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• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
  • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
  • B01J20/16—Alumino-silicates
  • B01J20/18—Synthetic zeolitic molecular sieves
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
  • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
  • B01J20/16—Alumino-silicates
  • B01J20/18—Synthetic zeolitic molecular sieves
  • B01J20/186—Chemical treatments in view of modifying the properties of the sieve, e.g. increasing the stability or the activity, also decreasing the activity
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
  • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
  • B01J20/28042—Shaped bodies; Monolithic structures
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
  • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
  • B01J20/28042—Shaped bodies; Monolithic structures
  • B01J20/28045—Honeycomb or cellular structures; Solid foams or sponges
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/30—Processes for preparing, regenerating, or reactivating
  • B01J20/3007—Moulding, shaping or extruding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/30—Processes for preparing, regenerating, or reactivating
  • B01J20/3042—Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/30—Processes for preparing, regenerating, or reactivating
  • B01J20/3071—Washing or leaching
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
  • B01J20/30—Processes for preparing, regenerating, or reactivating
  • B01J20/3078—Thermal treatment, e.g. calcining or pyrolizing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/082—X-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/084—Y-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
  • B01J29/7003—A-type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/06—Washing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2253/00—Adsorbents used in seperation treatment of gases and vapours
  • B01D2253/10—Inorganic adsorbents
  • B01D2253/106—Silica or silicates
  • B01D2253/108—Zeolites
  • B01D2253/1085—Zeolites characterized by a silicon-aluminium ratio
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
  • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
  • B01J35/57—Honeycombs

Definitions

• the invention relates to compact zeolitic shaped articles, which are characterized in that they have a zeolite content of at least 90%, and preferably at least 95%, determined by means of suitable adsorption methods. Furthermore, the present invention relates to a process for the preparation of compact zeolitic shaped articles, which is characterized in that a) a moldable mixture comprising zeolite and one or more zeolite precursor components and optionally water and optionally one or more organic additives is processed into shaped articles b) subjecting the shaped bodies thus obtained to a thermal treatment, and c) subjecting the thermally treated shaped bodies to watering, aging and contact with another component from which zeolite can be prepared in combination with the zeolite precursor components and subjected to conditions under which forms from the further component and the zeolite precursor components zeolite.
• a further aspect of the present invention relates to compact zeolitic moldings which can be produced according to such a method and to the use of such compact zeolitic moldings for adsorption processes or thermochemical applications, for example in energy storage, or as catalyst or constituent of a catalyst or as support material for zeolite membranes.
• the compact zeolitic moldings are characterized by high adsorption capacities, which are not impaired by an adsorptively inert binder or other adsorptively inert materials additionally contained in the compact zeolitic shaped body.
• Zeolites belong to the class of crystalline aluminosilicates and were originally discovered as natural minerals.
• the composition of the substance group of the zeolites can be described by the following formula (I):
• the factor n indirectly, the charge of the cation M is determined, which is typically present as alkali metal or alkaline earth metal cation.
• the factor y indicates how many water molecules are contained in the crystal.
• the molar ratio of Si0 2 to Al 2 0 3 in the empirical formula is called module (x). The module can not become smaller than 2 due to the Löwenstein rule 1 .
• zeolites with a faujasite structure in which, depending on their chemical composition, two types are distinguished.
• Products with a corresponding skeleton construction and a modulus of> 2, but less than 3.0, are referred to as X zeolites, while those with a modulus> 3.0 are referred to as Y zeolites.
• Another important zeolite is the Linde type A structure, which has a chemical composition of the zeolite framework characterized by a modulus of 2.
• the freely selectable cations can influence the pore size and accessibility of the zeolite framework and alter the polar properties of the zeolite type.
• Zeolites are due to their high chemical and thermal resistance, the present regular pore system with pore openings in the subnanometer range and the ability to form specific interactions with adsorbed molecules, inter alia due to a variable cation composition ideal adsorbents and are proven in both static, ie non-regenerative (z B. Drying of the washer volume in insulating glass windows 2 ) as well as in dynamic, ie regenerative (drying and purification of gases and liquids as well as for substance separation 2 ) adsorption processes used. Since the process of adsorption under heat release, the process of regeneration (desorption), however, under heat absorption, zeolites can also be used for heat storage and conversion and thus make a contribution to active environmental protection 3 .
