From Molecular Fragments to Crystals: A UV Raman Spectroscopic Study on the Mechanism of Fe-ZSM-5 Synthesis

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.

From waste to catalyst: Growth mechanisms of ZSM-5 zeolite from coal fly ash & rice husk ash and its performance as catalyst for tetracycline degradation in fenton-like oxidation

Coal fly ash (CFA), an industrial solid waste, can be utilized to synthesize Zeolite Socony Mobil-5 (ZSM-5) by incorporating an external silica source. In this study, a series of ZSM-5 zeolites were synthesized using rice husk ash (RHA) as the primary silica source and CFA as the primary aluminum source under controlled hydrothermal reaction conditions, and the growth mechanism of ZSM-5 was investigated. The process of ZSM-5 growth was featured by the transformation of hyperpoly silico-aluminate in CFA and RHA into monomers. These monomers formed crystal nuclei connected in a five-membered ring structure under the influence of Tetrapropyl ammonium hydroxide (TPAOH). The surplus monomeric silica-aluminate grew on the nucleus surface due to the addition of the silica source within RHA (RHA-SiO2), ultimately resulting in the development of ZSM-5 zeolite. Characterization results demonstrated that RHA-SiO2 exhibited favorable physical and chemical properties during the ZSM-5 synthesis, with a crystallinity of 99.03%, a specific surface area of 321.19 m2/g, a weight loss of only 3.06% at 800 °C and a total acidity of 0.65 mmol/g. To evaluate the catalytic performance of ZSM-5, Fe/Cu-modified ZSM-5 was developed and used as the catalyst for the degradation of tetracycline (TC) in Fenton-like oxidation. The results indicated that Fe/Cu-ZSM-5 exhibited excellent activity and stability as the catalyst for TC degradation and mineralization. The maximum TC degradation rate reached 99.02% in 10 min and the TOC removal could be up to 69.32% in 2 h. Characterization results indicated that the Fe/Cu ions redox cycle accelerated the generation of active species (1O2 and ˙OH) in Fenton-like systems. The ZSM-5 zeolite synthesized from solid waste demonstrated superb stability and catalytic activity, leading to the effective removal of TC. Since real wastewater generally contains various pollutants, future research efforts should focused on multi-pollutant treatment.

Maximizing Active Fe Species in ZSM-5 Zeolite Using Organic-Template-Free Synthesis for Efficient Selective Methane Oxidation

The selective oxidation of CH₄ in the aqueous phase to produce valuable chemicals has attracted considerable attention due to its mild reaction conditions and simple process. As the most widely studied catalyst for this reaction, Fe-ZSM-5 demonstrates high intrinsic activity and selectivity; however, Fe-ZSM-5 prepared using conventional methods has a limited number of active Fe sites, resulting in low CH₄ conversion per unit mass of the catalyst. This study reports a facile organic-template-free synthesis strategy that enables the incorporation of more Fe into the zeolite framework with a higher dispersion degree compared to conventional synthesis methods. Because framework Fe incorporated in this way is more readily transformed into isolated extra-framework Fe species under thermal treatment, the overall effect is that Fe-ZSM-5 prepared using this method (Fe-HZ5-TF) has 3 times as many catalytically active sites as conventional Fe-ZSM-5. When used for the selective oxidation of CH₄ with 0.5 M H₂O₂ at 75 °C, Fe-HZ5-TF produced a high C₁ oxygenate yield of 109.4 mmol g_cat^-1 h^-1 (a HCOOH selectivity of 91.1%), surpassing other catalysts reported to date. Spectroscopic characterization and density functional theory calculations revealed that the active sites in Fe-HZ5-TF are mononuclear Fe species in the form of [(H₂O)₃Fe(IV)═O]²⁺ bound to Al pairs in the zeolite framework. This differs from conventional Fe-ZSM-5, where binuclear Fe acts as the active site. Analysis of the catalyst and product evolution during the reaction suggests a radical-driven pathway to explain CH₄ activation at the mononuclear Fe site and subsequent conversion to C₁ oxygenates.

