Production of synthetic zeolites

Claim 1

A method of producing a crystalline synthetic faujasite of the zeolite "Y" type, comprising the steps of separately preparing a sodium silicate solution and a sodium aluminate solution, providing an activated system comprising a sodium silicate solution mixed with agitation for a period of at least about one-half hour with a seed amount of finely ground synthetic faujasite of the zeolite "Y" type at a temperature up to about 0° C., mixing the sodium aluminate solution with the activated system over a period of up to about five hours to provide a mixture having the following molar ratio: (4.4-8.5)Na.sub.2 O.Al.sub.2 O.sub.3.(10.1-16.0)SiO.sub.2.(145-200)H.sub.2 O, allowing the mixture to stand for up to about 24 hours at a temperature from about 0° C. to ambient, heating the mixture to a temperature of about 90° C.-105° C. and reacting at said temperature until the desired crystalline synthetic faujasite of the zeolite "Y" type is formed, and recovering said zeolite "Y".

Claim 2

A method of producing a crystalline synthetic faujasite of the zeolite "Y" type, comprising the steps of separately preparing a sodium silicate solution and a sodium aluminate solution, providing an activated system comprising a sodium silicate solution mixed with agitation for a period of at least about one-half hour with a seed amount of finely ground synthetic faujasite of the zeolite "Y" type at a temperature up to about 0° C., mixing the sodium aluminate solution with the activated system over a period of up to about five hours to provide a mixture having the following molar ratio: (4.4-8.5)Na.sub.2 O.Al.sub.2 O.sub.3.(10.1-16.0)SiO.sub.2.(145-200)H.sub.2 O, allowing the mixture to stand for up to about 24 hours at a temperature from about 0° C. to ambient, heating the mixture to a temperature of about 90° C.-105° C. and reacting at said temperature until the desired crystalline synthetic faujasite of the zeolite "Y" type is formed, and recovering said zeolite "Y".

Claim 11

A method of preparing a crystalline zeolite Y, comprising the steps of: (a) dissolving sand in a sodium hydroxide solution at a pressure of at least 100 psig and a temperature of at least 130° C. to produce a sodium silicate solution having a silica to sodium oxide molar ratio of between 1.7:1 and 5.0:1; (b) providing an activated system comprising the sodium silicate solution from step (a) mixed with agitation for a period of at least about one-half hour with a seed amount of finely ground bulk zeolite Y at a temperature up to about 0° C.; (c) forming a sodium aluminate solution; (d) adding the sodium aluminate to the activated system over a period of from about five minutes to five hours with stirring to produce a reaction mixture comprising a sodium silicate mother liquor and an amorphous sodium alumino silicate pigment, said mixture having a sodium oxide to silica molar ratio of between 0.5:1 and 1:1, a silica to alumina molar ratio of between 10:1 and 15:1, and a water to sodium oxide molar ratio of between 17:1 and 30:1; (e) allowing the mixture to stand up to about 24 hours at a temperature of about 0° C. to ambient; (f) heating and reacting the mixture at a temperature of about 90° C.-105° C. until crystalline zeolite Y is formed; and (g) recovering the zeolite Y.

Claim 12

A method of preparing a crystalline zeolite Y, comprising the steps of: (a) dissolving sand in a sodium hydroxide solution at a pressure of at least 100 psig and a temperature of at least 130° C. to produce a sodium silicate solution having a silica to sodium oxide molar ratio of between 1.7:1 and 5.0:1; (b) providing an activated system comprising the sodium silicate solution from step (a) mixed with agitation for a period of at least about one-half hour with a seed amount of finely ground bulk zeolite Y at a temperature up to about 0° C.; (c) forming a sodium aluminate solution; (d) adding the sodium aluminate to the activated system over a period of from about five minutes to five hours with stirring to produce a reaction mixture comprising a sodium silicate mother liquor and an amorphous sodium alumino silicate pigment, said mixture having a sodium oxide to silica molar ratio of between 0.5:1 and 1:1, a silica to alumina molar ratio of between 10:1 and 15:1, and a water to sodium oxide molar ratio of between 17:1 and 30:1; (e) allowing the mixture to stand up to about 24 hours at a temperature of about 0° C. to ambient; (f) heating and reacting the mixture at a temperature of about 90° C.-105° C. until crystalline zeolite Y is formed; and (g) recovering the zeolite Y.