Hierarchically Nanoporous Zeolites and Their Heterogeneous Catalysis: Current Status and Future Perspectives

Recycling Rusty Iron with Natural Zeolite Heulandite to Create a Unique Nanocatalyst for Green Hydrogen Production

Corrosion-induced iron rust causes severe danger, pollution, and economic problems. In this work, nanopowders of Fe2O3 and Fe2O3/zeolite are synthesized for the first time using rusted iron waste and natural zeolite heulandite by chemical precipitation. The chemical composition, nanomorphologies, structural parameters, and optical behaviors are investigated using different techniques. The Fe2O3/zeolite nanocomposite showed smaller sizes and greater light absorption capability in visible light than Fe2O3 nanopowder. The XRD pattern shows crystalline hematite (α-Fe2O3) with a rhombohedral structure. The crystallite sizes for the plane (104) of the Fe2O3 and Fe2O3/zeolite are 64.84 and 56.53 nm, respectively. The Fe2O3 and Fe2O3/zeolite have indirect bandgap values of 1.87 and 1.91 eV and direct bandgap values of 2.04 and 2.07 eV, respectively. Fe2O3 and Fe2O3/zeolite nanophotocatalysts are used for solar photoelectrochemical (PEC) hydrogen production. The Fe2O3/zeolite exhibits a PEC catalytic hydrogen production rate of 154.45 mmol/g.h @ 1 V in 0.9 M KOH solution, which is the highest value yet for Fe2O3-based photocatalysts. The photocurrent density of Fe2O3/zeolite is almost two times that of Fe2O3 catalyst, and the IPCE (incident photon-to-current conversion efficiency) reached ~27.34%@307 nm and 1 V. The electrochemical surface area (ECSA) values for Fe2O3 and Fe2O3/zeolite photocatalysts were 7.414 and 21.236 m2/g, respectively. The rate of hydrogen production for Fe2O3/zeolite was 154.44 mmol h-1/g. This nanophotocatalyst has a very low PEC corrosion rate of 7.6 pm/year; it can retain ~97% of its initial performance. Therefore, the present research can be applied industrially as a cost-effective technique to address two issues at once by producing solar hydrogen fuel and recycling the rusted iron wires.

Synthesis of Mesoporous Zeolites and Their Opportunities in Heterogeneous Catalysis

Currently, zeolites are one of the most important classes of heterogeneous catalysts in chemical industries owing to their unique structural characteristics such as molecular-scale size/shape-selectivity, heterogenized single catalytic sites in the framework, and excellent stability in harsh industrial processes. However, the microporous structure of conventional zeolite materials limits their applications to small-molecule reactions. To alleviate this problem, mesoporous zeolitic frameworks were developed. In the last few decades, several methods have been developed for the synthesis of mesoporous zeolites; these zeolites have demonstrated greater lifetime and better performance than their bulk microporous counterparts in many catalytic processes, which can be explained by the rapid diffusion of reactant species into the zeolite framework and facile accessibility to bulky molecules through the mesopores. Mesoporous zeolites provide versatile opportunities not only in conventional chemical industries but also in emerging catalysis fields. This review presents many state-of-the-art mesoporous zeolites, discusses various strategies for their synthesis, and details their contributions to catalytic reactions including catalytic cracking, isomerization, alkylation and acylation, alternative fuel synthesis via methanol-to-hydrocarbon (MTH) and Fischer–Tropsch synthesis (FTS) routes, and different fine-chemical syntheses.

Mesostructuring layered materials: self-supported mesoporous layered double hydroxide nanotubes

Synthesis of layered materials exhibiting hierarchical porosity remains challenging, but nevertheless worthwhile because it turns such solids into functional materials with high specific surface area. Using a soft-templating strategy in combination with the incorporation of 8-fold coordinated Eu3+, self-assembly of self-supported layered double hydroxide (LDH) nanotubes has been achieved. Heteromorphic equimolar substitution of Al3+ by Eu3+ in Zn2+/Al3+ LDH solids intercalated with 1,3,5-benzenetricarboxylate anions (BTC) assists precipitation of the double hydroxide layers onto the convex surface of Pluronic® P-123 worm-like micelles, yielding multilayer cylinders of BTC-intercalated LDHs. Removal of the micellar template is easily achieved by liquid extraction with methanol, yielding a network of interconnected, well-defined, self-supported, multi-walled, hollow cylindrical nanotubes. Removal of Eu3+ from the synthesis disables formation of the nanotubular morphology, but still yields LDHs containing a network of embedded mesopores, resulting in a specific surface area that is 5-fold higher as compared to standard LDHs.

