Spontaneous Pillaring of Pentasil Zeolites

Directional Transport in Hierarchically Aligned ZSM-5 Zeolites with High Catalytic Activity

Zeolites, the most technically important crystalline microporous materials, are indispensable cornerstones of chemical engineering because of their remarkable catalytic properties and adsorption capabilities. Numerous studies have demonstrated that the hierarchical engineering of zeolites can maximize accessible active sites and improve mass transport, which significantly decreases the internal diffusion limits to achieve the desired performance. However, the construction of hierarchical zeolites with ordered alignments and size-controlled substructures in a convenient way is highly challenging. Herein, we develop a facile procedure using two common structure-directing agents, tetrapropylammonium hydroxide (TPAOH) and tetraethylammonium hydroxide (TEAOH), to synthesize hierarchically aligned ZSM-5 (Hie-ZSM-5) crystals with a-axis alignment substructures of controllable size. The control of the substructure size (α) in the range of 10-60 nm and the corresponding similarity (r = α/β, where β is the size of Hie-ZSM-5) ranging from 0.004 to 0.033 can be tuned by varying the Si/Al ratios (40-120). A systematic investigation of the overall crystallization process, using time-dependent XRD, SEM, TEM, and solid-state magic-angle spinning NMR (13C, 27Al, 29Si) methods, enable us to construct a solid mechanism for the generation of Hie-ZSM-5. Most importantly, directional transport in the unique structures of Hie-ZSM-5 efficiently enhances mass diffusion, as well as catalytic activity and stability. These findings improve our understanding of the zeolite crystallization process and inspire novel methods for the rational design of hierarchical zeolites.

The Current Understanding of Mechanistic Pathways in Zeolite Crystallization

Zeolite catalysts and adsorbents have been an integral part of many commercial processes and are projected to play a significant role in emerging technologies to address the changing energy and environmental landscapes. The ability to rationally design zeolites with tailored properties relies on a fundamental understanding of crystallization pathways to strategically manipulate processes of nucleation and growth. The complexity of zeolite growth media engenders a diversity of crystallization mechanisms that can manifest at different synthesis stages. In this review, we discuss the current understanding of classical and nonclassical pathways associated with the formation of (alumino)silicate zeolites. We begin with a brief overview of zeolite history and seminal advancements, followed by a comprehensive discussion of different classes of zeolite precursors with respect to their methods of assembly and physicochemical properties. The following two sections provide detailed discussions of nucleation and growth pathways wherein we emphasize general trends and highlight specific observations for select zeolite framework types. We then close with conclusions and future outlook to summarize key hypotheses, current knowledge gaps, and potential opportunities to guide zeolite synthesis toward a more exact science.

Intergrowth Zeolites, Synthesis, Characterization, and Catalysis

Microporous zeolites that can act as heterogeneous catalysts have continued to attract a great deal of academic and industrial interest, but current progress in their synthesis and application is restricted to single-phase zeolites, severely underestimating the potential of intergrowth frameworks. Compared with single-phase zeolites, intergrowth zeolites possess unique properties, such as different diffusion pathways and molecular confinement, or special crystalline pore environments for binding metal active sites. This review first focuses on the structural features and synthetic details of all the intergrowth zeolites, especially providing some insightful discussion of several potential frameworks. Subsequently, characterization methods for intergrowth zeolites are introduced, and highlighting fundamental features of these crystals. Then, the applications of intergrowth zeolites in several of the most active areas of catalysis are presented, including selective catalytic reduction of NOx by ammonia (NH3-SCR), methanol to olefins (MTO), petrochemicals and refining, fine chemicals production, and biomass conversion on Beta, and the relationship between structure and catalytic activity was profiled from the perspective of intergrowth grain boundary structure. Finally, the synthesis, characterization, and catalysis of intergrowth zeolites are summarized in a comprehensive discussion, and a brief outlook on the current challenges and future directions of intergrowth zeolites is indicated.

