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Abstract

A method for making zeolite-Y particles may include forming an initial zeolite precursor solution including an alumina source material and a silica source material in a solvent, and subjecting the initial zeolite precursor solution to a first heating process to form zeolite-Y particles in a residual liquid solution, and separating the zeolite-Y particles from the residual liquid solution. The residual liquid solution may include some remaining non-crystalized silica source material, and the residual liquid solution may have a different alumina to silica molar ratio than the initial zeolite precursor. The method may further include forming a recycled zeolite precursor solution that may include at least a portion of the residual liquid solution and one or both of additional alumina source material or additional silica source material, such that the recycled zeolite precursor solution has an alumina to silica molar ratio within 10% of the alumina to silica ratio of the initial zeolite precursor solution. The method may further include subjecting the recycled zeolite precursor solution to a second heating process to form additional zeolite-Y particles.

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First Claim