Electron transfers in graphitized HZSM-5 zeolites

In the present work, we report the electron transfers occurring after ionization of the guest molecules of t-stilbene incorporated in graphitized HZSM-5 zeolites and we compare these results with the data obtained previously for graphite-free zeolites. Complementary diffuse reflectance UV-vis and Raman scattering spectroscopies provide evidence for stabilization of long lived charge separated states as observed in non-graphitized ZSM-5. The spectral features indicate that these species are located in the channels of the zeolite structure. However, the pulsed EPR technique shows strong coupling between unpaired electrons and the 13C atoms in the case of graphitized zeolites while this interaction is not observed in normal zeolites. This is assigned to the presence of charge transfer complexes in the close vicinity of graphite areas and to the possible electron transfer to the graphitized domain. Using cyclic voltammetry, an electrochemical response is observed for the first time in such systems demonstrating the role played by graphite in the electron transfers.

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.

Levulinic Acid Production from Delignified Rice Husk Waste over Manganese Catalysts: Heterogeneous Versus Homogeneous

Delignified rice husk waste (25.66% (wt) cellulose) was converted to levulinic acid using three types of manganese catalysts, i.e., the Mn3O4/hierarchical ZSM-5 zeolite and Mn3O4 heterogenous catalysts, as well as Mn(II) ion homogeneous counterpart. The hierarchical ZSM-5 zeolite was prepared using the double template method and modified with Mn3O4 through wet-impregnation method. The structure and physicochemical properties of the catalyst materials were determined using several solid-state characterization techniques. The reaction was conducted in a 200 mL-three neck-round bottom flask at 100 °C and 130 °C for a certain reaction time in the presence of 10% (v/v) phosphoric acid and 2% (v/v) H2O2 aqueous solution, and the product was analyzed using HPLC. In general, 5-hydroxymethyl furfural (5-HMF) as the intermediate product was produced after 2 h and decreased after 4 h reaction time. To conclude, the Mn3O4/hierarchical ZSM-5 heterogenous catalyst gave the highest yield (wt %) of levulinic acid (39.75% and 27.60%, respectively) as the main product, after 8 h reaction time.

Highly Selective Hierarchical ZnO/ZSM-5 Catalysts for Propane Aromatization

Hierarchical ZnO/ZSM-5 catalysts were prepared by desilication and impregnation with 2 wt % metallic ZnO. X-ray diffraction and Fourier transform infrared (FTIR) results showed that the structures of the hierarchical zeolites were relatively preserved despite desilication but were accompanied with sequential loss in crystallinity, likewise Bro̷nsted acidity causing decline in conversion or activity of the catalyst. However, pyridine FTIR shows enhancement of the Bro̷nsted acidic sites. Throughout the activity test, the hierarchical ZnO/ZSM-5 catalysts showed an outstanding performance within 5 h on stream with the average aromatic (benzene, toluene, and xylenes) selectivity trend, represented by their NaOH concentrations 0.3 M > 0.4 M > 0.2 M > 0.1 M corresponding to 61.0, 53.5, 40.3, and 36.8%, respectively. Their average propane conversions within the same period followed a consecutive trend 0.1 M > 0.2 M > 0.3 M > 0.4 M conforming to 34.1, 24.8, 17.3, and 10.2%, respectively. These were compared with that of the reference (ZnO/ZSM-5), which exhibited an average aromatic selectivity of 25.2% and propane conversion of 39.7%. Furthermore, the hierarchical catalyst generally displayed a low amount of C9+ heavier aromatics with the ZnO/ZSM-5(0.3 M) catalyst having the lowest C9+ selectivity of 23.7% compared to the reference catalyst with 72.7% at the same time on stream.

