A process of performing controlled alkaline treatments on inorganic porous solids, yielding superior physico-chemical and catalytic properties, whereby the particle and crystal size is not negatively influenced. The solids obtained from this process can be easily recovered from the alkaline solution.

A process of performing controlled alkaline treatments on inorganic porous solids, yielding superior physico-chemical and catalytic properties, whereby the particle and crystal size is not negatively influenced. The solids obtained from this process can be easily recovered from the alkaline solution.

The present invention relates to a process for preparing zeolite crystals continuously, comprising the continuous introduction of a composition capable of generating zeolite crystals into at least one crystallization reaction zone subjected to stirring means, giving said composition a flow characterized by a relative Reynolds number Re.sub.r of between 40 and 50 000, and the continuous recovery of the crystals formed according to a flow characterized by a net Reynolds number Re.sub.n of between 1 and 1500.

The present invention relates to a process for preparing zeolite crystals continuously, comprising the continuous introduction of a composition capable of generating zeolite crystals into at least one crystallization reaction zone subjected to stirring means, giving said composition a flow characterized by a relative Reynolds number Re.sub.r of between 40 and 50 000, and the continuous recovery of the crystals formed according to a flow characterized by a net Reynolds number Re.sub.n of between 1 and 1500.

FAU type binderless zeolitic adsorbents and methods for making the FAU type binderless adsorbents are described. The binderless zeolitic adsorbent comprises a first FAU type zeolite having a silica to alumina molar ratio below 3.0; a binder-converted FAU type zeolite having a silica to alumina molar ratio of from about 2.5 to about 6.0, wherein the binder-converted FAU type zeolite may be 5-50% of the binderless zeolitic adsorbent; and cationic exchangeable sites within the binderless zeolitic adsorbent. The FAU type binderless adsorbents may be used for xylene separation and purification in selective adsorptive separation processes using binderless zeolitic adsorbents.

FAU type binderless zeolitic adsorbents and methods for making the FAU type binderless adsorbents are described. The binderless zeolitic adsorbent comprises a first FAU type zeolite having a silica to alumina molar ratio below 3.0; a binder-converted FAU type zeolite having a silica to alumina molar ratio of from about 2.5 to about 6.0, wherein the binder-converted FAU type zeolite may be 5-50% of the binderless zeolitic adsorbent; and cationic exchangeable sites within the binderless zeolitic adsorbent. The FAU type binderless adsorbents may be used for xylene separation and purification in selective adsorptive separation processes using binderless zeolitic adsorbents.

Compositions and methods for preparing mesoporous and/or mesostructured materials from low SAR zeolites are provided herewith. In particular, methods are provided that involve: (a) providing a low SAR zeolite, (b) optionally subjecting the low SAR zeolite to an acid framework modification, and (c) subjecting the framework-modified zeolite to a mesopore formation treatment. The resulting mesoporous zeolites can have bi-modal mesoporosity and higher aluminum contents relative to existing mesoporous zeolites.

Compositions and methods for preparing mesoporous and/or mesostructured materials from low SAR zeolites are provided herewith. In particular, methods are provided that involve: (a) providing a low SAR zeolite, (b) optionally subjecting the low SAR zeolite to an acid framework modification, and (c) subjecting the framework-modified zeolite to a mesopore formation treatment. The resulting mesoporous zeolites can have bi-modal mesoporosity and higher aluminum contents relative to existing mesoporous zeolites.

Processes are provided for preparing molecular sieves for use as catalysts. The process involves preparing a synthesis mixture for the molecular sieve wherein the synthesis mixture includes a morphology modifier which may be selected from cationic surfactants having a single quaternary ammonium group comprising at least one hydrocarbyl group having at least 12 carbon atoms, nonionic surfactants, anionic surfactants, sugars, and combinations thereof.

The invention provides methods for completely removing aluminum from existing zeolite frameworks that have been previously considered unalterable due to their small pore sizes and stable crystal structures. Consequently, new combinations of metal atoms and zeolite structures can now be made using the methods disclosed herein. Metal atoms that have useful properties for catalysis and adsorption have been integrated into zeolite structures that provide advantageous size selection or solvation properties to increase rates, conversions, and yields of catalytic processes. The disclosed catalysts and methods reduce the cost of synthesizing useful materials and zeolite structures with compositions of matter that have not been reported.