• zeolites are used as catalyst 7 or catalyst component 8 or component for zeolite membranes 9 .
• Adsorbent filled with adsorbent beds Since in dynamic (regenerative) applications the adsorptively active component usually has to be circulated by a fluid medium, one uses in the corresponding process technology so-called Adsorbent filled with adsorbent beds. In this case, in order to avoid excessive pressure losses over these beds, the use of zeolite shaped bodies of a certain minimum size is unavoidable.
• honeycomb bodies Even with a ratio of web width to channel diameter of 1, with hexagonal and triangular honeycomb geometries more than 80% can be achieved (Table 1). From a geometrical point of view, it follows that with a ratio of web width to channel diameter of 3 to 1, all geometries achieve spatial fillings of approximately 95%. This honeycomb body can be easily flowed through. By the mutual closing of honeycomb channels also a forced flow through the webs and thus a further increase in efficiency can be achieved.
• these compact zeolitic shaped bodies can also be used for large or adsorption-selective separation (membrane separation).
• Table 1 Room filling for a ball bed and different honeycomb geometries.
• adsorption capacity of zeolite beds or full bodies depends on the proportion of adsorption-active zeolite substance.
• zeolite powder product of classical zeolite synthesis
• adsorption-inert excipients for the preparation of corresponding compact shaped bodies 13,14 or granules 15 are used in practice.
• the introduction of the above-mentioned binder causes a "dilution" of the active component and thus leads to lower adsorption capacities.
• Processes on the pure zeolite cause, as often in the process of shaping by build-up granulation, extrusion, etc. takes place compression and thereby a disadvantageous for the application transport pore system is formed 15.
• binder-containing zeolitic moldings must be highly porous in most applications, to Highly porous shaped articles are obtained, for example, by adding pore images to the zeolite powder / binder mixture prior to the shaping of binder-containing zeolitic shaped articles The added pore formers are burned out during the final thermal activation of the moldings, leaving behind a corresponding pore system 16 '17 . There is also the possibility of using water-soluble pore-forming agents 18 .
• a further possibility for the production of zeolite-containing, compact shaped bodies is the so-called “washcoating", in which adsorptive or catalytically active powders are used. ver on inert or low active, compact body (eg honeycomb body) applied as an outer zeolite layer, this also using a non-zeolite binder 19,20 .
• the prior art describes conventionally produced compact moldings based on binders whose binder content leads to a considerable reduction of the adsorptive or catalytically active fraction.
• binders whose binder content leads to a considerable reduction of the adsorptive or catalytically active fraction.
• These may be prepared by extrusion from a mixture of zeolite, a mixture of bi- and tri-layer clay minerals, inorganic fiber materials (eg, glass fiber 28 , zirconia 29 ), and glucans 328 .
• the equilibrium water adsorption capacity is reduced by the proportion of adsorptive-inert binder used.
• the apparent insufficient porosity of the transport pore system shows by the very slow water absorption.
• Siloxane compounds are also described as suitable binders for the preparation of zeolite 3A, 4A, 5A or X-honeycomb bodies 30 .
• adsorptive-inert binders are also formed from the siloxane compounds during processing, the solvent contained in the siloxane derivatives, albeit in a small amount, which can only be removed under solvent-specific safety regulations, is regarded as disadvantageous for this process .
• low activation temperature of max. 280 ° C speaks for an energy-saving activation process, however, the required state of activation of the finished moldings can be achieved at these temperatures, if at all, only within very long activation times.
• Activating describes in the present work a temperature treatment of the zeolitic material in which the zeolite is added to the activation state required for the use of the compact zeolitic shaped bodies, ie, retains a negligible residual moisture content for the application.
• pore formers To improve the transport pore structure in the production of compact, binder-containing zeolite shaped bodies, the use of pore formers is described 31 . Disadvantages here are the high temperatures (up to 850 ° C.) required for removing the pore formers and solidifying the binder. Also in this case, the adsorption capacity is reduced by the proportion of adsorption-inert binder.
• the compact zeolitic moldings produced should preferably have a maximum content of active zeolite material, for example in the form of faujasite-type zeolites (comprising both zeolite X and zeolite Y) or Linde type A structure.
