Process for preparation of synthetic faujasite molded body

Claim 1

A process for the preparation of a synthetic faujasite molded body, which comprises: (a) preparing a structure-inducing substance, which substance has a composition defined by the following oxide molar ratios: SiO 2 /Al 2 O 2 =14 to 60, M 2 O/Al 2 O 3 =15 to 40, and H 2 O/M 2 O=12 to 40, wherein M is an alkali metal, and which substance is prepared by: (1) mixing together an aqueous solution of an alkali metal silicate, an aqueous solution of an alkali metal aluminate and an aqueous solution of an alkali metal hydroxide to prepare a liquid phase substance having a composition defined by the following oxide molar ratios: SiO 2 /Al 2 O 3 =8 to 14, M 2 O/Al 2 O 3 =7 to 30, and H 2 O/M 2 O=10 to 14, wherein M is as defined above; (2) aging the liquid phase substance at a temperature of 20° to 60° C. for 10 minutes to 6 hours; and (3) incorporating an aqueous solution of an alkali metal silicate into the aged liquid phase substance to obtain the structure-inducing substance; (b) mixing the structure-inducing substance with a starting material mixture comprising as the main components a silica source, an alumina source, an alkali source and water in such a manner that the amount of Al 2 O 3 present in the structure-inducing substance is 1 to 30% by weight based on the total weight of Al 2 O 3 present in the starting material mixture; (c) kneading the starting material mixture and the structure-inducing substance; (d) molding the kneaded mixture into a desired shape; and (e) heating the molded body in an aqueous solution of an alkali metal silicate or an aqueous solution of an alkali metal hydroxide to form a synthetic faujasite molded body.