The Need

Zeolites are microporous structures with uses such as absorbents and catalysts. For example, in the petrochemical industry for fluid catalytic cracking and hydrocracking, absorbants to trap fission products from nuclear waste, and for domestic uses such as in detergents and cat litter. The material also plays a critical role in chemical synthesis and separations. While some zeolites structures occur naturally, most industrial zeolites are synthesized to guarantee uniformity and consistency. Zeolites are manufactured globally on a scale of millions of tons however current synthetic methods are time and energy intensive with some synthetic processes taking days to complete.

The Market

This innovation would be of primary interest to all major zeolite manufacturing companies.

• The North American market for zeolites was valued at $1.2 billion in 2011 and is projected to reach $1.5 billion by 2017, CAGR of 3.5%. ("Global Markets for Inorganic Nanoporous and Microporous Adsorbents," BCC Research, Apr. 2012)

• In the North American market, zeolites accounted for 54.5% of total adsorbent consumption. These zeolites included detergent builders as well as high-end materials such as those used in the petroleum refining industry.("Global Markets for Inorganic Nanoporous and Microporous Adsorbents," BCC Research, Apr. 2012)

The Technology

Researchers at The Ohio State University, led by Dr. Prabir Dutta, developed a method for synthesizing zeolites in approximately a quarter of the time required by the current industry methodology. The innovation was developed by implementing principles of super-saturation and rapid nucleation. The ability to more rapidly synthesize the compounds results in cutting manufacturing time by four times that currently used in the industry, which results in lowering operating costs while retaining comparable yields and purities. Further, multiple types of zeolites can be manufactured using this technology including the FAU and MF1 frameworks with varying Si/Al ratios.