• a first aspect of the present invention relates to compact zeolitic shaped articles, which are characterized in that they have a zeolite content of at least 90%, and preferably at least 95%, determined by means of suitable adsorption methods.
• zeolite content determined in this way, the water adsorption capacities of the compact zeolitic shaped bodies relating to the invention and of the starting zeolite powder of the same zeolite structure and the same chemical composition were set in relation.
• the compact zeolitic shaped bodies according to the invention are preferably based on zeolite Y, preferably with a modulus of greater than 4.9, more preferably in the range of 4.9 to 5.5, or zeolite X or zeolite A or a mixture of zeolite types.
• a compact zeolitic shaped article is a shaped article which preferably has a bulk filling of 80% or more, more preferably 85% or more, and most preferably 90% or more.
• No shaped bodies in the context of the present invention are shaped bodies from which conventional adsorbent or catalyst beds can be generated (for example in the form of spheres or short extruded (possibly also hollow) extruded bodies).
• spherical granules whose ball sizes, as described above, are optimally matched to one another, do not fall under the definition of a compact zeolitic shaped body. It is crucial that the compact zeolitic shaped body is used in its use as such, and not in the form of a bed of a plurality of bodies, which have the overall properties of a bed.
• the compact zeolitic moldings according to the present invention are not subject to any relevant restrictions.
• the compact zeolitic shaped bodies according to the invention may, for example, have the shape of a plate, a tube, a solid cylinder or a honeycomb. However, it is preferred that they have the highest possible space filling at the same time comparatively very good Have flow through, which is given for example in a honeycomb shape with wide webs and narrow channels.
• the compact zeolitic shaped articles according to this invention it is preferred that they are substantially free of non-zeolitic constituents.
• zeolites with a faujasite or Linde type A structure preference is given to zeolites with a faujasite or Linde type A structure, or mixtures of both zeolite types or their use in the process described below.
• the compact zeolitic shaped bodies according to the invention when they have been prepared on the basis of zeolite with Linde type A structure, preferably have a water absorption capacity of at least 22% by weight, particularly preferably of at least 24% by weight.
• the zeolitic compacts of the present invention are prepared from zeolite X, they have a water absorption capacity of at least 27% by weight, more preferably at least 29% by weight, and most preferably at least 30% by weight.
• the zeolitic compacts of the present invention when they are based on zeolite Y, they preferably have a water absorption capacity of at least 27% by weight, more preferably at least 28% by weight, and most preferably at least 29% by weight.
• a further aspect of the present invention relates to a process for the preparation of compact zeolitic shaped articles, which is characterized in that a) a moldable mixture comprising zeolite and one or more zeolite precursor components and optionally water and optionally one or more organic additives to moldings b) subjecting the resulting molded articles to thermal treatment, and c) subjecting the thermally treated molded articles to watering, aging and contacting with another component capable of producing zeolite in combination with the zeolite precursor components, and Conditions are exposed under which forms from the other component and the zeolite precursor components zeolite.
• Powdered zeolite is preferably used as the starting material in this process, but due to its structural composition it can not be plasticized in pure form and thus is not a preferred starting material for plastic forming processes.
• This zeolite is mixed with one or more zeolite precursor components.
• the main zeolite precursor component is preferably clay minerals having the chemical composition Al 2 Si 2 H 4 09, such as kaolinite or halloysite.
• Other zeolite precursor components may be, for example, caustic soda or soda water glass. Since the zeolite precursor components are to be converted into zeolite in the context of the process according to the invention, they must essentially consist of chemical elements / compounds which are also contained in the corresponding zeolite.
• kaolin which contains kaolinite as the main component, as a binder in z. B. intended for extrusion mixtures only very difficult to use, since these mixtures are significantly more difficult plastifiable compared to other systems.
• water and / or organic components with temporary binder action and / or lubricants in suitable amounts may be added as additives to the starting mixture consisting of zeolite and the zeolite precursor components.
• step a) The mass obtained is then processed in the course of step a) by a suitable method into moldings, d. H. brought into the desired shape.
• a suitable method for extrusion, pressing or casting are used.
• processing into shaped articles takes place by extrusion.
• the aggregates known in the prior art can be used.
• the plastic mixture prepared in a twin-screw kneader is preferably extruded to continuous strands with a vacuum screw extruder, the strands then being cut to a manageable length and then dried preferably to 5 to 20% dry loss, more preferably to 5 to 10% dry loss. Under dry loss, the water understood quantity that loses the examined sample in a treatment at 105 ° C within one hour.
