THERMAL AND HYDROTHERMAL STABILITIES

A typical NaY zeolite contains approximately 13 wt% Na20. To enhance activity and thermal and hydrothermal stability of NaY, the sodium level must be reduced. This is normally done by the ion exchanging of NaY with a medium containing rare earth cations and/ or hydrogen ions. Ammonium sulfate solutions are frequently employed as a source for hydrogen ions. 

MicrocrystalUne zeolites such as beta zeolite suffer from calcination. The crystallinity is decreased and the framework can be notably dealuminated by the steam generated [175]. Potential Br0nsted catalytic sites are lost and heteroatoms migrate to extra-framework positions, leading to a decrease in catalytic performance. Nanocrystals and ultrafine zeolite particles display aggregation issues, difficulties in regeneration, and low thermal and hydrothermal stabilities. Therefore, calcination is sometimes not the optimal protocol to activate such systems. Application of zeolites for coatings, patterned thin-films, and membranes usually is associated with defects and cracks upon template removal. 

This chapter discusses the synthesis, characterization and applications of a very unique mesoporous material, TUD-1. This amorphous material possesses three-dimensional intercoimecting pores with narrow pore size distribution and excellent thermal and hydrothermal stabilities. The basic material is Si-TUD-1 however, many versions of TUD-1 using different metal variants have been prepared, characterized, and evaluated for a wide variety of hydrocarbon processing applications. Also, zeolitic material can be incorporated into the mesoporous TUD-1 to take the advantage of its mesopores to facilitate the reaction of large molecules, and enhance the mass transfer of reactants, intermediates and products. Examples of preparation and application of many different TUD-1 are described in this chapter. 

The development of composite micro/mesoporous materials opens new perspectives for the improvement of zeolytic catalysts. These materials combine the advantages of both zeolites and mesoporous molecular sieves, in particular, strong acidity, high thermal and hydrothermal stability and improved diffusivity of bulky molecules due to reduction of the intracrystalline diffusion path length, resulting from creation of secondary mesoporous structure. It can be expected that the creation of secondary mesoporous structure in zeolitic crystals, on the one hand, will result in the improvement of the effectiveness factor in hydroisomerization process and, on the other hand, will lead to the decrease of the residence time of products and minimization of secondary reactions, such as cracking. This will result in an increase of both the conversion and the selectivity to isomerization products. 

Stability. Ultrastable Y zeolites, prepared by the hydrothermal treatment of ammonium Y zeolites, have considerable thermal and hydrothermal stability (6) The high... 

Aluminum-deficient Y zeolites prepared by partial removal of aluminum with a chelating agent (e.g. EDTA) also show improved thermal and hydrothermal stability compared to the parent zeolite. The optimum stability was found in the range of 25 to 50 percent of framework A1 extraction (8). However, the maximum degree of dealumination is also affected by the SiO /Al O ratio in the parent zeolite a higher ratio appears to allow more advanced dealumination without loss of crystallinity (8,25,45). Above 50 or 60 percent dealumination, significant loss of crystallinity was observed. Calcination of the aluminum-deficient zeolite resulted in a material with a smaller unit cell size and lower ion-exchange capacity compared to the parent zeolite. 

The characteristics of aluminophosphate molecular sieves include a univariant framework composition with Al/P = 1, a high degree of structural diversity and a wide range of pore sizes and volumes, exceeding the pore sizes known previously in zeolite molecular sieves with the VPI-5 18-membered ring material. They are neutral frameworks and therefore have nil ion-exchange capacity or acidic catalytic properties. Their surface selectivity is mildly hydrophilic. They exhibit excellent thermal and hydrothermal stability, up to 1000 °C (thermal) and 600 °C (steam). 

The introduction of silicon into hypothetical phosphorus sites produces negatively charged frameworks with cation-exchange properties and weak to mild acidic catalytic properties. Again, as in the case of the aluminophosphate molecular sieves, they exhibit excellent thermal and hydrothermal stability. 

The spectrum of adsorption pore sizes and pore volumes and the hydrophilic surface selectivity of the MeAPOs are similar to those described for the SAPOs. The observed catalytic properties vary from weakly to strongly acidic and are both metal- and structure-dependent. The thermal and hydrothermal stability of the MeAPO materials is somewhat less than that of the AIPO4 and SAPO molecular sieves. 