Facile synthesis of aluminosilicate zeolites with STT, CHA and MWW topology structures

Efficient synthesis of zeolites with different topologies is of great significance for both fundamental research and industrial application. Herein, the SSZ-23 zeolite, an odd zeolite containing 7-membered ring (7-MR) and 9-MR channels, has been synthesized under fluorine-free conditions via the route of pre-aging and pH regulation. By this novel synthesis route, the crystallization time can be significantly shortened to 3 days, nearly half as that by the conventional route in fluoride media. The pH value of the aging gel, i.e., the basicity, is found to play a key role in the synthesis, as SSZ-13 and SSZ-25 zeolites can be synthesized simply by changing the basicity of the same aging gel. Characterization results indicate that decreasing the basicity can promote the condensation between Si and Si/Al species and thus increase the framework density of the resulting zeolites. Finally, the dimethyl ether (DME) carbonylation reaction is employed to evaluate the catalytic properties of the above three zeolites with an identical chemical composition, and to reveal the unique confinement effect in various zeolite topologies.

A Six-Membered Ring Molecular Sieve Achieved by a Reconstruction Route

Zeolite molecular sieves with at least eight-membered rings are widely applied in industrial applications, while zeolite crystals with six-membered rings are normally regarded as useless products due to the occupancy of the organic templates and/or inorganic cation in the micropores that could not be removed. Herein, we showed that a novel six-membered ring molecular sieve (ZJM-9) with fully open micropores could be achieved by a reconstruction route. The mixed gas breakthrough experiments such as CH₃OH/H₂O, CH₄/H₂O, CO₂/H₂O, and CO/H₂O at 25 °C showed that this molecular sieve was efficient for selective dehydration. Particularly, a lower desorption temperature (95 °C) of ZJM-9 than that (250 °C) of the commercial 3A molecular sieve might offer an opportunity for saving more energy in dehydration processes.

Unique Role of GeO2 as a Noninvasive Promoter of Nano-Sized Zeolite Crystals

The synthesis of zeolites with nano-sized dimensions is often limited to a narrow design space that conventionally relies upon the design of organics to direct hierarchical materials. Here, it is demonstrated that the addition of an inorganic modifier, germanium oxide (GeO₂ ), to a zeolite growth mixture directs the formation of crystals with ultrasmall dimensions. This effect is observed for zeolites ZSM-11 and ZSM-5 over a range of synthesis conditions wherein the role of GeO₂  in zeolite crystallization deviates from its typical function as a heteroatom. Notably, the final products contain trace amounts of Ge, which indicates the inorganic modifier does not compete for sites in the zeolite framework based on its formation of a discrete phase that enables GeO₂  recovery. Catalytic tests using the methanol-to-hydrocarbons reaction reveal significant enhancement in the performance of zeolite catalysts prepared with GeO₂  compared to reported examples of nano-sized zeolites. These findings highlight a potentially generalizable and commercially viable synthesis method to reduce mass-transport limitations in zeolites for diverse applications.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

Recent Advances in the Seed-Directed Synthesis of Zeolites without Addition of Organic Templates

Zeolites have been widely employed in fields of petroleum refining, fine chemicals and environmental protection, but their syntheses are always performed in the presence of organic templates, which have many drawbacks such as high cost and polluted wastes. In recent years, the seed-directed synthesis of zeolites has been paid much attention due to its low-cost and environmentally friendly features. In this review, the seed-directed synthesis of Al-rich zeolites with homonuclear and heteronuclear features, the seed-directed synthesis of Si-rich zeolites assisted with ethanol and the utility of seed-directed synthesis have been summarized. This review could help zeolite researchers understand the recent progress of seed-directed synthesis.

Zeolite nanosheets for catalysis

Zeolites with well-defined micropores have been widely used as heterogeneous catalysts in the fields of petroleum refining, fine chemicals, and environment protection. However, the sole micropores in the zeolite structures usually impose diffusion constraints, which would greatly influence their catalytic performances. Therefore, it is highly desirable to shorten the diffusion pathway of zeolites and thus eliminate the diffusion constraints. One of the efficient methods is to synthesize zeolite nanosheets, which has become a hot topic in the past decades. In this tutorial review, the recent progresses in the synthesis of zeolite nanosheets and their relevant catalysis are briefly discussed. Various strategies for the synthesis of zeolite nanosheets are summarized including delamination, templated crystallization, additive-assisted synthesis, seed-directed synthesis, and gaseous expansion synthesis. In addition, the catalytic reactions of zeolite nanosheets with acidic and metal sites are also outlined. This tutorial review should be significant for the design and preparation of highly efficient zeolite catalysts.

