Optimal Aluminum-Assisted Mesoporosity Development in MFI Zeolites by Desilication

Effects of Additives and Metals on Crystallization of Nano-Sized HZSM-5 Zeolite for Glycerol Aromatization

Nano-sized HZSM-5 (n-HZSM-5) was synthesized and applied in the aromatization of glycerol. The effects of additives (carboxymethylcellulose sodium, NaCl, sodium alginate, etc.) on the chemical and physic properties of n-HZSM-5 during preparation were investigated. Metal modification was also investigated based on the synthesized n-HZSM-5. The results showed that the addition of carboxymethylcellulose sodium (CMC-Na), NaCl and sodium alginate (SA) led to forming smaller sizes of HZSM-5 and promoted the acid amounts of the catalysts, which increased its catalytic activities for obtaining BTX. The highest BTX yield of ~35% was obtained by SA derived n-HZSM-5, and the life of the catalyst were both obviously promoted by the additives with a highest of ~11 h by γ-(2,3-epoxypropoxy)propytrimethoxysilane (KH-560) derived n-HZSM-5. BTX yields could be improved by 40%by the addition of Zn and Cd in n-HZSM-5 while having little effect on the catalyst life.

Application of Response Surface Methodology for Ethanol Conversion into Hydrocarbons Using ZSM-5 Zeolites

The ethanol conversion into hydrocarbons (light olefins and aromatics) using alkali-treated HZSM-5 with different SiO2/Al2O3 ratios (23, 38, and 53) zeolites was evaluated. The desilicated SAR 38 zeolite exhibited significant growth on the external surface area (61–212 m2/g) and the mesopore volume (0.07–0.37 cm3/g) without significate reduction on XRD crystallinity (93%). All catalysts were active on the ethanol conversion into hydrocarbons. At the same set of variables, the alkali-treated HZSM-5 zeolites showed a better conversion and a high selectivity to C4–C9 hydrocarbons when compared to the parent microporous zeolites. Only the parent HZSM-5 zeolite (SAR 53) was chosen for the statistical study using the standard response surface methodology in combination with the central composite design. It was found that maximum BTEX (benzene, toluene, ethylbenzene, and xylenes) and minimum ethylene production were reached for the following conditions: temperature 450 °C, pressure 20 bar, and WHSV (weight hourly space velocity) 5 h−1.

Porosity Design of Shaped Zeolites for Improved Catalyst Lifetime in the Methanol-to-Hydrocarbons Reaction

Additional porosity, such as meso- and macropores, was introduced in zeolite extrudates with the intention intuit of improving the effective diffusivity of the catalysts. The samples were characterized in depth by nitrogen adsorption-desorption, mercury intrusion porosimetry, ammonia temperature programmed desorption and adsorption of pyridine followed by infrared spectroscopy. The results revealed no significant change in the acidity but an increase of the pore volume. According to significant improvement in the effective diffusivity, the samples were tested in the methanol-to-hydrocarbons reaction. The catalytic stability was greatly enhanced with an increase in the pore volume, demonstrating a relation between effective diffusivity and resistance to deactivation by coke formation. Further experiments also revealed a higher toluene adsorption capacity and a raise in the breakthrough time over the most porous samples due to better accessibility of toluene molecules into the active sites of the zeolite.

Hierarchical ZSM-5 Zeolite with Enhanced Catalytic Activity for Alkylation of Phenol with Tert-Butanol

Using polyethylene glycol as a mesoporous soft template, a series of hierarchically porous ZSM-5 zeolites were prepared. X-ray diffraction, infrared spectroscopy, N2 adsorption–desorption, and transmission electron microscopy results demonstrated that the resultant materials contained a micro–mesoporous structure. Since the existence of mesoporous structure favors the diffusion of large molecular reactants and products, the phenol conversion and selectivity to 2,4-Di-TBP on the hierarchical ZSM-5 zeolite can be improved for the alkylation of phenol with tert-butanol.

Fabrication of the Hierarchical HZSM-5 Membrane with Tunable Mesoporosity for Catalytic Cracking of n-Dodecane

Hierarchical HZSM-5 membranes were prepared on the inner wall of stainless steel tubes, using amphiphilic organosilane (TPOAC) and mesitylene (TMB) as a meso-porogen and a swelling agent, respectively. The mesoporosity of the HZSM-5 membranes were tailored via formulating the TPOAC/Tetraethylorthosilicate (TPOAC/TEOS) ratio and TMB/TPOAC ratio, in synthesis gel, and the prepared membranes were systematically characterized by X-ray diffraction (XRD), scanning electron microscope (SEM), N2 adsorption–desorption, N2 permeation, inductively coupled plasma (ICP), in situ fourier transform infrared (FT-IR), ammonia temperature-programmed desorption (NH3-TPD), etc. It was found that the increase of the TPOAC/TEOS ratio promoted a specific surface area and diffusivity of the HZSM-5 membranes, as well as decreased acidity; the increase of the TMB/TPOAC ratios led to an enlargement of the mesopore size and diffusivity of the membranes, but with constant acid properties. The catalytic performance of the prepared HZSM-5 membranes was tested using the catalytic cracking of supercritical n-dodecane (500 °C, 4 MPa) as a model reaction. The hierarchical membrane with the TPOAC/TEOS ratio of 0.1 and TMB/TPOAC ratio of 2, exhibited superior catalytic performances with the highest activity of up to 13% improvement and the lowest deactivation rate (nearly a half), compared with the microporous HZSM-5 membrane, due to the benefits of suitable acidity, together with enhanced diffusivity of n-dodecane and cracking products.

