Synthetic fraipontite and process for preparation thereof

Claim 2

A process for the preparation of a synthetic fraipontite type mineral having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al x )-O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises heating an oxide or hydroxide mixture or coprecipitate having a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO and 0 to 60 mole % of Al 2 O 3 in the presence of water to form a crystal of the fraipontite type by crystallization.

Claim 3

A process for the preparation of a micro-crystalline fraipontite type silicate material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al x )O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises reacting a water-soluble silicate, a water-soluble zinc solvent and a water-soluble aluminum salt and/or a water-soluble aluminate in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO and 0 to 60 mole % of Al 2 O 3 in the presence of water under heating at a temperature of up to 95° C. and a pH of 5 to 10 for a time sufficient to form a crystal, and heat-treating a formed coprecipitate in the presence of water at a temperature of 50° to 110° C.

Claim 4

A process for the preparation of a micro-crystalline fraipontite type silicate material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al x )O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises reacting a water-soluble silicate, a water-soluble zinc solvent and a water-soluble aluminum salt and/or a water-soluble aluminate in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO and 0 to 60 mole % of Al 2 O 3 in the presence of water under heating at a temperature of up to 95° C. and a pH of 5 to 10 for a time sufficient to form a crystal, and heat-treating a formed coprecipitate in the presence of water at a temperature of 50° to 110° C.

Claim 5

A process according to claim 2, wherein a solution of the water-soluble silicate is mixed with a solution containing the water-soluble zinc salt and the water-soluble aluminum salt to form a coprecipitate.

Claim 6

A process for the preparation of a synthetic fraipontite type material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al x )-O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises subjecting (a) silica or a silicon compound capable of forming silica under reaction conditions, (b) zinc flower, zinc hydroxide or a zinc compound capable of forming zinc hydroxide under reaction conditions and (c) alumina hydrate, or aluminum hydroxide under reaction conditions in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO and 0 to 60 mole % of Al 2 O 3 to hydrothermal reaction wherein reaction conditions comprise a temperature of 110° to 300° C. and a pressure of 0.5 to 87 kg/cm 2 for a time sufficient to form a crystal.

Claim 7

A process for the preparation of a synthetic fraipontite type material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al x )-O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises subjecting (a) silica or a silicon compound capable of forming silica under reaction conditions, (b) zinc flower, zinc hydroxide or a zinc compound capable of forming zinc hydroxide under reaction conditions and (c) alumina hydrate, or aluminum hydroxide under reaction conditions in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO and 0 to 60 mole % of Al 2 O 3 to hydrothermal reaction wherein reaction conditions comprise a temperature of 110° to 300° C. and a pressure of 0.5 to 87 kg/cm 2 for a time sufficient to form a crystal.

Claim 8

A process according to claim 4, wherein hydrothermal reaction is carried out in the presence of a salt of a basic nitrogen-containing compound with an acid.

Claim 9

A process according to claim 5, wherein said salt is an ammonium salt with a mineral acid.

Claim 10

A process according to claim 5, wherein said salt is made present in an amount of 10 to 300 mole% based on the zinc component.

Claim 11

A process for the preparation of a synthetic fraipontite type material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al 2 )-O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises subjecting (a) crystalline silica, (b) zinc flower, zinc hydroxide or a zinc compound capable of forming zinc hydroxide under reaction conditions and (c) alumina hydrate, aluminum hydroxide or an aluminum compound capable of forming alumina hydrate or aluminum hydroxide under reaction conditions in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO, and 2 to 60 mole % of Al 2 O 3 to hydrothermal reaction in the presence of a salt of a basic nitrogen-containing compound with an acid wherein reaction conditions comprise a temperature of 110° to 300° C. and a pressure of 0.5 to 87 kg/cm 2 for a time sufficient to form a crystal.

Claim 12

A process for the preparation of a synthetic fraipontite type material having a chemical structure represented by the formula (Zn 3-x Al x )(Si 2-x Al 2 )-O 5 (OH) 4 , wherein x is a number of from 0 to 1.75, which comprises subjecting (a) crystalline silica, (b) zinc flower, zinc hydroxide or a zinc compound capable of forming zinc hydroxide under reaction conditions and (c) alumina hydrate, aluminum hydroxide or an aluminum compound capable of forming alumina hydrate or aluminum hydroxide under reaction conditions in amounts corresponding to a three-component oxide composition comprising 5 to 45 mole % of SiO 2 , 35 to 65 mole % of ZnO, and 2 to 60 mole % of Al 2 O 3 to hydrothermal reaction in the presence of a salt of a basic nitrogen-containing compound with an acid wherein reaction conditions comprise a temperature of 110° to 300° C. and a pressure of 0.5 to 87 kg/cm 2 for a time sufficient to form a crystal.