Fundamentals and recent progress relating to the fabrication, functionalization and characterization of mesostructured materials using diverse synthetic methodologies

Since 1990 and the invention of the very first generation of ordered mesoporous silica materials, several innovative methodologies have been applied to synthesize, characterize, and modify silica/non-silica mesoporous materials. The growth of the mesoporous materials field has generated significant environmental and economic advantages compared to various other industrial developments. According to the literature, there are several key synthesis approaches and parameters that can affect the structural, textural and morphological characteristics of mesoporous materials. To date, huge attempts have been made to maximize the activities and selectivities of these materials through either the in situ or post-synthesis functionalization of the large interior surface areas and internal mesostructured frameworks in the presence of specific organic/inorganic components. However, the main challenge is to provide good control over the incorporation and distribution of multiple guest components within the mesostructured hosts. Mesostructured materials have received great attention for various applications, such as being used in electronics, medicine, photocatalysis, catalyst supports, catalysis, absorbers, sensors, gas separation, etc. In the current paper, several recent developments have been highlighted and reviewed regarding the fabrication and characterization of siliceous/non-siliceous mesoporous materials via various synthetic approaches. Furthermore, the availability of diverse functionalization methods has been reviewed to provide comprehensive approaches for synthesizing new generations of suitably modified mesoporous materials with superior structural, physicochemical, and textural characteristics.

Since 1990 and the invention of the very first generation of ordered mesoporous silica materials, several innovative methodologies have been applied to synthesize, characterize, and modify silica/non-silica mesoporous materials.

Designing a Mesoporous Zeolite Catalyst for Products Optimizing in n-Decane Hydrocraking

Mesoporous ZSM-5 zeolite is developed to enhance the catalytic performance in a hydrocracking reaction. The generated mesopores and mesoporous channels in the new catalyst supply more opportunities for reactant accessing the active sites according to the better mass transfer and diffusion. Meanwhile, the acidity of the mesoporous catalyst is also weakened because of the removal of Si and Al species from its MFI structure, which makes the products distribution drift to more valued chemicals such as olefins. In the modified mesoporous ZSM-5 zeolites via different metallic promoters, the olefins’ selectivity increases as the alkalinity of the catalyst increases. The reason for this is that the formed olefins will be further hydrogenated into corresponding alkanes immediately over the extremely acidic zeolite catalyst. Hence, the moderate alkalinity will limit this process, while at the same time the remaining olefins products will too. Furthermore, the Pd-based mesoporous ZSM-5 zeolite shows an excellent n-decane conversion and high propane selectivity due to the occurrence of hydrogen spillover via the Pd promoter. The phenomenon of hydrogen spillover supplies more chemisorbed sites of hydrogen atoms for hydrocracking and hydrogenating in this reaction. In short, this study explores the important effect factors in n-decane hydrocracking reaction activity and products distribution. It also shows a potential for the further industrial application of petroleum-derived fuel hydrocracking according to the optimized products distribution under metallic promoted mesoporous zeolite.

Overview of Current and Future Perspectives of Saudi Arabian Natural Clinoptilolite Zeolite: A Case Review

After a thorough review of existing studies of clinoptilolite zeolites, three areas for potential investigation of the Saudi Arabian zeolites were found. They are the characterizations, the catalytic activity, active sites, and uses of natural clinoptilolite zeolites. First, no analysis is available worldwide to compare the percentage weight of local zeolites with those sourced from other countries, nor does one exist for the establishment on the zeolite conversion of MBOH with water on acidic catalysts at lower temperatures. Secondly, a review of current literature on the topic revealed that basic and active sites of Saudi Arabian zeolites have yet to be examined. Future investigation of zeolite catalytic activity can be achieved by methyl butynol test reaction (MBOH) and absorption-desorption of ammonia. In the characterization of a range of international materials, the methyl butynol test reaction was utilized, including on natural zeolites, natural clays, and synthesized hydrotalcites. However, the catalytic performance of natural Saudi Arabian clinoptilolite zeolites by test reaction of MBOH conversion has not been yet investigated. Therefore, this article also includes an outline of the general testing conditions and parameters required to execute the accurate characterization of local Saudi clinoptilolite under optimal test conditions. Likewise, knowledge of the important active acidic centers of local materials is prescribed. This can be ascertained by determining the conditions together with the test parameters for the application of the “temperature-programmed desorption of ammonia” method in order to obtain an accurate determination of local Saudi clinoptilolite acidic centers. Additionally, an outline of the catalytic activity of worldwide clinoptilolite is given in this article together with kinetic investigations of other sources for the clinoptilolite zeolite in order to form the basis for the testing of local Saudi clinoptilolite. The percentage average of chemical composition (Wt.%) of natural clinoptilolite from various countries is also included. Finally, a future research plan is proposed here. This will form the basis for a complete study or survey to be compiled detailing the modifications needed to increase the surface areas for Saudi natural clinoptilolite zeolites using different methods of modifications. This could enhance its application as acid catalysts for use in the retardation of coke formation and for membrane separation on cationic exchange.