Design of a Small Organic Template for the Synthesis of Self-Pillared Pentasil Zeolite Nanosheets

Zeolite nanosheets with excellent mass transfer are attractive, but their successful syntheses are normally resulted from a huge number of experiments. Here, we show the design of a small organic template for the synthesis of self-pillared pentasil (SPP) zeolite nanosheets from theoretical calculations in interaction energies between organic templates and pentasil zeolite skeletons. As expected, the SPP zeolite nanosheets with the thickness at 10-20 nm have been synthesized successfully. Characterizations show that the SPP zeolite nanosheets with about 90% MFI and 10% MEL structures have good crystallinity, the house-of-card morphology, large surface area, and fully four-coordinated aluminum species. More importantly, methanol-to-propylene tests show that the SPP zeolite nanosheets exhibit much higher propylene selectivity and longer reaction lifetime than conventional ZSM-5 zeolite. These results offer a good opportunity to develop highly efficient zeolite catalysts in the future.

Hierarchical Catalysts Prepared by Interzeolite Transformation

Interzeolite transformation has been used to produce a novel family of hierarchical catalysts featuring excellent textural properties, strong acidity, and superior catalytic performance for the Friedel-Crafts alkylation of indole with benzhydrol, the Claisen-Schmidt condensation of benzaldehyde and hydroxyacetophenone, and the cracking of polystyrene. Intermediate solids of the FAU interzeolite transformation into BEA display both increased accessibility─due to the development of mesoporosity─and strong acidity─caused by the presence of ultrasmall crystals or zeolitic fragments in their structure. The use of surfactants allows for the development of the hierarchical catalysts with very narrow pore size distribution. The properties of interzeolite transformation intermediates (ITIs) can be fine-tuned simply by stopping the interconversion at different times.

Fluoride-free synthesis of beta zeolite with enrichment of polymorph B from a solvent-free route

Beta zeolite with enrichment of polymorph B is successfully synthesized in the absence of fluorine species under solvent-free conditions. The phase composition of polymorph B in the sample is about 70%.

Green Route for Synthesizing Pure Silica Zeolites with Six-Membered Rings

Green routes for synthesizing pure silica zeolites are attractive but still challenging. Herein, we for the first time show a green route for synthesizing pure silica zeolites with six-membered rings...

Advances in the synthesis and application of SSZ-39 zeolite

Zeolites, especially aluminosilicate zeolites, have been widely utilized in the process of petroleum refining, environmental protection, and fine chemicals. In the past decades, great attentions have been paid on the...

Controlling Nucleation Pathways in Zeolite Crystallization: Seeding Conceptual Methodologies for Advanced Materials Design

A core objective of synthesizing zeolites for widespread applications is to produce materials with properties and corresponding performances that exceed conventional counterparts. This places an impetus on elucidating and controlling processes of crystallization where one of the most critical design criteria is the ability to prepare zeolite crystals with ultrasmall dimensions to mitigate the deleterious effects of mass transport limitations. At the most fundamental level, this requires a comprehensive understanding of nucleation to address this ubiquitous materials gap. This Perspective highlights recent methodologies to alter zeolite nucleation by using seed-assisted protocols and the exploitation of interzeolite transformations to design advanced materials. Introduction of crystalline seeds in complex growth media used to synthesize zeolites can have wide-ranging effects on the physicochemical properties of the final product. Here we discuss the diverse pathways of zeolite nucleation, recent breakthroughs in seed-assisted syntheses of nanosized and hierarchical materials, and shortcomings for developing generalized guidelines to predict synthesis outcomes. We offer a critical analysis of state-of-the-art approaches to tailor zeolite crystallization wherein we conceptualize whether parallels between network theory and zeolite synthesis can be instrumental for translating key findings of individual discoveries across a broader set of zeolite crystal structures and/or synthesis conditions.