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.

Synthesis and Catalytic Applications of Advanced Sn- and Zr-Zeolites Materials

The incorporation of isolated Sn (IV) and Zr (IV) ions into silica frameworks is attracting widespread attention, which exhibits remarkable catalytic performance (conversion, selectivity, and stability) in a broad range of reactions, especially in the field of biomass catalytic conversion. As a representative example, the conversion route of carbohydrates into valuable platform and commodity chemicals such as lactic acid and alkyl lactates, has already been established. The zeotype materials also possess water-tolerant ability and are capable to be served as promising heterogeneous catalysts for aqueous reactions. Therefore, dozens of Sn- and Zr-containing silica materials with various channel systems have been prepared successfully in the past decades, containing 8 membered rings (MR) small pore CHA zeolite, 10-MR medium pore zeolites (FER, MCM-56, MEL, MFI, MWW), 12-MR large pore zeolites (Beta, BEC, FAU, MOR, MSE, MTW), and 14-MR extra-large pore UTL zeolite. This review about Sn- and Zr-containing metallosilicate materials focuses on their synthesis strategy, catalytic applications for diverse reactions, and the effect of zeolite characteristics on their catalytic performances.

Synthesis strategies to control the Al distribution in zeolites: thermodynamic and kinetic aspects

The activity and selectivity of acid-catalyzed chemistry is highly dependent on the Brønsted and Lewis acid sites generated by Al substitutions in a zeolite framework with the desired pore architecture. The siting of two Al atoms in close proximity in the framework of high-silica zeolites can also play a decisive role in improving the performance of redox catalysts by producing exchangeable positions for extra-framework multivalent cations. Thus, considerable attention has been devoted to controlling the Al incorporation through direct synthesis approaches and post-synthesis treatments to optimize the performance as (industrial) solid catalysts and to develop new acid- and redox-catalyzed reactions. This Feature Article highlights bottom-up synthetic strategies to fine-tune the Al incorporation in zeolites, interpreted with respect to thermodynamic and kinetic aspects. They include (i) variation in extra-framework components in zeolite synthesis, (ii) isomorphous substitution of other heteroatoms in the zeolite framework, and (iii) control over the (alumino)silicate network in the initial synthesis mixture via in situ and ex situ methods. Most synthetic approaches introduced here tentatively showed that the energy barriers associated with Al incorporation in zeolites can be variable during zeolite crystallization processes, occurring in complex media with multiple chemical interactions. Although the generic interpretation of each strategy and underlying crystallization mechanism remains largely unknown (and often limited to a specific framework), this review will provide guidance on more efficient methods to prepare fine-tuned zeolites with desired chemical properties.

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.

Controllable Synthesis of Ultrathin Defect-Rich LDH Nanoarrays Coupled with MOF-Derived Co-NC Microarrays for Efficient Overall Water Splitting

Water electrolysis has attracted immense research interest, nevertheless the lack of low-cost but efficient bifunctional electrocatalysts for both hydrogen and oxygen evolution reactions greatly hinders its commercial applications. Herein, the controllable synthesis of ultrathin defect-rich layered double hydroxide (LDH) nanoarrays assembled on metal-organic framework (MOF)-derived Co-NC microarrays for boosting overall water splitting is reported. The Co-NC microarrays can not only provide abundant nucleation sites to produce a large number of LDH nuclei for favoring the growth of ultrathin LDHs, but also help to inhibit their tendency to aggregate. Impressively, five types of ultrathin bimetallic LDH nanoarrays can be electrodeposited on the Co-NC microarrays, forming desirable nanoarray-on-macroarray architectures, which show high uniformity with thicknesses from 1.5 to 1.9 nm. As expected, the electrocatalytic performance is significantly enhanced by exploiting the respective advantages of Co-NC microarrays and ultrathin LDH nanoarrays as well as the potential synergies between them. Especially, the optimal Co-NC@Ni₂ Fe-LDH as both cathode and anode can afford the lowest cell voltage of 1.55 V at 10 mA cm^-2 , making it one of the best earth-abundant bifunctional electrocatalysts for water electrolysis. This study provides new insights into the rational design of highly-active and low-cost electrocatalysts and facilitates their promising applications in the fields of energy storage and conversion.