Incorporating Hierarchy into Conventional Zeolites for Catalytic Biomass Conversions: A Review

Zeolites are promising catalysts that are widely used in petrochemical, oil, and gas industries due to their unique characteristics, such as ordered microporous networks, good hydrothermal stability, large surface area, tunable acidity, and shape-selectivity. Nevertheless, the sole presence of microporous channels in zeolites inevitably restricts the diffusion of bulky reactants and products into and out of the microporous networks, leading to retarded reaction rates or catalyst deactivation. This problem can be overcome by developing hierarchical zeolites which involve mesoporous and macroporous networks. The meso- and macro-porosities can enhance the mass transport of molecules and simultaneously maintain the intrinsic shape selectivity of zeolite microporosity. Hierarchical zeolites are mainly developed through post-synthesis and pre-synthesis or in situ modification of zeolites. In this review, we evaluated both pre-synthesis and post-synthesis modification strategies with more focus on post-synthesis modification strategies. The role of various synthesis strategies on the intrinsic properties of hierarchical zeolites is discussed. The catalytic performance of hierarchical zeolites in important biomass reactions, such as catalytic pyrolysis of biomass feedstock and upgradation of bio-oil, has been summarized. The utilization of hierarchical zeolites tends to give a higher aromatic yield than conventional zeolites with microporosity solely.

Layer like porous materials with hierarchical structure

Many chemical compositions produce layered solids consisting of extended sheets with thickness not greater than a few nanometers. The layers are weakly bonded together in a crystal and can be modified into various nanoarchitectures including porous hierarchical structures. Several classes of 2-dimensional (2D) materials have been extensively studied and developed because of their potential usefulness as catalysts and sorbents. They are discussed in this review with focus on clays, layered transition metal oxides, silicates, layered double hydroxides, metal(iv) phosphates and phosphonates, especially zirconium, and zeolites. Pillaring and delamination are the primary methods for structural modification and pore tailoring. The reported approaches are described and compared for the different classes of materials. The methods of characterization include identification by X-ray diffraction and microscopy, pore size analysis and activity assessment by IR spectroscopy and catalytic testing. The discovery of layered zeolites was a fundamental breakthrough that created unprecedented opportunities because of (i) inherent strong acid sites that make them very active catalytically, (ii) porosity through the layers and (iii) bridging of 2D and 3D structures. Approximately 16 different types of layered zeolite structures and modifications have been identified as distinct forms. It is also expected that many among the over 200 recognized zeolite frameworks can produce layered precursors. Additional advances enabled by 2D zeolites include synthesis of layered materials by design, hierarchical structures obtained by direct synthesis and top-down preparation of layered materials from 3D frameworks.

Acidic Zeolite L as a Highly Efficient Catalyst for Dehydration of Fructose to 5-Hydroxymethylfurfural in Ionic Liquid

Zeolite L was synthesized by the hydrothermal method and post-treated by NH₄ exchange to adjust its acidity. The samples were systematic characterized by various techniques including XRD, X-ray fluorescence spectroscopy, N₂ adsorption-desorption, scanning electron microscopy, pyridine IR spectroscopy, and NH₃ temperature-programmed desorption. The results demonstrated that the NH₄ -exchange post-treatment increased the surface area, micropore volume, and acidity of zeolite L. The catalytic performance of the samples was tested in the dehydration of fructose to 5-hydroxymethylfurfural (HMF) in ionic liquid (1-butyl-3-methylimidazolium bromide, [bmim]Br). 99.1 % yield of HMF was obtained when the KL-80 °C-1 h sample (KL zeolite treated with 1 m NH₄ NO₃ solution at 80 °C for 1 h) was used. The high efficiency could be attributed to the appropriate acid properties of the catalyst. The zeolite catalyst could be reused four times without significant decrease in activity.