Hierarchical Low Si/Al Ratio Ferrierite Zeolite by Sequential Postsynthesis Treatment: Catalytic Assessment in Dehydration Reaction of Methanol

In contrast to high silica zeolites, it is difficult to obtain mesoporosity in zeolites with low Si/Al ratio (e.g., <20) via conventional NaOH-based treatment, making the obtainment of hierarchical zeolites with high acidity a challenging target. In this paper, we report the preparation of hierarchical FER-type zeolite at low Si/Al molar ratio (about 10) by postsynthesis etching involving a sequence of three treatments with NaAlO2, HCl, and NaOH solutions and investigate the effect of both NaAlO2 solution concentration and time of treatment on the textural properties. The obtained materials exhibit a mesoporous volume higher than the parent ferrierite with no significant effect on the sample acidity. The catalytic activity of some samples was investigated in vapour-phase methanol dehydration to dimethyl ether, revealing the superiority of hierarchical zeolites in terms of methanol conversion, although the presence of mesopores causes formation of light hydrocarbons at high temperatures.

Facile creation of hierarchical nano-sized ZSM-5 with a large external surface area via desilication–recrystallization of silicalite-1 for conversion of methanol to hydrocarbons

Mesoporous ZSM-5 with large external surface and strong acidity were created through desilication–recrystallization of nano-sized silicalite-1, and the catalytic lifetime of its regenerated catalyst is 2.5 times longer than fresh catalyst.

Organotemplate-Free β Zeolites: From Zeolite Synthesis to Hierarchical Structure Creation

Interest in the production of β zeolites in the absence of organic structure-directing agent (OSDA) has continued to grow consistently during the past decade. During this time, numerous strategies have been proposed to manipulate the hierarchy of zeolite pore structures in order to facilitate the transport of bulky reactants and to improve the accessibility of active sites in zeolite catalysts. In this work, we describe an organotemplate-free route to produce hierarchical β zeolites. Using OSDA-free β as the starting zeolites, we explored the applicability of various postsynthetic approaches to create hierarchical structures with mesoporosity, including framework stabilization, dealumination, conventional desilication, and hydrothermal desilication. While framework stabilization and dealumination were not effective in generating mesoporosity, they were necessary as modification steps to determine the efficacy of hierarchical structure creation. Compared to conventional desilication, hydrothermal desilication produces larger mesopores and much better preservation of microporosity and acidity because of the occurrence of recrystallization. The cost-effective, scalable production of organotemplate-free hierarchical β zeolites could greatly enhance the adoption of β zeolites in oil refining and petrochemical industries, where the advantages of hierarchically structured zeolites can dramatically improve catalytic performances in formulated catalysts.

Basic Treatment in Natural Clinoptilolite for Improvement of Physicochemical Properties

Natural zeolites are low in cost and exhibit interesting properties for applications in adsorption and catalysis. However, the fact that they are natural materials, not obtained in pure form, and can incorporate various compensating ions can compromise their properties and restrict their use. As their textural and chemical properties are of great relevance for adsorption and catalysis applications, this work aims to study the modification of the natural zeolite clinoptilolite to obtain materials with better physicochemical properties. Clinoptilolite was treated with NaOH under various conditions. The treated material was characterized by X-ray diffraction, X-ray fluorescence, N2 adsorption and desorption at 77 K, CO2 adsorption at 273 K, and pyridine adsorption. The treatment allowed the removal of silicon from the material, improving the textural properties and preserving the structural Al. With the removal of Si, the Si/Al ratio decreased, and consequently, the number of acid and adsorptive sites increased. In addition, statistical planning revealed that the concentration of NaOH is the parameter that most influences the improvement of the textural properties.

Synthesis of Engineered Zeolitic Materials: From Classical Zeolites to Hierarchical Core-Shell Materials

The term "engineered zeolitic materials" refers to a class of materials with a rationally designed pore system and active-sites distribution. They are primarily made of crystalline microporous zeolites as the main building blocks, which can be accompanied by other secondary components to form composite materials. These materials are of potential importance in many industrial fields like catalysis or selective adsorption. Herein, critical aspects related to the synthesis and modification of such materials are discussed. The first section provides a short introduction on classical zeolite structures and properties, and their conventional synthesis methods. Then, the motivating rationale behind the growing demand for structural alteration of these zeolitic materials is discussed, with an emphasis on the ongoing struggles regarding mass-transfer issues. The state-of-the-art techniques that are currently available for overcoming these hurdles are reviewed. Following this, the focus is set on core-shell composites as one of the promising pathways toward the creation of a new generation of highly versatile and efficient engineered zeolitic substances. The synthesis approaches developed thus far to make zeolitic core-shell materials and their analogues, yolk-shell, and hollow materials, are also examined and summarized. Finally, the last section concisely reviews the performance of novel core-shell, yolk-shell, and hollow zeolitic materials for some important industrial applications.

