Synthesis of pure zeolite Y using soluble silicate, a two-level factorial experimental design

Four methods were used for the synthesis of pure zeolite Y using soluble silicate as a silica source: (1) the gelling of soluble silicate to silica–alumina gel, by aluminate (or aluminium sulphate), (2) the precipitation of soluble silicate to precipitated silica–alumina gel, by aluminate (or aluminium sulphate), (3) the gelling of soluble silicate by sulphuric acid plus alumina impregnation, and (4) the precipitation of soluble silicate by sulphuric acid plus alumina impregnation. A 2⁴ two-level factorial design was used to study the influence of four different variables on the purity of zeolite Y (expressed in terms of degree of crystallinity). The ageing time turned out to be the most significant variable. Synthesis time, alkalinity and mixing rate were also found to be statistically significant. X-ray diffraction patterns were used to characterize the samples, which ranged from well-crystallized faujasite structures to amorphous materials. The highest purity achieved in method (1) was 38%. The best synthesis condition derived from method (1) was applied to the other three methods. Only method (4) yielded the pure zeolite Y. Therefore, the effect of silica–alumina precursor preparation on producing the pure zeolite Y is extremely important.