-application mixing unit. 
     
     
         4 . The system according to  claim 1 , where a majority of the consistently-sized ZSM-22 zeolite catalyst crystals within the pre-selected nano-scale crystal size range exhibit lengths varying from about 50 nm to about 600 nm, and widths ranging from about 55 nm to about 75 nm. 
     
     
         5 . The system according to  claim 2 , where the system is operable to control a ratio of silicon to aluminum to produce the consistently-sized ZSM-22 zeolite catalyst crystals within the pre-selected crystal size range. 
     
     
         6 . The system according to  claim 1 , where in the first isothermal stage microwave irradiation is applied to heat the zeolite-forming solution to between about 35° C. and about 65° C. for between about 3 minutes and about 7 minutes, with stirring applied at a speed between about 200 rpm and about 300 rpm. 
     
     
         7 . The system according to  claim 6 , where in the second isothermal stage microwave irradiation is applied to heat the zeolite-forming solution to between about 90° C. and about 120° C. for between about 5 and about 15 minutes, with stirring applied at a speed between about 200 rpm and about 300 rpm. 
     
     
         8 . The system according to  claim 7 , where the non-ionic surfactant is added after the second isothermal stage. 
     
     
         9 . The system according to  claim 8 , where in the third isothermal stage microwave irradiation is applied to heat the zeolite-forming solution to between about 35° C. and about 65° C. for between about 60 and about 80 hours, with stirring applied at a speed between about 350 rpm and about 450 rpm. 
     
     
         10 . The system according to  claim 9 , where in the fourth isothermal stage microwave irradiation is applied to heat the zeolite-forming solution to between about 155° C. and about 205° C. for between about 8 and about 16 hours.