Synthesis of maximum aluminum X zeolites

Claim 2

A process for the synthesis of Maximum Aluminum X-type zeolite comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1, about 5% to 50% sodium and/or potassium hydroxide, and 40% to 90% water (all by weight); (b) agitating said mixture at between about 45° C.-60° C. for about 1 to 24 hours; and (c) recovering Maximum Aluminum X-type zeolite as a product.

Claim 3

A process, as recited in claim 1, wherein said mixture includes from 5% to 30% sodium hydroxide and from 3% to 15% potassium hydroxide.

Claim 4

A process, as recired in claim 1, wherein said clays are calcined at a temperature above 700° C.

Claim 5

A process as recited in claim 1 wherein the mixture formed in step (a) is immediately seeded with Maximum Aluminum X-type zeolite.

Claim 6

Maximum Aluminum X-type zeolite synthesized by the process comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1, about 5% to 50% sodium and/or potassium hydroxide, and 40% to 90% water (all by weight); (b) agitating said mixture at between about 45° C.-60° C. for about 1 to 24 hours; and (c) recovering Maximum Aluminum X-type zeolite as a product.

Claim 7

Maximum Aluminum X-type zeolite synthesized by the process comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1, about 5% to 50% sodium and/or potassium hydroxide, and 40% to 90% water (all by weight); (b) agitating said mixture at between about 45° C.-60° C. for about 1 to 24 hours; and (c) recovering Maximum Aluminum X-type zeolite as a product.

Claim 8

Maximum Aluminum X-type zeo-lite, synthesized by the process recited in claim 5, wherein said mixture includes from 5% to 30% sodium hydroxide and from 3% to 5% potassium hydroxide.

Claim 9

Maximum Aluminum X-type zeolite, synthesized by the process recited in claim 6, wherein said clays are calcined at a temperature above 700° C.

Claim 10

Maximum Aluminum X-type zeolite, synthesized by the process recited in claim 5, wherein the mixture formed in step (a) is immediately seeded with Maximum Aluminum X-type zeolite.

Claim 11

A process for the synthesis of Maximum Aluminum X-type zeolite comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1, about 5% to 50% zodium and/or potassium hydroxide, and 40% to 90% water (all by weight); (b) agitating said mixture at a temperature between 50° C.-0 80%C for 0.5 hours to 12 hours; (c) seeding the mixture with Maximnm Aluminum X-type zeolite 1 to 120 minutes after forming said mixture in step (a) and (d) recovering Maximum Aluminum X-type zeolite as product.

Claim 12

A process for the synthesis of Maximum Aluminum X-type zeolite comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1, about 5% to 50% zodium and/or potassium hydroxide, and 40% to 90% water (all by weight); (b) agitating said mixture at a temperature between 50° C.-0 80%C for 0.5 hours to 12 hours; (c) seeding the mixture with Maximnm Aluminum X-type zeolite 1 to 120 minutes after forming said mixture in step (a) and (d) recovering Maximum Aluminum X-type zeolite as product.

Claim 13

A process, as recited in either of claims 4 and 9 wherein said mixture is seeded by addition of from 0.1% to 25% by weight (relative to clay) Maximum Aluminum Xtype zeolite.

Claim 14

A process, as recited in either of claims 4 and 9 wherein said mixture is seeded by addition of from 1% to 10% by weight (relative to clay) Maximum Aluminum X-type zeolite.

Claim 15

A process, as recited either of claims 4 and 9 wherein said mixture is seeded by addition of from 2% to 5% by weight (relative to clay) Maximum Aluminum X-type zeolite.

Claim 16

The process of one of claims 1, 2, 4 and 9 wherein said Maximum Aluminum X-type zeolite is recovered as substantially spherical aggregates of 0.1-100 uM diameter.

Claim 17

The process of one of claims 1, 2, 4 and 9 wherein said Maximum Aluminum X-type zeolite is recovered as substantially spherical aggregates of 0.5-50 uM diameter.

Claim 18

Maximum Aluminum X-type zeolite synthesized by the process comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1 about 5% to 50% sodium and/or potassium hydroxide, and 40% to 90% water (all by weight)' (b) agitating said mixture at a temperature between 50° C.-80° C. for 0.5 hours to 12 hours; (c) seeding the mixture with Maximum Aluminum X-type zeolite 1 to 120 minutes after forming said mixture in step (a) and (d) recovering Maximum Aluminum X-type zeolite as product.

Claim 19

Maximum Aluminum X-type zeolite synthesized by the process comprising the steps of: (a) forming a mixture of from 2% to 50% calcined kaolin clays, said clays having a silicon to aluminum ratio of from 0.75:1 to 1.15:1 about 5% to 50% sodium and/or potassium hydroxide, and 40% to 90% water (all by weight)' (b) agitating said mixture at a temperature between 50° C.-80° C. for 0.5 hours to 12 hours; (c) seeding the mixture with Maximum Aluminum X-type zeolite 1 to 120 minutes after forming said mixture in step (a) and (d) recovering Maximum Aluminum X-type zeolite as product.

Claim 20

Maximum Aluminum X-type zeolite, synthesized by the process recited in either of claims 8 and 15 wherein said mixture is seeded by addition of from 0.1% to 25% by weight (relative to clay) Maximum Aluminum X-type zeolite.

Claim 21

Maximum Aluminum X-type zeolite, synthesized by the process recited in either of claims 8 and 15, wherein said mixture is seeded by addition of from 1% to 10% by weight (relative to clay) Maximum Aluminum X-type zeolite.

Claim 22

Maximum Aluminum X-type zeolite, synthesized by the process recited in either of claims 8 and 15 said mixture is seeded by addition of from 2% to 5% by weight (relative to clay) Maximum Aluminum X-type zeolite.

Claim 23

An improved ion-exchange capacity zeolite, said zeolite having: (a) A Silicon to Aluminum ratio of from 1.0 to 1.2; (b) A unit cell constant (a 0 ) of about 25.0 Å; (c) An X-ray powder diffraction pattern characterized by having at least the following five peaks ______________________________________ Order of XRD Peaks hkl ______________________________________ 1 111 2 751 3 642 4 533 5 331 ______________________________________

Claim 24

An improved ion-exchange capacity zeolite, said zeolite having: (a) A Silicon to Aluminum ratio of from 1.0 to 1.2; (b) A unit cell constant (a 0 ) of about 25.0 Å; (c) An X-ray powder diffraction pattern characterized by having at least the following five peaks ______________________________________ Order of XRD Peaks hkl ______________________________________ 1 111 2 751 3 642 4 533 5 331 ______________________________________