US4511667A
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Composite zeolite-asbestos catalysts
Assignee: Concordia University
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Filing: 1984-01-16
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Granted: 1985-04-16
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Expires: 2004-01-16
Abstract
Abstract Composite zeolite-asbestos materials containing a zeolite component formed directly from an asbestos material are described. Usually the composite will comprise a matrix of asbestos and discrete zeolite crystal formations intimately associated therewith. In the case of chrysotile asbestos, the matrix usually retains its fibrous character and when the zeolite is ZSM-5, characteristic spherical nodules of the zeolite are present. The composite product may be used as a zeolite based shape selective catalyst or a zeolite-based morphological support for polyfunctional shape selective catalysts.
Inventors
- 👤 Raymond L. V. Mao
- 👤 Peter H. Bird
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 13:58
CPC Classifications
B; B01; B01J; B01J29/00; B01J29/04; B01J29/06; B01J29/70; C; C10; C10G; C10G3/00; C10G3/42; C10G3/44; C10G3/48; C10G3/49; B01J2229/00; B01J2229/10; B01J2229/26; B01J2229/30; B01J2229/42; Y; Y02; Y02P; Y02P30/00; Y02P30/20
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
21 words
A composite crude zeolite-asbestos-zeolite promoter material having a microstructure having intermingled crude zeolite and asbestos formations together with a zeolite-promoter substance.
Claim 2
Dependent Claim
21 words
A composite crude zeolite-asbestos-zeolite promoter material having a microstructure having intermingled crude zeolite and asbestos formations together with a zeolite-promoter substance.
Claim 3
Dependent Claim
64 words
The material of claim 1 comprising: (a) a silicon oxide (b) aluminum oxide (c) magnesium oxide (d) ferric oxide (e) sodium oxide, (f) a zeolite-promoter substance, (g) water in which the mole ratios are: (b)/(a) between 0.001 and 0.5; (c)/(a) between 0.01 and 1.5; (d)/(a) between 0.005 and 0.1; (e)/(a) between 0.001 and 0.5; (f)/(a) between 0.001 and 0.8; (g)/(a) between 0.5 and 20.
Claim 4
Dependent Claim
15 words
The material of claim 2 in which the zeolite-promoter substance (f) is a zeolite-structure-forming substance.
Claim 5
Dependent Claim
47 words
The material of claim 3 in which the zeolite-structure-forming substance is a tetraalkylammonium compound of the formula ##STR3## in which R 1 , R 2 , R 3 , R 4 are selected from lower alkyl groups, and X is one of a halide and a hydroxide.
Claim 6
Dependent Claim
12 words
The material of claim 4 wherein the tetraalkylammonium compound is tetrapropylammonium bromide.
Claim 7
Dependent Claim
15 words
The material of claim 2 wherein the zeolite promoter substance (f) is a zeolite-crystal-growing substance.
Claim 8
Dependent Claim
11 words
The material of claim 6 wherein the zeolite-crystal-growing substance is triethanolamine.
Claim 9
Dependent Claim
15 words
A solid composite zeolite-asbestos material having a microstructure having intimately intermingled zeolite and asbestos components.
Claim 10
Dependent Claim
15 words
A solid composite zeolite-asbestos material having a microstructure having intimately intermingled zeolite and asbestos components.
Claim 11
Dependent Claim
16 words
The composite zeolite-asbestos material of claim 8 wherein the zeolite component has been made in situ.
Claim 12
Dependent Claim
19 words
The composite zeolite-asbestos material of claim 8 wherein the zeolite is selected from a ZSM-5 zeolite and X-type zeolite.
Claim 13
Dependent Claim
30 words
The composite zeolite-asbestos material of claim 10 wherein zeolite crystal formations are retained on a matrix of chrysotile asbestos fibers, the composite having the x-ray pattern shown in Table 1.
Claim 14
Dependent Claim
48 words
The composite zeolite-asbestos material of claim 11 comprising: (a) a silicon oxide (b) aluminum oxide (c) magnesium oxide (d) ferric oxide (e) sodium oxide, the mole ratio of (b)/(a) between 0.001 and 0.5; (c)/(a) between 0.01 and 1.5; (d)/(a) between 0.005 and 0.1; (e)/(a) between 0.001 and 0.5.
Claim 15
Dependent Claim
40 words
The composite zeolite-asbestos material of claim 12 in which the zeolite is a ZSM-5 zeolite, the mole ratio of (b)/(a) being between 0.001 and 0.2; (c)/(a) between 0.01 and 1.5; (d)/(a) between 0.005 and 0.1; (e)/(a) between 0.001 and 0.2.
Claim 16
Dependent Claim
40 words
The composite zeolite-asbestos material of claim 12 in which the zeolite is an X-type zeolite, the mole ratio of (b)/(a) being between 0.3 and 0.5; (c)/(a) between 0.01 and 1.5; (d)/(a) between 0.005 and 0.1; (e)/(a) between 0.3 and 0.5.
Claim 17
Dependent Claim
17 words
The composite zeolite-asbestos materials of claim 8 in the form of a catalyst incorporating a catalyst carrier.