Understanding Surface and Interfacial Chemistry in Functional Nanomaterials via Solid-State NMR

Surface and interfacial chemistry is of fundamental importance in functional nanomaterials applied in catalysis, energy storage and conversion, medicine, and other nanotechnologies. It has been a perpetual challenge for the scientific community to get an accurate and comprehensive picture of the structures, dynamics, and interactions at interfaces. Here, some recent examples in the major disciplines of nanomaterials are selected (e.g., nanoporous materials, battery materials, nanocrystals and quantum dots, supramolecular assemblies, drug-delivery systems, ionomers, and graphite oxides) and it is shown how interfacial chemistry can be addressed through the perspective of solid-state NMR characterization techniques.

Determination of the positions of aluminum atoms introduced into SSZ-35 and the catalytic properties of the generated Brønsted acid sites

Al atoms were introduced into three of the four possible sites with constant proportions in the zeolite SSZ-35 lattice.

Recent advances in the textural characterization of hierarchically structured nanoporous materials

This review focuses on important aspects of applying physisorption for the pore structural characterization of hierarchical materials such as mesoporous zeolites.

Organosilane with Gemini-Type Structure as the Mesoporogen for the Synthesis of the Hierarchical Porous ZSM-5 Zeolite

A new kind of organosilane (1,6-bis(diethyl(3-trimethoxysilylpropyl)ammonium) hexane bromide) with a gemini-type structure was prepared and used as a mesoporogen for the synthesis of hierarchical porous ZSM-5 zeolite. There are two quaternary ammonium centers along with double-hydrolyzable -RSi(OMe)3 fragments in the organosilane, which results in a strong interaction between this mesoporogen and silica-alumina gel. The organosilane can be easily incorporated into the ZSM-5 zeolite structure during the crystallization process, and it was finally removed by calcination, leading to secondary pores in ZSM-5. The synthesized ZSM-5 has been systematically studied by XRD, nitrogen adsorption, SEM, TEM, TG, and solid-state one-dimensional (1D) and two-dimensional (2D) NMR, which reveal information on its detailed structure. It has a hierarchical porosity system, which combines the intrinsic micropores coming from the crystalline structure and irregular mesopores created by the organosilane template. Moreover, the mesoposity including pore size and volume within ZSM-5 can be systematically tuned by changing the organosilane/TEOS ratio, which confirms that this organosilane has high flexibility of use as a template for the synthesis of hierarchical porous zeolite.

Mesoporous MEL, BEA, and FAU zeolite crystals obtained by in situ formation of carbon template over metal nanoparticles

Highly crystalline zeolites with intracrystalline mesopores are synthesized through a straightforward and feasible templating method.

Recent advances of pore system construction in zeolite-catalyzed chemical industry processes

The kaleidoscopic applications of zeolite catalysts (zeo-catalysts) in petrochemical processes has been considered as one of the major accomplishments in recent decades. About twenty types of zeolite have been industrially applied so far, and their versatile porous architectures have contributed their most essential features to affect the catalytic efficiency. This review depicts the evolution of pore models in zeolite catalysts accompanied by the increase in industrial and environmental demands. The indispensable roles of modulating pore models are outlined for zeo-catalysts for the enhancement of their catalytic performances in various industrial processes. The zeolites and related industrial processes discussed range from the uni-modal micropore system of zeolite Y (12-ring micropore, 12-R) in fluid catalytic cracking (FCC), zeolite ZSM-5 (10-R) in xylene isomerization and SAPO-34 (8-R) in olefin production to the multi-modal micropore system of MCM-22 (10-R and 12-R pocket) in aromatic alkylation and the hierarchical pores in FCC and catalytic cracking of C4 olefins. The rational construction of pore models, especially hierarchical features, is highlighted with a careful classification from an industrial perspective accompanied by a detailed analysis of the theoretical mechanisms.

Tailoring and visualizing the pore architecture of hierarchical zeolites

This review provides an overview of the different synthesis methods and microscopy techniques for tailoring and visualizing the pore architecture of hierarchical zeolites.

Preparation and characterization of Ni/mZSM-5 zeolite with a hierarchical pore structure by using KIT-6 as silica template: an efficient bi-functional catalyst for the reduction of nitro aromatic compounds

Ni/mZSM-5 hierarchical zeolite and the acidic form of it were prepared as novel bi-functional catalysts which showed excellent activity for reduction of nitro aromatic compounds in aqueous medium at room temperature.