Optimized Synthesis of ZSM‐11 Catalysts using 1,8‐Diaminooctane as a Structure‐Directing Agent

Understanding formation thermodynamics of structurally diverse zeolite oligomers with first principles calculations

The mechanisms of many zeolitic processes, including nucleation and interzeolite transformation, are not fully understood owing to complex growth mixtures that obfuscate in situ monitoring of molecular events. In this work, we provide insights into zeolite chemistry by investigating the formation thermodynamics of small zeolitic species using first principles calculations. We systematically study how formation energies of pure-silicate and aluminosilicate species differ by structure type and size, temperature, and the presence of alkali or alkaline earth metal cations (Na⁺, K⁺, and Ca²⁺). Highly condensed (cage-like) species are found to be strongly preferred to simple rings in the pure-silicate system, and this thermodynamic preference increases with temperature. Introducing aluminum leads to more favorable formation thermodynamics for all species. Moreover, for species with a low Si/Al ratio (≤2), a thermodynamic preference does not exist among structure types; instead, a pool of diverse aluminosilicate structures compete in formation. Metal cation effects strongly depend on the presence of aluminum, cage size, cation type, and location, since each of these factors can alter electrostatic interactions between cations and zeolitic species. We reveal that confined metal cations may destabilize pure-silicate cages due to localized interactions; conversely, they stabilize aluminosilicates due to strong cation-framework attractions in sufficiently large cages. Importantly, this work rationalizes a series of experimental observations and can potentially guide efforts for controlling zeolite nucleation/crystallization 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.

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.

Computational elucidation of the aging time effect on zeolite synthesis selectivity in the presence of water and diquaternary ammonium iodide

An example of zeolite selectivity (MFI → MOR) driven by synthesis aging time has been studied. Using N,N,N',N'-tetramethyl-N,N'-dipropyl-ethylenediammonium diiodide (TMDP) as an organic structure-directing agent (OSDA), the zeolite phases obtained at 2 h (MFI 97%), 8 h (MFI 84%, MOR 16%) and 24 h (MFI 43%, MOR 57%) have been characterized by powder X-ray diffraction. The results suggest that at intermediate aging time, namely 8 h and 24 h, the dominant phase (MFI) is displaced by MOR. Different techniques (FT-IR, Raman, ¹³C MAS NMR, TGA/DTG and HC microanalysis) have been employed to verify the OSDA integrity and occlusion inside the zeolite micropores as well as to quantify the water and OSDA loading. The ¹H MAS NMR of the as-made occluded zeolite was compared with the spectra of TMDP and the recovered OSDA from the sample by extraction with water. The comparison indicated that TMDP was not structurally intact, indicating the chemical transformation of TMDP to imidazolinium homologues through the Hofmann degradation process. Furthermore, careful acidic breakdown of the aluminosilicate shell, covered on the zeolite samples by hydrofluoric acid, revealed that the remaining OSDA had been partially degraded to lower molecular weight ammonium salt, confirmed by ¹H NMR and mass spectrometry measurements. A computational study was performed by using a force field based methodology, including accurate loading of water and OSDA in the zeolite (MFI and MOR) unit cells. The results show an important contribution of the presence of water. The samples with larger aging time (8 h and 24 h) incorporate less water and show partial TMDP degradation, whilst at the shortest aging time (2 h), there is a larger water content and TMDP remains intact. The larger accessible volume of MFI justifies that this is the dominant phase at short aging times (large water content) since it can accommodate a larger number of water molecules than MOR. The OSDA partial degradation also plays a role. At longer aging times the partial OSDA decomposition has been considered in the models by including TMDP + Imidaz, which is more stabilized by MOR, whilst at shorter aging times the only OSDA present, TMDP, is better stabilized by MFI.

Factors controlling the molecular modification of one-dimensional zeolites

Interactions between organic molecules and inorganic materials are ubiquitous in many applications and often play significant roles in directing pathways of crystallization. It is frequently debated whether kinetics or thermodynamics plays a more prominent role in the ability of molecular modifiers to impact crystal nucleation and growth processes. In the case of nanoporous zeolites, approaches in rational design often capitalize on the ability of organics, used as either modifiers or structure-directing agents, to markedly impact the physicochemical properties of zeolites. It has been demonstrated for multiple topologies that modifier-zeolite interactions can alter crystal size and morphology, yet few studies have distinguished the roles of thermodynamics and kinetics. We use a combination of calorimetry and molecular modeling to estimate the binding energies of organics on zeolite surfaces and correlate these results with synthetic trends in crystal morphology. Our findings reveal unexpectedly small energies of interaction for a range of modifiers with two zeolite structures, indicating the effect of organics on zeolite crystal surface free energy is minor and kinetic factors most likely govern growth modification.

Finned zeolite catalysts

There is growing evidence for the advantages of synthesizing nanosized zeolites with markedly reduced internal diffusion limitations for enhanced performances in catalysis and adsorption. Producing zeolite crystals with sizes less than 100 nm, however, is non-trivial, often requires the use of complex organics and typically results in a small product yield. Here we present an alternative, facile approach to enhance the mass-transport properties of zeolites by the epitaxial growth of fin-like protrusions on seed crystals. We validate this generalizable methodology on two common zeolites and confirm that fins are in crystallographic registry with the underlying seeds, and that secondary growth does not impede access to the micropores. Molecular modelling and time-resolved titration experiments of finned zeolites probe internal diffusion and reveal substantial improvements in mass transport, consistent with catalytic tests of a model reaction, which show that these structures behave as pseudo-nanocrystals with sizes commensurate to that of the fin. This approach could be extended to the rational synthesis of other zeolite and aluminosilicate materials.

Insight into the Formation of Nanostructured MFI Sheets and MEL Needles Driven by Molecular Recognition

Mesoporous and nanostructured zeolite-based catalysts experience prolonged lifetimes due to increased mass transfer and reduced micropore obstruction by coke formation as compared to their bulky microporous counterparts. Diquaternary ammonium structure-directing agents (SDAs) can be used to synthesize hierarchical MFI sheet-like and MEL needle-like zeolites. An explanation of the underlying molecular-level details of the synthesis of these nanostructured zeolites is presented on the basis of non-covalent interactions between the template and zeolite surfaces as well as silicate oligomers studied by means of classical molecular dynamics. Use was made of Si₁₁ and Si₃₃ silicate oligomers that contain structural features of the framework to be formed as originally proposed by the Leuven group. Molecular recognition is driven by a combination of strong electrostatic and weaker dispersion interactions. An analysis of the early stage of zeolite formation is necessary, as the template adsorption energies in the fully formed zeolite crystals cannot explain the preferential growth of the MFI sheets or MEL needles. Specifically, it is found that the differences in dispersion interactions between the SDA alkyl chains and the silicate oligomers are decisive in the formation of particular zeolite structures.

Computational screening of structure directing agents for the synthesis of zeolites. A simplified model

Zeolite micropores become more energetically stable by the occlusion of organic structure directing agents (templates). This energetic stabilisation, if approximated by van der Waals zeo-template interactions, can be calculated in a fast way by using modern computing techniques incorporating big data handling algorithms for massive screening. A software suite is presented which calculates an arbitrarily large 2-D matrix (template×zeolite) giving the zeo-template van der Waals interaction energy corresponding to the minimum energy conformation assuming one template molecule in a pure silica zeolite unit cell. With the goal of simplicity, the software only needs two coordinate input files of template and zeolite unit cell. Though a number of approximations have been considered, the software allows to compare, for a given template, which competing zeolite phases may become more stabilised. Applied to zeolite hypothetical databases, it may be of help to suggest templates for their synthesis.

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.