Atomically Dispersed Co2+ Sites Incorporated into a Silicalite-1 Zeolite Framework as a High-Performance and Coking-Resistant Catalyst for Propane Nonoxidative Dehydrogenation to Propylene

Propane nonoxidative dehydrogenation (PDH) is a promising route to produce propylene with the development of shale gas exploration technology. Co-based catalysts with low cost and low toxicity could activate C-H effectively, but they suffer from deactivation with coke formation. In this work, a catalyst formed by incorporating highly dispersed Co sites into a Silicalite-1 zeolite framework (Co-Silicalite-1) is synthesized by a hydrothermal protocol in the presence of ammonia, which exhibits superior propane dehydrogenation catalytic performance with 0.0946 mmol C₃H₆·s^-1·g_Co^-1 and propylene selectivity higher than 98.5%. It also shows outstanding catalytic stability and coking resistance in a 3560 min time-on-stream. Combined characterization results demonstrate that the tetrahedrally coordinated Co²⁺ site serves as the PDH catalytic active site, which is stabilized by Si-O units of the zeolite framework. Incorporation of Co sites into the zeolite framework could avoid the reduction of Co species to metallic Co. Moreover, the catalytic performance is improved by the enhanced propane adsorption and propylene desorption.

Syntheses of -Type Zeolites with the Presence of Both Octyltrimethylammonium Chloride and -Type Zeolite Seeds

Structure-directing agents (SDAs) play important roles in directing the formation of specific zeolite frameworks. Mechanisms and working hypothesis were proposed for understanding how SDAs work during the crystallization of zeolites. The lately reported cooperative structure-directing effect based on the investigation into the synthetic system containing both seed and organic species is one of them and is believed to be effective for synthesizing zeolites which are difficult to access or with novel structures. However, more examples are still needed to support the thesis. Herein, we report for the first time the syntheses of MTT-type zeolites with the simultaneous presences of octyltrimethylammonium chloride (OTMAC) and SFE zeolite seeds in the borosilicate system. SFE borosilicate zeolites serve as exotic seeds for the crystallization of MTT-type zeolites and together with OTMAC play cooperative structure-directing roles. Besides, Al,B-MTT and heteroatom (Zr, V, and Fe)-incorporated MTT-type zeolites were directly synthesized with the introduction of metal sources into the borosilicate system. Physicochemical properties of the obtained MTT zeolites were characterized by X-ray diffraction, scanning electron microscopy, transmission electron microscopy, N₂ physisorption, NH₃-TPD, ²⁷Al NMR, ¹³C NMR, ¹¹B NMR, UV-visible spectroscopy, and UV Raman spectroscopy. The herein-reported phenomenon provides an example to better understand the mechanism of zeolite crystallization, and the synthesized zeolites may act as promising catalytic materials in several organic reactions.

A low-cost route to prepare Fe-doped ZSM-22 zeolite with the assistance of a precursor solution

To decrease the synthesis cost and avoid the migration of framework Fe, an Fe-doped ZSM-22 zeolite was prepared with the assistance of a small amount of precursor solution in the absence of an additional organic template.

New advances in using Raman spectroscopy for the characterization of catalysts and catalytic reactions

Gaining insight into the mode of operation of heterogeneous catalysts is of great scientific and economic interest. Raman spectroscopy has proven its potential as a powerful vibrational spectroscopic technique for a fundamental and molecular-level characterization of catalysts and catalytic reactions. Raman spectra provide important insight into reaction mechanisms by revealing specific information on the catalysts' (defect) structure in the bulk and at the surface, as well as the presence of adsorbates and reaction intermediates. Modern Raman instrumentation based on single-stage spectrometers allows high throughput and versatility in design of in situ/operando cells to study working catalysts. This review highlights major advances in the use of Raman spectroscopy for the characterization of heterogeneous catalysts made during the past decade, including the development of new methods and potential directions of research for applying Raman spectroscopy to working catalysts. The main focus will be on gas-solid catalytic reactions, but (photo)catalytic reactions in the liquid phase will be touched on if it appears appropriate. The discussion begins with the main instrumentation now available for applying vibrational Raman spectroscopy to catalysis research, including in situ/operando cells for studying gas-solid catalytic processes. The focus then moves to the different types of information available from Raman spectra in the bulk and on the surface of solid catalysts, including adsorbates and surface depositions, as well as the use of theoretical calculations to facilitate band assignments and to describe (resonance) Raman effects. This is followed by a presentation of major developments in enhancing the Raman signal of heterogeneous catalysts by use of UV resonance Raman spectroscopy, surface-enhanced Raman spectroscopy (SERS), and shell-isolated nanoparticle surface-enhanced Raman spectroscopy (SHINERS). The application of time-resolved Raman studies to structural and kinetic characterization is then discussed. Finally, recent developments in spatially resolved Raman analysis of catalysts and catalytic processes are presented, including the use of coherent anti-Stokes Raman spectroscopy (CARS) and tip-enhanced Raman spectroscopy (TERS). The review concludes with an outlook on potential future developments and applications of Raman spectroscopy in heterogeneous catalysis.