• the processing into shaped articles takes place by pressing a mixture of zeolite, zeolite precursor components and / or water and / or one or more organic additives, preferably a polyvinyl alcohol solution.
• a kaolin-zeolite mixture preferably by means of a thermal granulation process according to the prior art, more preferably by means of a mechanical granulation process according to the prior art by adding a solution consisting of one or more organic components with temporary binder effect in a mixer containing the kaolin-zeolite mixture is prepared. After homogenization, the granules thus obtained can be dried and pressed on a dry press to give moldings.
• the processing into shaped bodies by pouring a zeolite-kaolin-water mixture (optionally with the addition of further components) in a dry plaster mold.
• the kaolin-zeolite mixture be treated with deionized water and a dispersing agent (preferably bifunctional carboxylic acids) in a grinding drum with the aid of grinding balls to form a homogeneous, pourable slurry.
• a dispersing agent preferably bifunctional carboxylic acids
• the slip thus prepared is poured into a porous mold.
• the mold extracts the water from the zeolite-kaolin-water mixture, forming a so-called shard, which is removed from this mold after a corresponding service life and then dried.
• the starting material used in the process according to the invention is preferably a dried zeolite powder of the type 4A or X or Y, this preferably having a modulus of greater than 4.9, more preferably in the range of greater than 4.9 to 5.5.
• the described zeolite powders can also be used as filter cake or as slurry. in which the corresponding moisture content must be taken into account in the production of the mass to be deformed.
• the major zeolite precursor component does not exceed a level of non-zeolite convertible constituents, such as mica or quartz, of 5% by weight, and preferably 1% by weight.
• the zeolite and the zeolite precursor components are preferably used in a weight ratio of 10: 1 to 1:10, more preferably 1: 1 to 6: 1, in the moldable mixture in step a) of the described method.
• organic components having a temporary binder effect and / or lubricants and / or water, as described for similar systems in the prior art, may be incorporated into the mixture as required.
• step b) of the process described above the shaped bodies obtained from step a) are subjected to a thermal treatment. It is preferred if the moldings to temperatures of 550 ° C to 850 ° C, preferably 550 ° C to 650 ° C, heated. For this thermal treatment, it is expedient if the shaped bodies are first dried before the thermal treatment, preferably to a dry loss of 5-10%. During the thermal treatment, any organic constituents that may still be present are removed, the zeolite precursor components undergo structural conversion and the solids are solidified. Subsequently, the shaped bodies thus obtained are cooled without cracking.
• the moldings can be cut to the desired shape, if necessary.
• the thermally treated moldings are brought into contact with another component, they are preferably subjected to a washing in step c).
• the thermally treated moldings are treated with water or a dilute sodium hydroxide solution (between 0.5% and 5%, preferably between 1% and 2% NaOH solution).
• the other component which is also contacted with the thermally treated moldings during step c) is a component which optionally contains chemical elements or compounds in the nature or quantity which are superior to the zeolite precursor components lacking zeolite to be prepared in step c).
• the further component is preferably an alkali silicate or alkali aluminate solution, more preferably a sodium silicate solution or a sodium aluminate solution.
• step c) faujasite-type zeolite is to be formed, an alkali silicate solution is used as further component, while it is preferred in the intended production of zeolite with Linde type A structure in step c) is, if as an additional component an alkali aluminate solution is used.
• the contacting of the thermally treated molded body with the further component in step c) is preferably carried out at a temperature in the range of 75 ° C to 100 ° C and more preferably in the range of 80 ° C to 95 ° C.
• the further component is contacted with the zeolite precursor components over a period of 1 to 48 hours, preferably 8 to 24 hours.
• the contacting of the further component with the zeolite precursor components in addition to the previously described temperature treatment comprises an aging preceding this temperature treatment, which at a temperature of 15 ° C to 60 ° C, preferably 20 ° C to 35 ° C, over a period of 0.5 h to 24 h, preferably from 1 h to 5 h. It is immaterial whether a solution of the further component for the aging and the temperature treatment is used, or whether a first solution of the further component is used for the aging, while for the temperature treatment, a second solution is used. The second solution may be the same or different in composition from the first solution.
