Method of making zeolite Y

Claim 1

A method of producing a crytalline synthetic faujasite of the zeolite "Y" type of a desired particle size, comprising the steps of separately preparing a sodium silicate solution and a sodium aluminate solution, providing an activated low water system comprising a sodium silicate solution with a seed amount up to about 10 percent by weight of the mixture of synthetic faujasite of the Zeolite "Y" type, mixing the sodium aluminate solution with the activated system over a period of up to about five hours to form a reaction mixture having the following molar ratios: sodium oxide to silica--0.5:1 to 1:1, silica to alumina--10:1 to 15:1, and water to sodium oxide--17:1 to 30:1, allowing the mixture to stand for up to about 24 hours at a temperature from about 0° C. to ambient, drying and particulating the resulting mixture to a Zeolite "Y" of a particle size of about 65 to 80 microns, slurrying the particles and then heating the mixture to a temperature of about 80° C.-120° C. until the desired crystalline synthetic faujasite of the Zeolite "Y" type is formed, and recovering said Zeolite "Y" of an average particle size range of about 65 to 80 microns.

Claim 2

A method of producing a crytalline synthetic faujasite of the zeolite "Y" type of a desired particle size, comprising the steps of separately preparing a sodium silicate solution and a sodium aluminate solution, providing an activated low water system comprising a sodium silicate solution with a seed amount up to about 10 percent by weight of the mixture of synthetic faujasite of the Zeolite "Y" type, mixing the sodium aluminate solution with the activated system over a period of up to about five hours to form a reaction mixture having the following molar ratios: sodium oxide to silica--0.5:1 to 1:1, silica to alumina--10:1 to 15:1, and water to sodium oxide--17:1 to 30:1, allowing the mixture to stand for up to about 24 hours at a temperature from about 0° C. to ambient, drying and particulating the resulting mixture to a Zeolite "Y" of a particle size of about 65 to 80 microns, slurrying the particles and then heating the mixture to a temperature of about 80° C.-120° C. until the desired crystalline synthetic faujasite of the Zeolite "Y" type is formed, and recovering said Zeolite "Y" of an average particle size range of about 65 to 80 microns.

Claim 16

A method of preparing a crystalline zeolite Y, comprising the steps of: (a) preparing a sodium silicate solution having a silica to sodium oxide molar ratio of between 1.7:1 and 4.2:1; (b) providing an activated system comprising a seed amount of bulk zeolite Y up to about 10 percent by weight of the mixture 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) drying the mixture of step (e) and particulating same to a particle size range of about 65 to 80 microns; (g) slurring the particles produced in step (f) in water; (h) heating and reacting the particles of step (g) at a temperature of about 80° C. to 120° C. until crystalline zeolite Y of a particle size range of about 65 to 80 microns is formed; and (i) recovering the zeolite Y of a particle size range of about 65 to 80 microns.

Claim 17

A method of preparing a crystalline zeolite Y, comprising the steps of: (a) preparing a sodium silicate solution having a silica to sodium oxide molar ratio of between 1.7:1 and 4.2:1; (b) providing an activated system comprising a seed amount of bulk zeolite Y up to about 10 percent by weight of the mixture 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) drying the mixture of step (e) and particulating same to a particle size range of about 65 to 80 microns; (g) slurring the particles produced in step (f) in water; (h) heating and reacting the particles of step (g) at a temperature of about 80° C. to 120° C. until crystalline zeolite Y of a particle size range of about 65 to 80 microns is formed; and (i) recovering the zeolite Y of a particle size range of about 65 to 80 microns.