Rapid and Mass Production of Porous Materials Using a Continuous Microwave Equipment

A continuous microwave equipment (CME) has been successfully developed in order to achieve an extremely rapid and mass production for ZSM-5 and NaY zeolite. A precursor mixture for synthesis of ZSM-5 was prepared by mixing aluminosilicate gel with a nanoseed solution obtained under microwave irradiation, and pumped continuously into the CME. Duration time in the CME was 5 min to accomplish the crystallization of ZSM-5 under microwave irradiation. In the case of NaY zeolite, the precursor gel without nanoseeds was also introduced into the CME and crystallization time was within 30 min. Results from X-ray diffraction patterns and scanning electron microscopy indicate that the structural properties of ZSM-5 and NaY zeolite thus obtained are similar to those of the materials obtained using batch-type microwave instrument and by conventional hydrothermal synthesis. Advantages and applications of the CME will be also discussed along with microwave effect.