Co-hydrolysis and Seed-Induced Synthesis of Basic Mesoporous ZSM-5 Zeolites with Enhanced Catalytic Performance

Synthesis of Chainlike ZSM-5 with a Polyelectrolyte as a Second Template for Oleic Acid and Ethanol Cracking into Light Olefins

Chainlike ZSM-5 was synthesized in a tetrapropylammonium hydroxide (TPAOH) and poly(diallydimethylammonium chloride) (PDDA) dual-template system. The synthesis parameters and formation mechanism of chainlike zeolites were investigated. The optimized composition of the synthesis mixture was as follows: the PDDA/SiO₂, TPAOH/SiO₂, SiO₂/Al₂O₃, and H₂O/SiO₂ molar ratios are, respectively, 0.16, 0.4, 50, and 40, with tetraethyl orthosilicate and aluminum nitrate as silicon/aluminum sources. The resultant ZSM-5 showed a cross-linked chainlike morphology, mesopore-dominated pore structure, and mild acidity. The formation of the chainlike zeolite was attributed to synergistic actions between PDDA and TPAOH. TPAOH acted as an alkali source and helped to induce nucleation and control the crystal size. PDDA acted as a soft template to promote crystal nucleation, and a hard template to form a three-dimensional mesoporous structure. Light olefin (C_2-4 ⁼) selectivities from cracking of ethanol and oleic acid over the present chainlike ZSM-5 at 400 °C reached 90 and 75.7%, respectively, which were much higher than those from commercial ZSM-5 (75 and 52.3%, respectively), demonstrating the excellent hydrothermal stability and catalytic performance of the synthesized chainlike zeolite.

Facile Morphology and Porosity Regulation of Zeolite ZSM-5 Mesocrystals with Synergistically Enhanced Catalytic Activity and Shape Selectivity

The morphology and mesoporosity of zeolite are two vital properties to determine its performance in diverse applications involving adsorption and catalysis; while it remains a big challenge for the synthesis and regulation of zeolites with exceptional morphology/porosity only through inorganic-ions-based modification. Herein, by simply optimizing the alkali metal type (K⁺ or Na⁺), as well as alkali/water ratio and crystallization temperature, the zeolite ZSM-5 mesocrystals with diverse mesostructures are simply and controllably prepared via fine-tuning the crystallization mechanism in an organotemplate-free, ions-mediated seed-assisted system. Moreover, the impacts of these key parameters on the evolution of seed crystals, the development and assembly behavior of aluminosilicate species and the solution-phase process during zeolite crystallization are investigated by means of directional etching in NH₄F or NaOH solutions. Except for the morphology/mesoporosity modulation, their physical and chemical properties, such as particle size, microporosity, Si/Al ratio and acidity, can be well maintained at a similar level. As such, the p/o-xylene adsorption and catalytic performance of o-xylene isomerization are used to exhaustively evaluate the synergistically enhanced catalytic activity and shape selectivity of the obtained products. This work demonstrates the possibility of effectively constructing novel zeolite mesostructures by simply altering parameters on simple ions-controlled crystallization and provides good models to inspect the impacts of mesoporosity or morphology on their catalytic performances.

Mesocrystal morphology regulation by "alkali metals ion switch": Re-examining zeolite nonclassical crystallization in seed-induced process

HYPOTHESIS

It is a Holy Grail to realize the goal-oriented synthesis of zeotype crystals via direct thermodynamic/kinetic control of crystallization in the simplest inorganic system. Especially, the most commonly used counter cations (i.e., Na⁺ and K⁺) are in turn believed to play merely the role of balancing charges and stabilizing frameworks, which make the simple ion-based morphology/porosity control remain big challenges.

EXPERIMENTS

We re-examined the role of Na⁺ and K⁺ to fine-tune the classical/nonclassical crystallization process in a seed-induced system with the simplest composition (Si/Al sources, inorganic alkali, and H₂O), and proposed an "ion switch" strategy. By analyzing the multiple growth curves, tracking the precursor evolution, and observing epitaxial crystallization behavior, a distinctive "ion switch"-worked nonclassical mechanism was uncovered.

FINDINGS

By the "ion switch" strategy, ZSM-5 mesocrystals were fine-regulated with diverse architecture from single crystal to nanocrystallite assembly and intracrystal mesopore-enriched crystal. Such simple ions-controlled crystallization was achieved through microstructure heterogeneity of zeolitic building-blocks triggered by different counterions and their corresponding assembly behavior from oriented attachment to random deposition. Furthermore, this protocol can be extended to a wider H₂O/SiO₂ range, mixed Na⁺/K⁺ systems, and other alkali metal ions from Li⁺ to Cs⁺, and ZSM-5 mesocrystals with extended morphologies can be obtained.

State of the Art and Perspectives of Hierarchical Zeolites: Practical Overview of Synthesis Methods and Use in Catalysis

Microporous zeolites have proven to be of great importance in many chemical processes. Yet, they often suffer from diffusion limitations causing inefficient use of the available catalytically active sites. To address this problem, hierarchical zeolites have been developed, which extensively improve the catalytic performance. There is a multitude of recent literature describing synthesis of and catalysis with these hierarchical zeolites. This review attempts to organize and overview this literature (of the last 5 years), with emphasis on the most important advances with regard to synthesis and application of such zeolites. Special attention is paid to the most common and important 10- and 12-membered ring zeolites (MTT, TON, FER, MFI, MOR, FAU, and *BEA). In contrast to previous reviews, the research per zeolite topology is brought together and discussed here. This allows the reader to instantly find the best synthesis method in accordance to the desired zeolite properties. A summarizing graph is made available to enable the reader to select suitable synthesis procedures based on zeolite acidity and mesoporosity, the two most important tunable properties.