Manipulation of amorphous precursors to enhance zeolite nucleation

Crystallization in media comprised of amorphous precursors is becoming a more common phenomenon for numerous synthetic, biological, and natural materials that grow by a combination of classical and nonclassical pathways. Amorphous phases can exhibit a wide range of physicochemical properties that may evolve during the course of nucleation and crystal growth. This creates challenges for establishing causal relationships between amorphous precursor properties and their effect(s) on the selection of mechanistic pathways of crystallization and ultimately the properties of the crystalline product. In this study, we examine ways to manipulate the composition and colloidal stability of amorphous (alumino)silicate precursors that are prevalent in nanoporous zeolite syntheses. Changes in the amorphous precursor properties are evaluated on the basis of their ability to enhance rates of crystal formation. Here, we use fumed silica as the primary silicon source and examine the effects of infusing the source or growth medium with additional alkali metal, which serves as an inorganic structure-directing agent to facilitate the formation of porous crystal structures. We also assess the impact of adding a polymer additive, which reduces the colloidal stability of precursors, wherein we posit that the confined pockets of solution within the interstitial spaces of the precursor aggregates play an important role in regulating the rate of zeolite crystallization. Three commercially relevant zeolites (mordenite, SSZ-13, and ZSM-5) were selected for this study based on their diverse frameworks and methods of preparation. Our findings reveal that alkali infusion significantly reduces the crystallization times for mordenite and SSZ-13, but has little impact on ZSM-5 synthesis. Conversely, we find that polymer addition markedly enhanced the rates of crystallization among all three zeolites, suggesting that this method may be a general approach to reduce zeolite synthesis times. Given the relatively high costs associated with commercial zeolite production, identifying new methods to improve the efficiency of hydrothermal syntheses can have significant practical implications beyond the fundamental benefits of developing new routes to tailor nonclassical crystallization.

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.

Enhanced Selectivity and Stability of Finned Ferrierite Catalysts in Butene Isomerization

Designing zeolite catalysts with improved mass transport properties is crucial for restrictive networks of either one- or two-dimensional pore topologies. Here, we demonstrate the synthesis of finned ferrierite (FER), a commercial zeolite with two-dimensional pores, where protrusions on crystal surfaces behave as pseudo nanoparticles. Catalytic tests of 1-butene isomerization reveal a 3-fold enhancement of catalyst lifetime and an increase of 12 % selectivity to isobutene for finned samples compared to corresponding seeds. Electron tomography was used to confirm the identical crystallographic registry of fins and seeds. Time-resolved titration of Brønsted acid sites confirmed the improved mass transport properties of finned ferrierite compared to conventional analogues. These findings highlight the advantages of introducing fins through facile and tunable post-synthesis modification to impart material properties that are otherwise unattainable by conventional synthesis methods.

Reaction Kinetics Regulated Formation of Short-Range Order in an Amorphous Matrix during Zeolite Crystallization

The crystallization of zeolites, a disorder-to-order transformation of aluminosilicates, has not been thoroughly understood because the nucleation events in the amorphous matrix are difficult to recognize from the diverse structural changes, especially for the dense hydrogel systems. Therefore, relationships between the synthesis conditions, the generated amorphous species, and the crystallization behavior of zeolites remain unclear. Herein, by comparatively investigating the structural evolution of the aluminosilicate matrix in a dense hydrogel system when different Si reactants (fumed silica and silicate solution) are employed, we demonstrate that the reactivity of the reactants and the kinetics of the condensation reaction is critical to the formation of short-range order in an amorphous matrix, which greatly influences the nucleation frequency of zeolites. It was revealed that an amorphous solid containing plentiful Al-rich four-membered rings and Si-rich six-membered rings could be produced when fumed silica gradually reacted with sodium aluminate solution at 80 °C. It is considered that the interaction between these rings promotes the construction of the essential building units of zeolite X (FAU). In contrast, a complex aluminosilicate matrix was formed immediately when sodium silicate solution was mixed with sodium aluminate solution due to the intense condensation reaction. Furthermore, this complex matrix became more stable when the reactant mixture was hydrothermally treated at 80 °C, which significantly impedes the crystallization process. Aging the reactant mixture at ambient temperature before heating, instead, facilitated the formation of short-range order in the amorphous matrix, which increases the nucleation frequency of zeolites.