Copper-Iron Bimetal Ion-Exchanged SAPO-34 for NH3-SCR of NOx

SAPO-34 was prepared with a mixture of three templates containing triethylamine, tetraethylammonium hydroxide, and morpholine, which leads to unique properties for support and production cost reduction. Meanwhile, Cu/SAPO-34, Fe/SAPO-34, and Cu-Fe/SAPO-34 were prepared through the ion-exchanged method in aqueous solution and used for selective catalytic reduction (SCR) of NOx with NH3. The physical structure and original crystal of SAPO-34 are maintained in the catalysts. Cu-Fe/SAPO-34 catalysts exhibit high NOx conversion in a broad temperature window, even in the presence of H2O. The physicochemical properties of synthesized samples were further characterized by various methods, including XRD, FE-SEM, EDS, N2 adsorption-desorption isotherms, UV-Vis-DRS spectroscopy, NH3-TPD, H2-TPR, and EPR. The best catalyst, 3Cu-1Fe/SAPO-34 exhibited high NOx conversion (> 90%) in a wide temperature window of 250–600 °C, even in the presence of H2O. In comparison with mono-metallic samples, the 3Cu-1Fe/SAPO-34 catalyst had more isolated Cu2+ ions and additional oligomeric Fe3+ active sites, which mainly contributed to the higher capacity of NH3 and NOx adsorption by the enhancement of the number of acid sites as well as its greater reducibility. Therefore, this synergistic effect between iron and copper in the 3Cu-1Fe/SAPO-34 catalyst prompted higher catalytic performance in more extensive temperature as well as hydrothermal stability after iron incorporation.

Fabrication of a core–shell MFI@TON material and its enhanced catalytic performance for toluene alkylation

Core–shell MFI@TON composites were designed and synthesized as a highly shape-selective catalyst for toluene alkylation by passivating the nonselective acid sites and tuning the diffusion behavior.

Environmental mineralization of caffeine micro-pollutant by Fe-MFI zeolites

Environmentally emerging micro-pollutant, caffeine, was mineralized (i.e., full degradation) by the isomorphic incorporation of Fe into silicalite-1 (mordenite framework inverted (MFI) structure zeolite) through a microwave synthesis method. The Fe incorporation conferred mesopore formation that facilitated caffeine access and transport to the MFI zeolite structure. Increasing the Fe content favored the formation of Fe(O)₄ sites within the MFI structure. The catalytic activity for the degradation of caffeine increased as a function of Fe(O)₄ sites via a Fenton-like heterogeneous reaction, otherwise not attainable using Fe-free pure MFI zeolites. Caffeine degradation reached 96% (TOC based) for zeolites containing 2.33% of Fe.

1,3-Disulfoimidazolium chloronickellate immobilized HZSM-5 framework as visible-light-induced heterogeneous photocatalyst for advanced oxidation process

Hybrid photocatalysts of [Dsim]₂[NiCl₄]/HZSM-5 were prepared by wet impregnation and their application is demonstrated as feasible heterogeneous photocatalysts for oxidative degradation of methylene blue under sunlight.

A novel synthetic strategy of Fe-ZSM-35 with pure framework Fe species and its formation mechanism

A novel two-step crystallization process of Fe-ZSM-35 zeolite was designed, and analyzed by UV resonance Raman spectroscopy.

