Method for producing crystalline, inorganic ion exchange materia

Chemistry of inorganic compounds – Silicon or compound thereof – Oxygen containing

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423332, C01B 3336

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active

059390409

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to a method for producing crystalline, inorganic ion exchange material, specifically silicate builders, useful for ion exchangers and alkalizers.


BACKGROUND ART

Since silicate ion exchange materials have alkaline buffering properties, they are highly useful for detergent builders. Particularly, since the silicate ion exchange materials in crystalline forms have excellent cationic exchange capacities, they are greatly useful for detergent builders.
Among the methods for producing silicate builders, Japanese Patent Laid-Open No. 5-66888 discloses a method using water glass as a starting material. In this method, the method for producing crystalline sodium silicate having a layered structure is produced by a method comprising the steps of spray-drying a water glass solution to form amorphous sodium silicate, and heating the resulting sodium silicate in a firing zone while recirculating a portion of the product. However, this method requires drying off large amounts of the water content from the water glass, which makes it disadvantageous from an energy-saving viewpoint.
Japanese Patent Laid-Open No. 6-72008 discloses a method for directly baking the glassy product to solve the above problems. In this method, crystalline sodium silicate is produced by the steps of pulverizing a water glass product obtainable by cooling a fused mixture of sand and soda, and then heating the pulverized product. However, in this method, since the resulting product comprises a two-component system of Na.sub.2 O--SiO.sub.2, the control of the crystalline system becomes difficult, rendering the method unsatisfactory for ion exchange materials for detergents.


DISCLOSURE OF THE INVENTION

In view of the above problems, an object of the present invention is to provide a method for easily producing high-performance silicate ion exchange material using inexpensive cullets.
This object is achieved by a specific method for producing an ion exchange material of the present invention.
Specifically, the gist of the present invention is as follows: having the following composition: following relationships: y/(x.sub.1 +x.sub.2)=1.0 to 2.1, z/y=0 to 1.0, x.sub.1 /x.sub.2 =0.01 to 2.0, and Me stands for Ca and/or Mg, the method comprising the steps of adding and blending one or more alkali metal compounds, or one or more alkali metal compounds and one or more alkaline earth metal compounds in cullets having a composition of SiO.sub.2 /Na.sub.2 O=1.5 to 4.2, and baking the resulting mixture; the following relationship: z/y=0.002 to 0.32, and Mg/Ca=0.01 to 100; are obtainable by the steps of fusing a mixture of silica sand and sodium carbonate at a temperature of from 1000 to 1400.degree. C., and cooling the resulting mixture; cullets are sodium silicate cullets (SiO.sub.2 /Na.sub.2 O ratio of from 2.5 to 3.5); cullets have a composition of SiO.sub.2 /(Na,K).sub.2 O=2.1 to 4.2, K/Na=0 to 2.0, and Ca/Si=0 to 0.32; cullets is from 0.01 to 2.0; alkali metal compound is selected from the group consisting of potassium hydroxide, sodium hydroxide, potassium carbonate, sodium carbonate, potassium sulfate, and sodium sulfate, and wherein the alkaline earth metal compound is selected from the group consisting of calcium oxide, magnesium oxide, calcium hydroxide, magnesium hydroxide, calcium carbonate, magnesium carbonate, calcium nitrate, magnesium nitrate, calcium chloride, magnesium chloride, calcium sulfate, and magnesium sulfate; and average particle size of from 2 to 9000 .mu.m, and wherein a 12-60% by weight KOH aqueous solution and a 12-60% by weight NaOH aqueous solution are added as alkali metal compounds, thereby giving a water content of from 1 to 45% by weight after addition.


BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a graph showing an X-ray diffraction pattern of an inorganic ion exchange material powder obtained in Example 1.


BEST MODE FOR CARRYING OUT THE INVENTION

The method for producing a crystalline, inorganic ion exchange material having the following composition: following relat

REFERENCES:
patent: 5427711 (1995-06-01), Sakaguchi et al.
patent: 5567404 (1996-10-01), Lee et al.
patent: 5614160 (1997-03-01), Gill et al.
patent: 5618783 (1997-04-01), Sakaguchi et al.
patent: 5643358 (1997-07-01), Borgstedt et al.
patent: 5739098 (1998-04-01), Denkewicz et al.

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