• washing solutions are preferably water, more preferably to deionized water and or sodium hydroxide solutions, the latter preferably at a concentration of 0.01 to 10%, and particularly preferably at a concentration of 0.5 to 5%.
• the product may additionally be washed with water, preferably deionized water, then dried and subsequently activated.
• the compact zeolitic shaped bodies according to the invention are treated as follows in step c):
• the compact shaped bodies obtained in step b) are first subjected to a "washing".
• a "washing" For this purpose, the material in a stirred vessel or in a filled with compact moldings column continuously with wash water or a dilute sodium hydroxide solution (between 0.5% and 5%, preferably between 1 and 2% NaOH solution) flows through.
• the weight ratio of demineralized water or sodium hydroxide solution to form compact shaped bodies is from 5: 1 to 50: 1, preferably from 8: 1 to 18: 1.
• the washing is carried out at a temperature between 15 ° C and 40 ° C, preferably at room temperature. Within 3 min to 120 min, preferably from 15 min to 60 min, the washing process is completed.
• the compact, wetted moldings are preferably in an aqueous reaction solution consisting of sodium silicate and sodium hydroxide in the case of conversion of non-zeolitic material in zeolite with faujasite structure and in an aqueous reaction solution consisting of sodium and sodium hydroxide in the case of the conversion of non-zeolitic constituents in Zeolite aged with linden type A structure, d. h.,
• the material is at 15 ° C to 60 ° C, preferably between 20 ° C and 35 ° C for 0.5 h to 24 h, preferably for 0.5 h to 5 h in the respective solution.
• the subsequent conversion of the non-zeolitic constituents into zeolite can be carried out in a suitable vessel, preferably a stirred vessel or else in a column continuously filled with the reaction solution of similar concentration or the same solution as used for the aging, filled with the compact shaped bodies, be performed.
• the weight ratio of reaction solution to compact moldings is between 5: 1 and 50: 1, preferably 8: 1 to 18: 1.
• the reaction temperature is between 75 ° C and 100 ° C, preferably between 80 ° C and 95 ° C choose.
• the time to reach completely made of zeolite compact molded body is between 8 h and 48 h. After the end of the reaction time, the compact zeolitic moldings are washed with demineralized water until the pH is below 12.
• an upstream washing step with dilute sodium hydroxide solution of a concentration between 0.01% and 10%, preferably between 0.5 and 5% NaOH solution, the amount of washing water can be reduced.
• the spent reaction solution from the conversion step can be worked up and reused for a subsequent treatment step with new compact moldings.
• a further aspect of the present invention relates to compact moldings consisting entirely of zeolite, hereinafter referred to as compact zeolitic moldings, obtainable according to a process as described above.
• These compact zeolitic shaped bodies preferably have a zeolite content of at least 90%, and preferably at least 95%, determined by means of suitable adsorption methods.
• the compact zeolitic shaped bodies according to the invention preferably consist of zeolite Y, preferably with a modulus of greater than 4.9, more preferably in the range of greater than 4.9 to 5.5, or zeolite X or zeolite A.
• the compact zeolitic shaped bodies which can be produced by this process can be in the form of a honeycomb structure, a single or multi-channel tube, a plate or a solid cylinder, for example.
• Another aspect of the present invention relates to the use of the above-described compact zeolitic shaped bodies as adsorbents, for example for gas treatment in industrial adsorption processes. Further preferred uses of the shaped bodies according to the invention relate to processes for thermochemical energy storage, for example in heat pumps or for refrigeration, as a catalyst or catalyst component or as a carrier for zeolite membranes.
• the compact zeolitic moldings according to the invention show a zeolite content determined by X-ray analysis of between 86 and 100%. Since the equilibrium adsorption capacities are only slightly below those of the starting zeolite powder used, it can be assumed that the compact zeolitic shaped bodies consist of approximately 100% zeolite, but, as already described in FIG. 23 , a portion of this zeolite can not be detected by X-ray diffraction. Obviously, similar phenomena occur in both processes despite different production methods.
• the explained production method thus achieved the goal of producing compact zeolitic shaped bodies which have a high volume filling with active zeolite matter.
• the various ceramic forming technologies make the manufacturing process flexible in that it is possible to produce precisely the molded body geometry that appears most advantageous for later use.