Claim 13

A process according to claim 8, wherein the crystalline silica is cristobalite type silica.

Claim 14

A process according to claim 8, wherein said salt is made present in an amount of 10 to 300 mole% based on the zinc component.

Claim 15

Crystalline synthetic fraipontite having a chemical structure represented by the formula: (Zn.sub.3-x Al.sub.2)(Si.sub.2-x Al.sub.x)O.sub.5 (OH).sub.4 wherein x is a number of from 0 to 1.75, consisting of zinc phyllosilicate or aluminum-containing zinc phyllosilicate having the following X-ray diffraction pattern: ______________________________________ Spacing dx (Å) Relative Intensity I/Io ______________________________________ 8.4-6.4 40-70 3.9-3.5 40-70 2.7-2.6 100 2.5-2.4 50-80 1.6-1.7 50-80 ______________________________________ a Hunter whiteness of at least 80% and a specific surface area of at least 10 m 2 /g.

Claim 16

Crystalline synthetic fraipontite having a chemical structure represented by the formula: (Zn.sub.3-x Al.sub.2)(Si.sub.2-x Al.sub.x)O.sub.5 (OH).sub.4 wherein x is a number of from 0 to 1.75, consisting of zinc phyllosilicate or aluminum-containing zinc phyllosilicate having the following X-ray diffraction pattern: ______________________________________ Spacing dx (Å) Relative Intensity I/Io ______________________________________ 8.4-6.4 40-70 3.9-3.5 40-70 2.7-2.6 100 2.5-2.4 50-80 1.6-1.7 50-80 ______________________________________ a Hunter whiteness of at least 80% and a specific surface area of at least 10 m 2 /g.

Claim 17

Microcrystalline synthetic fraipontite as set forth in claim 11, which has a specific surface area of at least 100 m 2 /g.

Claim 18

A synthetic fraipontite mineral having a chemical structure represented by the formula: (Zn.sub.3-x Al.sub.x)(Si.sub.2-x Al.sub.x)O.sub.5 (OH).sub.4 wherein x is a number of from 0 to 1.75, consisting of aluminum-containing zinc phyllosilicate having lamellar plate-like crystals and having a Hunter whiteness of at least 80% and a specific surface area of at least 10 m 2 /g, said zinc phyllosilicate having the following X-ray diffraction pattern as determined by Cu-Kα rays: ______________________________________ Spacing (2θ) Relative Intensity I/Io ______________________________________ 11-14 85-115 24-26 45-75 33-35 25-55 37-39 15-45 44-46 0-25 59-61 5-35 ______________________________________ and the half-value width of each of the three strong peaks being less than 0.5° expressed as 2θ.

Claim 19

A synthetic fraipontite mineral having a chemical structure represented by the formula: (Zn.sub.3-x Al.sub.x)(Si.sub.2-x Al.sub.x)O.sub.5 (OH).sub.4 wherein x is a number of from 0 to 1.75, consisting of aluminum-containing zinc phyllosilicate having lamellar plate-like crystals and having a Hunter whiteness of at least 80% and a specific surface area of at least 10 m 2 /g, said zinc phyllosilicate having the following X-ray diffraction pattern as determined by Cu-Kα rays: ______________________________________ Spacing (2θ) Relative Intensity I/Io ______________________________________ 11-14 85-115 24-26 45-75 33-35 25-55 37-39 15-45 44-46 0-25 59-61 5-35 ______________________________________ and the half-value width of each of the three strong peaks being less than 0.5° expressed as 2θ.

Claim 20

A process according to claim 2 wherein the pH value of the reaction mixture is maintained at 6 to 9.

Claim 21

A process according to claim 2 wherein the coprecipitate is heat treated at a temperature of 70° to 95° C. for 0.5 to 5 hours.

Claim 22

A process according to claim 4 wherein said reaction conditions comprise a temperature of 140° to 200° C., a pressure of 2.5 to 15 kg/cm 2 and a reaction time of 3 to 24 hours.

Claim 23

A process according to claim 8 wherein the hydrothermal reaction is conducted in an aqueous slurry having a solid concentration of 3 to 30% by weight.

Claim 24

A process according to claim 8 wherein said reaction conditions comprise a temperature of 140° to 200° C., a pressure of 2.5 to 15 kg/cm 2 and a reaction time of 3 to 24 hours.