In the early 70 s, FCC formulations containing 10-40% CREY (calcined rare-earth exchanged Y zeolites) were widely employed because these catalysts offered improved chemical as well as thermal and hydrothermal stability over FCC compositions containing equivalent amounts of (low sodium) HY crystals (23-25). The... 

Different procedures can be used in practice to activate the zeolite, and the choice of a particular method will depend on the catalytic characteristics desired. If the main objective is to prepare a very active cracking catalyst, then a considerable percentage of the sodium is exchanged by rare earth cations. On the other hand, if the main purpose is to obtain gasoline with a high RON, ultrastable Y zeolites (USY) with very low Na content are prepared. Then a small amount of rare earth cations is exchanged, but a controlled steam deactivation step has to be introduced in the activation procedure to obtain a controlled dealumination of the zeolite. This procedure achieves a high thermal and hydrothermal stability of the zeolite, provided that silicon is inserted in the vacancies left by extraction of A1 from the framework (1). The commercial catalysts so obtained have framework Si/Al ratios in the... 

Thermal and hydrothermal stability are necessary but not sufficient criteria for an acceptable cracking catalyst, since both the life expectancy and the activity of the zeolite catalyst is of importance to the refiner. Activity is controlled by the catalyst manufacturer in one of two ways, by either adding more zeolite or increasing the stability and activity of the zeolite. 

From 1967 to 1969, Kerr published a series of papers on the question of thermal and hydrothermal stabilities of sodium and hydrogen zeolite Y (22-26). These studies indicated that upon removal of about one-third of the aluminum from zeolite Y, using ethylenediaminetetraacetic acid (H4EDTA), the thermal and hydrothermal stabilities were much enhanced. This was observed for both sodium (23) and hydrogen (25) forms of the zeolite. The latter was prepared by careful calcination of an ammonium zeolite from which about 30% of the ammonium and aluminum had been removed. Kerr also showed that the true or normal hydrogen zeolite with... 

The addition of water-soluble polymers such as polyethylene oxide (PEO) or polyvinyl alcohol (PVA) into the synthetic mixture of the C TMAX-HN03-TE0S-H20 system (n = 16 or 18 X = Br or Cl) under shear flow is found to promote uniformity and elongation of rope-like mesoporous silica. The millimeter-scaled mesoporous silica ropes are found to possess a three-level hierarchical structure. The addition of water-soluble polymer does not affect the physical properties of the silica ropes. Moreover, further hydrothermal treatment of the acid-made material under basic ammonia conditions effectively promotes reconstruction of the silica nanochannels while maintaining the rope-like morphology. As a result, a notable enhancement in both thermal and hydrothermal stability is found. 

Substitution of silicon by other atoms like Ti or Al was reported to improve the thermal and hydrothermal stability to some extent [6]. It was also reported that improved hydrothermal stability could be achieved by adjusting the gel pH several times during crystallization process [7], Post-synthesis silylation technique has also been reported to enhance the hydrothermal stability of mesoporous materials by increasing the hydrophobicity of the samples [8,9]. However, it is most desirable to develop a method for preparing hydrother-mally stable mesoporous material by direct synthesis route. 

The unique properties of lanthanide-based materials, e.g., lanthanide-silicates and lanthanide-doped silicas, can be related to the special properties of the 4f" orbitals. Among lanthanide oxides, only Ce, Pr and Tb form dioxides, which crystallize in one simple structure with M4+ ions showing octahedral coordination [17]. For instance, cerium dioxide exhibits an 8 4 catiomanion coordination [18]. Its characteristic feature is the ability to undergo oxidation-reduction cycles in a reversible way [19], It was shown that the presence of Ce and La additives in mesoporous silicas, e.g., MCM-41 [10,11] and MSU-X [12], improves their thermal and hydrothermal stability. 

In our previous paper we have reported that silica MCM-41 exhibits a large amount of reversible adsorption, high thermal and hydrothermal stabilities, and little catalytic acidity and is an excellent adsorbent in PSA process for recovery of 2-propanol and toluene vapors [1]. Here we present the results of PSA of butanone on silica MCM-41 and discuss the effect of pretreatment temperatures on adsorption properties of MCM-41. 

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