• zeolite 4A Zeolon, MAL AG with the following properties was used:
• Ignition loss mass loss after 1 h at 950 ° C
• Starting material 2 zeolite X.
• zeolite Y Zeolite Y (CBV100, Zeolyst International), having the following properties, was used for the examples of compact binderless zeolite Y moldings described herein:
• the commercially available kaolin KF-2 (Prosco Ressources) has the following properties:
• a honeycomb continuous strand is made of a plastic mass produced in the double-shaft kneader consisting of 78% by weight of zeolite 4A and 18% by weight of bentonite (ceratosil, inorganic binder), 2% by weight of organic component having a temporary binder effect (Tylose CER 40600). and 2% by weight of glycerin and water by extrusion with a vacuum screw extruder.
• the strand is cut into approximately 300 mm long honeycomb pieces and dried at 60 ° C.
• the honeycomb in 9 cm long pieces cut and then thermally treated at 600 ° C. In this temperature treatment, the organic substances and water are removed and the structure of the honeycomb is solidified by the inorganic binder.
• Comparative Material 1 Zeolite 3A Powder
• the commercially available zeolite 3A powder (Luoyang Jianlong Chemical Industrial Co., LTD.) Has the following characteristics:
• Comparative Material 2 (Zeolite 5A Powder)
• the zeolite 5A powder (Chemietechnik Bad Köstritz GmbH) has the following properties:
• a plastic mass is produced in a twin-shaft mixer by means of 5% by weight of the temporary binder organic component MHPC 20000, 2% glycerol and water.
• the molding of the plasticized mass takes place in a vacuum screw extruder.
• the mass is vented in the vacuum chamber of the extruder and pressed by means of a press screw by a shaping tool to a honeycomb shape.
• the formed honeycomb arises as a compact continuous molding. It is cut after extrusion to a suitable length of 100 mm for subsequent technological steps, dried to a dry loss of 5% and then tempered horizontally on kiln furniture at 550 ° C.
• the compact, tempered honeycombs are cut dry to a length of 9 cm.
• the non-zeolitic constituents of the honeycombs are converted to zeolite with Linde type A structure.
• this honeycombs are watered with a total weight of 50 g with 300 ml of deionized water, ie 30 minutes left in water. After the predetermined time, the water is largely poured off and replaced by the reaction solution. This consists of 500 ml of deionized water, 38 g of 50% sodium hydroxide solution and 8.5 g of sodium aluminate (20% Na 2 0, 20% Al 2 0 3 ).
• the honeycombs are aged in this solution for 1 h at room temperature and then heated to 85 ° C and held at this temperature for 16 h.
• the material is cooled and the supernatant solution removed by decantation.
• the honeycombs are washed three times with 200 ml of demineralized water, filtered as dry as possible with the aid of negative pressure on a Buchner funnel, then completely dried under an IR lamp and finally activated at 450 ° C within 2 h.
• the material prepared in this way shows a crystallinity (XRD) based on the starting zeolite powder of 92% and a static water absorption capacity of 24.7%.
• the zeolite content determined by the water adsorption capacity is 99.6%.
• the material produced in this way has a residual moisture content of 0.8% by mass (determined by Karl Fischer titration (700 ° C.)).
• the following table shows a comparison between the starting zeolite powder, the clay-bound and the binder-free zeolite honeycomb with Linde type A structure.
• Table 2 Comparison between zeolite 4A powder, clay-bonded and binder-free zeolite 4A.
• Zeolite 4A Powder Binderless Wa4A honeycomb (conventio) (zeolite 4A, more compact
• Crystallinity fXRD X-ray powder diffractometer (XRD) "D4 ENDEAVOR” from Bruker-AXS GmbH, Düsseldorf, software package "DIFFRACplus”
• Water absorption capacity The material is activated for 2 h at 450 ° C and loaded with water at 55% relative humidity and 25 ° C until equilibrium is reached.
• Average pore diameter Hg porosimeter PASCAL P140, -P440 from Porotec.
• Static CQ 2 and N 2 adsorption capacity The material is activated at 400 ° C for 2 h below 0.01 mbar. The measurement is carried out at 25 ° C. on a sorption apparatus "GEMINI" from Micromeritics.
