High density zeolites and their production

Abstract

Novel synthetic zeolite compositions of extremely small particle sizes that have increased loading capability, and process technology for producing such compositions are described. So far as is presently known, it has never been possible to form such compositions heretofore. The process technology involves, inter alia, contacting the zeolite cake formed in its production with a specified type of treating agent and then subjecting the treated zeolite to physical subdivision.

That which is claimed is:  
     
         1 . A composition which comprises (i) a synthetic zeolite and (ii) from about 0.2 to about 4.5 wt %, based on the total weight of (i) and (ii), of an electrolyte from a treating agent which transferred protons to one or more bases that existed in a zeolite filter cake formed during the production of said zeolite.  
     
     
         2 . A composition of  claim 1  wherein the amount of said electrolyte is in the range of about 0.2 to about 1.5 wt % based on the total weight of (i) and (ii).  
     
     
         3 . A composition of either of claims  1  or  2  wherein the synthetic zeolite is a type-A zeolite.  
     
     
         4 . A composition of  claim 1  in which the composition contains, if any, no more than about 3 wt % of particles greater than 30 microns in size.  
     
     
         5 . A composition of  claim 1  in which the composition contains, if any, no more than about 3 wt % of particles greater than 20 microns in size.  
     
     
         6 . A composition of  claim 1  in which the composition contains, if any, no more than about 3 wt % of particles greater than 10 microns in size.  
     
     
         7 . A composition of any of claims  4 ,  5 , or  6  wherein the synthetic zeolite is a type-A zeolite.  
     
     
         8 . A composition of  claim 1  wherein the amount of (ii) is in the range of about 0.2 to about 1.5 wt % based on the total weight of (i) and (ii).  
     
     
         9 . A composition of  claim 8  wherein the composition contains, if any, no more than about 3 wt % of particles greater than 20 microns in size.  
     
     
         10 . A composition of  claim 8  wherein the composition contains, if any, no more than about 3 wt % of particles greater than 10 microns in size.  
     
     
         11 . A composition of any of claims  8 ,  9  or  10  wherein the synthetic zeolite is a type-A zeolite.  
     
     
         12 . A composition of any of claims  1 ,  2 ,  4 ,  5 ,  8 ,  9  or  10  wherein 
 A) the synthetic zeolite is a type-A zeolite; and  
 B) the electrolyte of (ii) is (a) a polyacrylic acid that has a weight average molecular weight of less than about 10,000, (b) a partially protonated polyacrylic acid in which the weight average molecular weight of the corresponding unprotonated polymer is less than about 10,000, (c) an acrylic acid-maleic acid copolymer that has a weight average molecular weight of less than about 10,000, (d) a partially protonated acrylic acid-maleic acid copolymer in which the weight average molecular weight of the corresponding unprotonated polymer is less than about 10,000, or (e) a mixture of any two or more of (a), (b), (c), and (d).  
 
     
     
         13 . A composition of any of claims  1 ,  2 ,  4 ,  5 ,  8 ,  9  or  10  wherein 
 A) the synthetic zeolite is a type-A zeolite; and  
 B) the electrolyte of(ii) is (a) phosphoric acid, (b) a partially protonated phosphoric acid, (c) pyrophosphoric acid, (d) a partially protonated pyrophosphoric acid, (e) a polyphosphoric acid, (f) a partially protonated polyphosphoric acid, (g) citric acid, (h) a partially protonated citric acid, (i) carbonic acid, (j) a partially protonated carbonic acid, (k) sulfuric acid, (l) a partially protonated sulfuric acid, or a mixture of any two or more of (a) through (l).