Tailoring the reaction mixture composition for preparing zeolite coatings on aluminum supports in alkaline environments

Various alkaline reaction mixture compositions were tested for determining their suitability to be used in the direct crystallization of zeolites on aluminum supports. No organic materials, such as templates, complexing agents, and corrosion inhibitors were included in the reaction mixtures. It was observed that aluminum supports remained quite stable in alkaline synthesis mixtures when suitable reaction mixture compositions with relatively high silica content were used. These favorable compositions might be recognized from their sodium silicate/(sodium hydroxide + sodium aluminate) mass ratios, as depicted in this study. Coatings were prepared on aluminum by using some of these compositions. It was determined that aluminum hydroxide phases commonly forming on the support could be eliminated to a great extent and consequently, crystalline coatings of zeolites P and Y were obtained on aluminum surfaces. The coatings exhibited trivial mass loss in the mechanical stability tests applied.