• GEMINI a sorption apparatus
• Comparative Material 1 (zeo-binder-free honeycomb
• Lith 3A powder (Zeolite 3A, Example 2)
• Comparative Material 1 zeolite binder-free honeycomb
• zeolite X powder 850 g of kaolin (starting material 4) and 25 g of sodium hydroxide solution (50% strength) is replaced by 5% of the organic component with temporary binder effect MHPC 20000, 2% glycerol, lubricant and Water produced a plastic mass in a Doppelwellenkneter.
• the molding of the plasticized mass takes place in a vacuum screw extruder.
• the mass is vented in the vacuum chamber of the extruder and pressed by a press screw through a 7-channel forming tube tool.
• the formed 7-Kanalrohr arises as a compact Endlosformmaschine. It is cut after extrusion to a suitable length of 500 mm for the subsequent technological steps, dried to a dry loss of 5% and then tempered lying on kiln furniture at 550 ° C:
• the annealed 7-channel pipes are cut dry to a length of 100 mm.
• the non-zeolitic constituents of the 7-channel tubes are converted to faujasite-type zeolite.
• 7-channel pipes with a total weight of 30 g are watered with 200 ml of deionized water, ie left in water for 60 minutes. After the predetermined time, the water is largely poured off and replaced by the reaction solution. This consists of 240 ml of deionized water, 54 g of 50% sodium hydroxide solution and 15 g of sodium silicate (8% Na 2 0, 27% Si0 2 ).
• the watered 7-channel tubes are aged in this solution for 2 h at room temperature, then heated to 85 ° C and held at this temperature for 16 h.
• the material is cooled and the supernatant solution removed by decantation.
• the 7-channel tubes are washed three times with 200 ml deionized water each time, filtered as dry as possible using a Büchner funnel and then completely dried under an IR lamp.
• the material prepared in this way shows a crystallinity (XRD) based on the starting zeolite powder of 90% and a static water absorption capacity of 29.2%.
• the zeolite content determined by the water adsorption capacity is 94.8%.
• the following table shows a comparison between the starting zeolite powder and the compact, binder-free zeolite moldings with faujasite structure.
• Table 3 Comparison between zeolite powder and binderless zeolite 7-sewer pipes with faujasite structure.
• Figure 2 shows the diffractograms of zeolite X powder (broken line, starting material 2) and the produced 7-channel zeolitic tube with faujasite. Structure and zeolite X composition (solid line, Example 4) shown. These are almost identical.
• zeolite Y powder starting material 3
• 300 g of kaolin starting material 4 and 80 g of 50% sodium hydroxide solution
• the plasticized material is shaped in a vacuum screw extruder, where the mass in the vacuum chamber of the extruder is vented and pressed by means of a press screw through a 1-channel pipe producing tool
• the 1-channel pipe is formed as a continuous strand is cut after extrusion to a suitable length of 500 mm for the subsequent technological steps, dried to a dry loss of 5% and then tempered on kiln furniture at 550 ° C.
• the tempered 1-canaole tubes are cut dry to a length of 200 mm.
• the non-zeolitic constituents of the 1-channel pipes are converted to faujasite-type zeolite.
• 1-channel pipes with a total weight of 30 g are watered with 200 ml of 1% sodium hydroxide solution, ie left in 1% sodium hydroxide solution for 60 min.
• the sodium hydroxide is poured off as far as possible and replaced by the reaction solution. This consists of 190 ml of deionized water, 8 g of 50% sodium hydroxide solution and 60 g of sodium silicate (8% Na 2 0, 27% Si0 2 ).
• the watered 1-channel pipes are aged in this solution for 2 h at room temperature and then heated to 90 ° C and held at this temperature for 20 h.
• the material is cooled and the supernatant solution removed by decantation.
• the 1-channel tubes are washed in 150 ml of a 1% sodium hydroxide solution and washed twice with 150 ml of deionized water, filtered as dry as possible using a Büchner funnel and then completely dried under an IR lamp.
• the material prepared in this way shows a crystallinity (XRD) based on the starting zeolite powder of 96% and a static water absorption capacity of 28.0%.
• the zeolite content determined by the water adsorption capacity is 96.2%.
• the following table shows a comparison between the starting zeolite powder and the binderless 1-channel pipes with faujasite structure and zeolite Y composition.
• Table 4 Comparison between zeolite powder and binderless zeolite l sewer pipes of faujasite structure and zeolite Y composition.