A Cationic Oligomer as an Organic Template for Direct Synthesis of Aluminosilicate ITH Zeolite

There are a large number of zeolites, such as ITH, that cannot be prepared in the aluminosilicate form. Now, the successful synthesis of aluminosilicate ITH zeolite using a simple cationic oligomer as an organic template is presented. Key to the success is that the cationic oligomer has a strong complexation ability with aluminum species combined with a structural directing ability for the ITH structure similar to that of the conventional organic template. The aluminosilicate ITH zeolite has very high crystallinity, nanosheet-like crystal morphology, large surface area, fully four-coordinated Al species, and abundant acidic sites. Methanol-to-propylene (MTP) tests reveal that the Al-ITH zeolite shows much higher selectivity for propylene and longer lifetime than commercial ZSM-5. FCC tests show that Al-ITH zeolite is a good candidate as a shape-selective FCC additive for enhancing propylene and butylene selectivity.

Advances in the Synthesis of Ferrierite Zeolite

As one of the most important porous materials, zeolites with intricate micropores have been widely employed as catalysts for decades due to their large pore volume, high surface area, and good thermal and hydrothermal stabilities. Among them, ferrierite (FER) zeolite with a two-dimensional micropore structure is an excellent heterogeneous catalyst for isomerization, carbonylation, cracking, and so on. In the past years, considering the important industrial application of FER zeolite, great efforts have been made to improve the synthesis of FER zeolite and thus decrease the synthesis cost and enhance catalytic performance. In this review, we briefly summarize the advances in the synthesis of FER zeolite including the development of synthesis routes, the use of organic templates, organotemplate-free synthesis, the strategies of morphology control, and the creation of intra-crystalline mesopores. Furthermore, the synthesis of hetero-atomic FER zeolites such as Fe-FER and Ti-FER has been discussed.

Oxidative desulfurization of model oil over Ta-Beta zeolite synthesized via structural reconstruction

As to metallosilicate zeolites, ions with larger size such as Ta⁵⁺ in the gels greatly retarded their crystallization during the hydrothermal synthesis, affording long-winded synthesis periods, up-limited framework-substituted metal contents, or even frustrated outcome. An efficient hydrothermal synthesis strategy for metallosilicate, in this case of Ta framework-substituted *BEA zeolite, via structural reconstruction was proposed to stride the gap. The Ta content in our developed Ta-Beta-Re-50 zeolite achieved up to 5.48 % (Si/Ta = 52), breaking through the limitation of Ta contents for conventional method (Si/Ta > 100). Additionally, this Ta-Beta-Re zeolite possessed nanosized crystals (20-40 nm) and short crystallization time (8 h), significantly improving space-time yields of practical zeolite production. Through spectroscopic study, it was confirmed that the existence of zeolite structural units intensively facilitated the formation of nucleation and crystal growth. This innovative Ta-Beta zeolite demonstrated high catalytic performances for oxidation desulfurization, far outperforming traditional fluoride-mediated Ta-Beta-F, which was ascribed to its excellent diffusion properties and incredible high isolated Ta contents. Additionally, the catalytic performance of Ta-Beta-Re could be regenerated after simple calcination and the deactivation may be caused by pore blocking of organics. This work provides a new method for rationally design and construction of metallosilicate materials with high activity for catalytic oxidation applications, which can bridge the conceptual and technical gap between periodic trends and zeolite material synthesis.

A Bottom-Up Strategy for the Synthesis of Highly Siliceous Faujasite-Type Zeolite

High-silica zeolite Y is a desired catalytic material for oil refining and the petrochemical industry. However, its direct synthesis remains a symbolic challenge in the field of zeolite synthesis, with a limited improvement of the framework SiO₂ /Al₂ O₃ ratio (SAR) from ≈5 to 9 over the past 60 years. Here, the synthesis of highly siliceous zeolite Y with tunable SAR up to 15.6 through a cooperative strategy is reported, which involves the use of FAU nuclei, a bulky organic structure-directing agent (OSDA), and a gel system with low alkalinity (named NOA-co strategy). A series of quaternary alkylammonium ions is discovered as effective OSDAs based on the NOA-co strategy, and the relevant crystallization mechanism is elucidated. Moreover, the high-silica products are demonstrated to have greatly improved (hydro)thermal stability, high concentration of strong acid sites, and uniform acid distribution, which lead to superior catalytic performance in the cracking of bulky hydrocarbons. It is anticipated that this synthetic strategy will benefit the synthesis and development of zeolitic catalysts in a wide range of reaction processes.