Claim 18
Independent Claim
144 words
A method of making a composite zeolite-asbestos-zeolite promoter material having intimately intermingled zeolite and asbestos formations together with a zeolite-promoter substance which comprises: (a) leaching asbestos with acid solution until part of the metal components of the asbestos lattice is solubilized; (b) impregnating the dried solid from (a) with a mixture of zeolite promoter substance and alkali metal hydroxide in aqueous solution, incubating at an elevated temperature sufficient to favor the formation of complex silicates and adding a solution of an aluminate of an alkali metal and continuing to incubate at an elevated temperature to obtain a geliform suspension, adding further zeolite promoter substance, the quantities and properties of materials added being sufficient to ensure the production of zeolite in subsequent treatment; and (c) heating the resulting incubated mixture sufficiently to yield crude zeolite formations in situ and yield the composite zeolite-asbestos-zeolite promoter material.
Claim 19
Independent Claim
144 words
A method of making a composite zeolite-asbestos-zeolite promoter material having intimately intermingled zeolite and asbestos formations together with a zeolite-promoter substance which comprises: (a) leaching asbestos with acid solution until part of the metal components of the asbestos lattice is solubilized; (b) impregnating the dried solid from (a) with a mixture of zeolite promoter substance and alkali metal hydroxide in aqueous solution, incubating at an elevated temperature sufficient to favor the formation of complex silicates and adding a solution of an aluminate of an alkali metal and continuing to incubate at an elevated temperature to obtain a geliform suspension, adding further zeolite promoter substance, the quantities and properties of materials added being sufficient to ensure the production of zeolite in subsequent treatment; and (c) heating the resulting incubated mixture sufficiently to yield crude zeolite formations in situ and yield the composite zeolite-asbestos-zeolite promoter material.
Claim 20
Dependent Claim
31 words
The method of claim 16 with the additional step between (a) and (b) of diluting the mixture with water sufficiently to allow solubilized silica to be precipitated in the solid lattice.
Claim 21
Dependent Claim
34 words
The method of claim 16 in which the metal components of the asbestos lattice being solubilized are primarily magnesium components and at least 50% of the magnesium atoms of the asbestos lattice is solubilized.
Claim 22
Dependent Claim
58 words
The method of claim 16 in which the degree of leaching is between 50 and 99.8% and the acid concentration used is between 1N and 2.5N, the acid is hydrochloric acid, the alkali metal hydroxide used to impregnate in (b) is sodium hydroxide, and the aluminate of an alkali metal used to impregnate in (b) is sodium aluminate.
Claim 23
Dependent Claim
25 words
The method of claim 16 in which the zeolite promoter substance is a zeolite-structure-forming substance and the zeolite formations resulting from step (c) are ZSM-5.
Claim 24
Dependent Claim
46 words
The method of claim 16 in which the zeolite-structure-forming substance is a tetraalkylammonium compound of the formula ##STR4## wherein R 1 , R 2 , R 3 , R 4 are selected from lower alkyl groups and X is one of a halide and a hydroxide.
Claim 25
Dependent Claim
13 words
The method of claim 21 in which the tetralkylammonium compound is tetrapropylammonium bromide.
Claim 26
Dependent Claim
39 words
The method of claim 20 in which the temperature used to impregnate in (b) is between 70° C. and 80° C., and the temperature used to form ZSM-5 zeolite formations in (c) is between 140° C. and 190° C.
Claim 27
Dependent Claim
24 words
The method of claim 16 in which the zeolite-promoter substance is a zeolite-crystal-growing substance and the zeolite resulting from step (c) is X-type zeolite.
Claim 28
Dependent Claim
46 words
The method of claim 24 in which the zeolite-crystal-growing substance is triethanolamine, the elevated temperature used to impregnate in step (b) is between 55° C. and 65° C. and the elevated temperature used to form zeolite in step (c) is between 60° C. and 80° C.
Claim 29
Dependent Claim
55 words
The method of claim 16 followed by (d) washing to remove extraneous ions from the solid residue resulting from step (c) and drying the resulting solid residue; and (e) subjecting the solid residue composite to an elevated temperature sufficient to remove zeolite-promoter substance, to leave a composite zeolite-asbestos material and to free catalytically active surfaces.
Claim 30
Dependent Claim
46 words
The method of claim 26 step (d) in which the solid residue is washed with water until the pH of the washing liquid is less than 9, and the method of step (e) in which the elevated temperature used is between 450° C. and 800° C.
Claim 31
Dependent Claim
56 words
The method of claim 26 followed by the additional steps of treating the composite zeolite-asbestos material with aqueous ammonium salts or with dilute acid under reflux conditions to convert to an H-form catalyst, separating, drying and subsequently heating the solid residue resulting therefrom to an elevated temperature to form catalytically active surfaces in said H-form catalyst.
Claim 32
Dependent Claim
25 words
The method of claim 28 in which the aqueous ammonium salt is ammonium chloride, and the elevated temperature is between 475° C. and 550° C.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-04-15 | 1988-10-15 | 1989-04-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-04-15 | 1992-10-15 | 1993-04-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-04-15 | 1996-10-15 | 1997-04-16 | $7700.00 | Window Closed / Lapsed |