• Zeolite Y powder Binder-free compact shaped article (starting material by the faujasite structure and zeolite
• FIG. 3 shows the diffractograms of zeolite Y powder (broken line, starting material 3) and the produced zeolitic 1-channel pipe (solid line, example 5) of the faujasite structure and zeolite Y composition. These are almost identical.
• the non-zeolitic constituents of the 1-channel pipes are converted to faujasite-type zeolite.
• 1-channel tubes with a total weight of 30 g with a reaction solution consisting of 190 ml of deionized water, 8 g of 50% sodium hydroxide solution and 60 g of sodium silicate (8% Na 2 0, 27% Si0 2 ), then to 90 ° C. heated and held at this temperature for 20 h.
• the 1-channel tubes are washed three times with 200 ml deionized water each time, filtered as dry as possible using a Büchner funnel and then completely dried under an IR lamp.
• the material prepared in this way shows a crystallinity (XRD) based on the starting zeolite powder of 81%, a modulus of 5.3 and a static water absorption capacity of 26.9%.
• the zeolite content determined by water adsorption is 92.4%.
• the production of the 1-channel pipes is carried out analogously to Example 5. After annealing, the non-zeolitic constituents are converted to zeolite with a faujasite structure.
• 1-channel pipes with a total weight of 30 g with a solution consisting of 190 ml of deionized water, 8 g of 50% sodium hydroxide solution and 60 g of sodium silicate (8% Na 2 0, 27% Si0 2 ) and the mixture for two 2 h aged at room temperature, then the mixture is heated to 90 ° C and held at this temperature for 20 h.
• the 1-channel tubes are washed three times with 200 ml deionized water each time, filtered as dry as possible using a Büchner funnel and then completely dried under an IR lamp.
• the material produced in this way shows a crystallinity (XRD) based on the starting zeolite powder of 84%, a modulus of 5.3 and a static water absorption capacity of 27.5%.
• the zeolite content determined by water adsorption is 94.5%.
• zeolite with Linde type A structure (starting material 1), kaolin (starting material 4) and caustic soda in a ratio of 30 parts by weight of kaolin (dry) to 70 parts by mass of zeolite 4A (dry) to 3.5 parts by mass of a 50% NaOH solution is prepared dropwise adding a 2% 10% Mowiol binder solution in a mixer at 1000 rev / min a moist mixture. The mixture is stored for homogenization of the moisture covered for 24 hours. Thereafter, the mixture is rubbed through a sieve with a mesh size of 1 mm and the sieve granules thus obtained dried to a dry loss of 6%.
• the granules are pre-pressed on a dry press with a pressure of 600 MPa to cylinders with a diameter of 18 mm and a thickness of 10 mm.
• a granular material is obtained.
• moldings having a diameter of 60 mm and a thickness of 3 mm are then produced on the dry press at a specific pressure of 1000 MPa. provides.
• the tempering of these slices is carried out horizontally on sintered SiC slabs at 500 ° C.
• the non-zeolitic constituents of the shaped bodies are converted analogously to Example 1 into zeolite with Linde type A structure.
• Table 5 Properties of the binderless zeolite 4A slices.
• Zeolite 4A powder (Aus Binder-free disc
• starting material 1) (zeolite 4A, example 8)
• a 10 l milling drum initially weighing 4 kg of grinding balls having a size of 20 mm, then adding 4 kg of a raw material mixture consisting of 70 parts by mass of zeolite 4A powder (dry) and 30 parts by mass of kaolin (dry).
• a raw material mixture consisting of 70 parts by mass of zeolite 4A powder (dry) and 30 parts by mass of kaolin (dry).
• Dolapix CE64 the grinding drum is closed and the slurry is milled on a grinding stand for 24 h. After the milling time, the slurry is poured through a 0, 1 mm sieve. The casting of the slurry takes place as a plate measuring 100 ⁇ 100 ⁇ 12 mm 3 in dry plaster molds.
• the plate After a service life of about 75 minutes (depending on the body formation, which in turn depend on room temperature and humidity), the plate is removed from the mold and dried to a dry loss of 5%. The dried plates are annealed to firing plates of engobed SiC at 500 ° C.
• Table 6 Properties of the binderless zeolite 4A plate.
• Zeolite 4A powder (Aus Binder-free disc

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