Stable Fe/ZSM-5 Nanosheet Zeolite Catalysts for the Oxidation of Benzene to Phenol

Fe/ZSM-5 nanosheet zeolites of varying thickness were synthesized with di- and tetraquaternary ammonium structure directing agents and extensively characterized for their textural, structural, and catalytic properties. Introduction of Fe3+ ions in the framework of nanosheet zeolites was slightly less effective than in bulk ZSM-5 zeolite. Steaming was necessary to activate all catalysts for N2O decomposition and benzene oxidation. The higher the Fe content, the higher the degree of Fe aggregation was after catalyst activation. The degree of Fe aggregation was lower when the crystal domain size of the zeolite or the Fe content was decreased. These two parameters had a substantial influence on the catalytic performance. Decreasing the number of Fe sites along the b-direction strongly suppressed secondary reactions of phenol and, accordingly, catalyst deactivation. This together with the absence of diffusional limitations in nanosheet zeolites explains the much higher phenol productivity obtainable with nanostructured Fe/ZSM-5. Steamed Fe/ZSM-5 zeolite nanosheet synthesized using C22-6-3·Br2 (domain size in b-direction ∼3 nm) and containing 0.24 wt % Fe exhibited the highest catalytic performance. During the first 24 h on stream, this catalyst produced 185 mmolphenol g-1. Calcination to remove the coke deposits completely restored the initial activity.

Establishing hierarchy: the chain of events leading to the formation of silicalite-1 nanosheets

In applying a multi-scale spectroscopic and computational approach, we demonstrate that the synthesis of stacked zeolite silicalite-1 nanosheets, in the presence of a long-tail diquaternary ammonium salt surfactant, proceeds through a pre-organised phase in the condensed state. In situ small-angle X-ray scattering, coupled to paracrystalline theory, and backed by electron microscopy, shows that this phase establishes its meso-scale order within the first five hours of hydrothermal synthesis. Quasi in situ vibrational and solid-state NMR spectroscopy reveal that this meso-shaped architecture already contains some elementary zeolitic features. The key to this coupled organisation at both micro- and meso-scale, is a structure-directing agent that is ambifunctional in shaping silica at the meso-scale whilst involved in molecular recognition at the micro-scale. The latter feature is particularly important and requires the structure-directing agent to reside within the silica matrix already at early stages of the synthesis. From here, molecular recognition directs stabilization of precursor species and their specific embedding into a lattice, as shown by force-field molecular dynamics calculations. These calculations, in line with experiment, further show how it is possible to subtly tune both the zeolite topology and aspect ratio of the condensating crystals, by modifying the headgroup of the structure-directing agent.

Promotion effect of Fe in mordenite zeolite on carbonylation of dimethyl ether to methyl acetate

Fe-modified mordenite samples were synthesized and employed in dimethyl ether carbonylation reaction, resulting in an evident improvement of the stability.

Influence of single- and double-flame spray pyrolysis on the structure of MnOx/γ-Al2O3 and FeOx/γ-Al2O3 catalysts and their behaviour in CO removal under lean exhaust gas conditions

Manganese and iron oxides on alumina prepared by two-nozzle flame synthesis show improved CO-oxidation activity due to minimized composite formation.

Investigation on the effect of zeolite precursor on the formation process of MCM-41 containing zeolite Y building units

The formation process of MCM-41 containing zeolite Y building units has been investigated by UV Raman spectroscopy, (29)Si and (27)Al MAS NMR spectroscopy, X-ray diffraction (XRD), N2 adsorption and electron microscopy (SEM and TEM). It is found that the precursor containing zeolite Y secondary building units promotes the formation of a metastable mesopore structure just after mixing the zeolite precursors with CTAB. In contrast, the low-polymerized aluminosilicates and well-crystallized zeolite crystals cannot be assembled with CTAB at this stage. The result supports that the zeolite secondary building units should promote to the formation of the mesopore wall. This has been ascribed to its high anionic charge density as well as the appropriate multidentate coordination. Lowering down the pH value to 9.3 facilitates the further polymerization of the aluminosilicate species to build up a stable mesoporous phase.

Methods for in situ spectroscopic probing of the synthesis of a zeolite

Unraveling the crystallization mechanism of zeolites remains an increasingly important challenge in chemistry. During the last decade, in situ spectroscopic methods have provided an unprecedented level of detail of the underlying molecular mechanisms and their kinetics. Magnetic resonance, vibrational and X-ray absorption techniques have emerged as principal tools for the in situ observation of crystallization. In this tutorial review, we discuss how these in situ methods have contributed to our understanding of the complex and diverse molecular processes that govern zeolite crystallization.