Crystal Engineering for Catalysis

Crystal engineering relies upon the ability to predictively control intermolecular interactions during the assembly of crystalline materials in a manner that leads to a desired (and predetermined) set of properties. Economics, scalability, and ease of design must be leveraged with techniques that manipulate the thermodynamics and kinetics of crystal nucleation and growth. It is often challenging to exact simultaneous control over multiple physicochemical properties, such as crystal size, habit, chirality, polymorph, and composition. Engineered materials often rely upon postsynthesis (top-down) processes to introduce properties that would otherwise be challenging to attain through direct (bottom-up) approaches. We discuss the application of crystal engineering to heterogeneous catalysts with a focus on four general themes: ( a) tailored nanocrystal size, ( b) controlled environments surrounding active sites, ( c) tuned morphology with well-defined facets, and ( d) hierarchical materials with disparate pore size and active site distributions. We focus on nonporous materials, including metals and metal oxides, and two classes of porous materials: zeolites and metal organic frameworks. We review novel synthesis methods involving synergistic experimental and computational design approaches, the challenges facing catalyst development, and opportunities for future advancement in crystal engineering.

Enhanced Hydrolysis of Cellulose in Ionic Liquid Using Mesoporous ZSM-5

Mesoporous ZSM-5 prepared by alkaline treatment was demonstrated as an efficient catalyst for the cellulose hydrolysis in ionic liquid (IL), affording a high yield of reducing sugar. It was demonstrated that mesoporous ZSM-5 (SiO₂/Al₂O₃ = 38) had 76.2% cellulose conversion and 49.6% yield of total reducing sugar (TRS). In comparison, the conventional ZSM-5 had a mere 41.3% cellulose conversion with 33.2% yield of TRS. The results indicated that the important role of mesopores in zeolites in elevating the TRS yield may be due to the diffusional alleviation of cellulose macromolecules. The effects of reaction time, temperature, and the ratio of catalyst to cellulose were investigated for optimal reaction conditions. It was found that IL could enter the inner channel of mesoporous ZSM-5 to promote the generation of H⁺ from Brönsted acid sites, which facilitated hydrolysis. Moreover, the mesoporous ZSM-5 showed excellent reusability for catalytic cycles by means of calcination of the used one, promising for its practical applications in the hydrolysis of cellulose.

Enhanced n-dodecane hydroisomerization performance by tailoring acid sites on bifunctional Pt/ZSM-22 via alkaline treatment

Acidity controlled Pt/ZSM-22 catalysts for n-dodecane hydroisomerization were explored through a simple and efficient post-treatment with different NaOH concentrations, and then the resulting samples were characterized.

One-pot synthesis of cup-like ZSM-5 zeolite and its excellent oxidative desulfurization performance

A one-step method to synthesize small size cup-like hollow ZSM-5 single crystals is reported in this paper. Characterization methods show that the product has a typical ZSM-5 structure and most crystals are uniform, mono dispersed crystal shells with distinct hollow structure. The average size of a single crystal is about 350 nm. Every cup-like hollow ZSM-5 crystal can act as a microreactor in the reaction, and the ZSM-5 based catalyst POM-MOF-ZSM-5 (polyoxometalates (POM), metal–organic frameworks (MOF)) shows excellent oxidative desulfurization performance of DBT (dibenzothiophene).

One-pot synthesis of small size cup-like hollow ZSM-5 single crystals and their oxidative desulfurization performance.

Mesoporous Silica Scaffolds as Precursor to Drive the Formation of Hierarchical SAPO-34 with Tunable Acid Properties

Using a distinctive bottom-up approach, a hierarchical silicoaluminophosphate, SAPO-34, has been synthesized using cetyl trimethylammonium bromide (CTAB) encapsulated within ordered mesoporous silica (MCM-41) that serves as both the silicon source and mesoporogen. The structural and textural properties of the hierarchical SAPO-34 were contrasted against its microporous analogue, and the nature, strength, and accessibility of the Brønsted acid sites were studied using a range of physicochemical characterization tools; notably probe-based FTIR and solid-state magic angle spinning (SS MAS) NMR spectroscopies. Whilst CO was used to study the acid properties of hierarchical SAPO-34, bulkier molecular probes (including pyridine, 2,4,6-trimethylpyridine and 2,6-di-tert-butylpyridine) allowed particular insight into the enhanced accessibility of the acid sites. The activity of the hierarchical SAPO-34 catalyst was evaluated in the industrially-relevant, acid-catalyzed Beckmann rearrangement of cyclohexanone oxime to ϵ-caprolactam, under vapor-phase conditions. These catalytic investigations revealed a significant enhancement in the yield of ϵ-caprolactam using our hierarchical SAPO-34 catalyst compared to SAPO-34, MCM-41, or a mechanical mixture of these two phases. The results highlight the merits of our design strategy for facilitating enhanced mass transfer, whilst retaining favorable acid site characteristics.