Electrochemically Enhanced Dissolution of Silica and Alumina in Alkaline Environments

Dissolution of mineral surfaces at asymmetric solid-liquid-solid interfaces in aqueous solutions occurs in technologically relevant processes, such as chemical/mechanical polishing (CMP) for semiconductor fabrication, formation and corrosion of structural materials, and crystallization of materials relevant to heterogeneous catalysis or drug delivery. In some such processes, materials at confined interfaces exhibit dissolution rates that are orders of magnitude larger than dissolution rates of isolated surfaces. Here, the dissolution of silica and alumina in close proximity to a charged gold surface or mica in alkaline solutions of pH 10-11 is shown to depend on the difference in electrostatic potentials of the surfaces, as determined from measurements conducted using a custom-built electrochemical pressure cell and a surface forces apparatus (SFA). The enhanced dissolution is proposed to result from overlap of the electrostatic double layers between the dissimilar charged surfaces at small intersurface separation distances (<1 Debye length). A semiquantitative model shows that overlap of the electric double layers can change the magnitude and direction of the electric field at the surface with the less negative potential, which results in an increase in the rate of dissolution of that surface. When the surface electrochemical properties were changed, the dissolution rates of silica and alumina were increased by up to 2 orders of magnitude over the dissolution rates of isolated compositionally similar surfaces under otherwise identical conditions. The results provide new insights on dissolution processes that occur at solid-liquid-solid interfaces and yield design criteria for controlling dissolution through electrochemical modification, with relevance to diverse technologies.

Direct Synthesis of Aluminosilicate IWR Zeolite from a Strong Interaction between Zeolite Framework and Organic Template

A large amount of zeolite structures are still not synthetically available or not available in the form of aluminosilicate currently. Despite significant progress in the development of predictive concepts for zeolite synthesis, accessing some of these new materials is still challenging. One example is the IWR structure as well. Despite successful synthesis of Ge-based IWR zeolites, direct synthesis of aluminosilicate IWR zeolite is still not successful. In this report we show how a suitable organic structure directing agent (OSDA), through modeling of an OSDA/zeolite cage interaction, could access directly the aluminum-containing IWR structure (denoted as COE-6), which might allow access to new classes of materials and thus open opportunities in valuable chemical applications. The experimental results reveal that the COE-6 zeolites with a SiO₂/Al₂O₃ ratio as low as 30 could be obtained. Very interestingly, the COE-6 zeolite has much higher hydrothermal and thermal stabilities than those of the conventional Ge-Al-IWR zeolite. In methanol-to-propylene (MTP) reaction, the COE-6 zeolite exhibits excellent selectivity for propylene, offering a potential catalyst for MTP reaction in the future.

Tracking the rearrangement of atomic configurations during the conversion of zeolite to zeolite

In order to realize designed synthesis, understanding the formation mechanism of zeolites at an atomic level has long been aspired, but remains challenging due to the fact that the knowledge of atomic configurations of the species formed during the process is limited. We focus on a synthesis system that crystallizes CHA zeolite from FAU zeolite as the sole source of tetrahedral atoms of Si and Al, so that end-to-end characterization can be conducted. Solid-state 29Si MAS NMR is followed by high-throughput computational modeling to understand how atomic configurations changed during the interzeolite conversion. This reveals that the structural motif commonly found in FAU and CHA is not preserved during the conversion; rather, there is a specific rearrangement of silicates and aluminates within the motif. The atomic configuration of CHA seems to be influenced by that of the starting FAU, considering that CHA synthesized without using FAU results in a random Al distribution. A Metropolis Monte-Carlo simulation combined with a lattice minimization technique reveals that CHA derived from FAU has energetically favorable, biased atomic locations, which could be a result of the atomic configurations of the starting FAU. These results suggest that by choosing the appropriate reactant, Al placement could be designed to enhance the targeted properties of zeolites for catalysis and adsorption.

Deleterious effects of non-framework Al species on the catalytic performance of ZSM-5 crystals synthesized at low temperature

ZSM-5 synthesis at low temperature leads to a large percentage of non-framework octahedral and penta-coordinated aluminum species that negatively impact catalyst performance.

Controlled aggregation of core(amorphous silica)@shell(TPA+-polysilicate) nanoparticles at room temperature by selective removal of TPA+ ions from the nanoparticle shell

Displacement of TPA⁺ ions from the nanoparticle shell exposes the terminal silanol groups, which enables the aggregation of the collided nanoparticles.