Innovations in hierarchical zeolite synthesis

Constructing Intrapenetrated Hierarchical Zeolites with Highly Complete Framework via Protozeolite Seeding

Creation of intrapenetrated mesopores with open highway from external surface into the interior of zeolite crystals are highly desirable that can significantly improve the molecular transport and active sites accessibility of microporous zeolites to afford enhanced catalytic properties. Here, different from traditional zeolite-seeded methods that generally produced isolated mesopores in zeolites, nanosized amorphous protozeolites with embryo structure of zeolites were used as seeds for the construction of single-crystalline hierarchical ZSM-5 zeolites with intrapenetrated mesopores (mesopore volume of 0.51 cm3  g-1 ) and highly complete framework. In this strategy, in contrast to the conventional synthesis, only a small amount of organic structure directing agents and a low crystallization temperature were adopted to promise the protozeolites as the dominant growth directing sites to induce crystallization. The protozeolite nanoseeds provided abundant nucleation sites for surrounding precursors to be crystallized, followed by oriented coalescence of crystallites resulting in the formation of intrapenetrated mesopores. The as-prepared hierarchical ZSM-5 zeolites exhibited ultra-long lifetime of 443.9 hours and a high propylene selectivity of 47.92 % at a WHSV of 2 h-1 in the methanol-to-propylene reaction. This work provides a facile protozeolite-seeded strategy for the synthesis of intrapenetrated hierarchical zeolites that are highly effective for catalytic applications.

Evaluating the efficacy of zeolites synthesized from natural clay for the methanol-to-hydrocarbon process

Introducing sustainability into advanced catalytic material design is essential to address growing environmental concerns. Among them, synthesizing inorganic zeolite materials from non-traditional sources (like natural clay) offers several advantages, contributing to sustainability and environmental stewardship. With this objective, we used kaolin to synthesize zeolites with different topologies: SSZ-13 (8-MR with CHA topology), ZSM-5 (10-MR with MFI topology), and Beta (12-MR with BEA topology) (MR: member ring), where a simple and flexible synthetic protocol was adopted without any significant changes. All these zeolites were subjected to catalytic performance evaluation concerning the industrially relevant methanol-to-hydrocarbon (MTH) process. Herein, the kaolin-derived zeolites, especially ZSM-5, led to superior performance and demonstrated enhanced catalyst deactivation-resistant behavior compared to their zeolite counterparts prepared from traditional synthetic routes. Various characterization tools (including under operando conditions) were employed to understand their reactions and deactivation mechanisms. Overall, making zeolites from non-traditional sources presents a pathway for sustainable and environmentally friendly material production, offering benefits such as reduced resource dependence, lower energy consumption, and tailored physicochemical properties beneficial to catalysis. In a broader context, such a research approach contributes to the transition toward a more sustainable and circular economy.

Hierarchical Zeolite Synthesis by Alkaline Treatment: Advantages and Applications

Zeolites are of great interest to the scientific and industrial communities due to their interesting catalytic properties, such as high specific area, shape selectivity, and thermal and hydrothermal stability. For this reason, zeolites have been intensively studied and applied in several reactions of great industrial interest. However, the size of zeolite micropores may hinder the diffusion of bulky molecules in the pore system, limiting the use of zeolites in some reactions/applications that use bulky molecules. One way to address this limitation is to generate secondary porosity (in the range of supermicropores, mesopores and/or macropores) in such a way that it connects with the existing micropores, creating a hierarchical pore system. There are different hierarchical approaches; however, most are not economically viable and are complicated/time-consuming. Alkaline treatment has been highlighted in recent years due to its excellent results, simplicity, speed and low cost. In this review, we highlight the importance of alkaline treatment in the generation of secondary porosity and the parameters that influence alkaline treatment in different zeolitic structures. The properties and catalytic performance of hierarchical zeolites prepared by alkaline treatment are extensively discussed. It is expected that this approach will be useful for understanding how alkaline treatment acts on different hierarchical structures and will thus open doors to achieve other hierarchical zeolites by this method.

Research Progress on Modifications of Zeolite Y for Improved Catalytic Properties

Zeolite Y, as a solid acid catalyst with excellent performance, is a landmark in petroleum refining and chemical industry production–especially in catalytic cracking reactions. Improving the SAR of Y zeolite, enriching its pore structure, and modifying it with heteroatoms can realize the multifunctional catalysis of Y zeolite, improve the application value of it, and then meet the demands of petroleum refining. In this review, the synthesis of Y zeolites with high SAR, multistage pores, and heteroatom modification is summarized.

Catalytic pyrolysis of biomass over zeolites for bio-oil and chemical production: A review on their structure, porosity and acidity co-relation

The oxygenated compounds found in bio-oil limit their application as a transportation fuel. Several studies were reported on eliminating the oxygenated components from bio-oil so as to improve its fuel properties. This work is dedicated to studying the shape selectivity, porosity, structure, acidity of zeolites and their effect in bio-oil and chemicals production. The unified pore size, specific structure, controlled Si/Al ratio, unique channels and circular entrances, mesoporosity, and acidity are the utmost discerning parameters for aromatics production and deoxygenation reaction. The conversion of biomass-derived oxygenates to aromatics using zeolite is subjected to the reactants entering the pore, conversion inside the pore, and diffusing out of the products from the zeolite pores. These approaches were considered for an in-depth understanding of zeolite properties, which will enhance the fundamental understanding of pyrolysis.

Protolytic Ring-Opening Cracking of Methylcyclohexane over Hierarchical High-Silica USY Zeolite: A Haag-Dessau Cracking

To reveal the influence of acid sites with different spatial locations of USY zeolite with different micro-/mesoporous structures and Si/Al ratio, catalytic cracking of methylcyclohexane on the zeolites is employed to study the synergism effects of acid sites and porous structures (“active region”) in the hierarchical USY zeolites. The results showed that the hierarchical USY zeolites have increased numbers of accessibly strong Brønsted acid sites and greatly enhanced diffusion ability due to the hierarchical pore-structure, resulting in mainly monomolecular protolytic scission in cracking reactions and less bimolecular hydrogen transfer. The isomerization reaction is from intramolecular transalkylation and the isomerics are the intermediates of the cracking reaction. The protolytic cracking that occurs in hierarchical high-silica USY-zeolites follows the Haag-Dessau cracking.

G, Prabhakaran K, Joseph K, Salih A. Selective catalytic reduction of NO over hierarchical Cu ZSM-5 coated on an alumina foam support

Hydrothermal coating of hierarchical Cu ZSM-5 catalyst on alumina foam.

Mesoporogen-free synthesis of single-crystalline hierarchical beta zeolites for efficient catalytic reactions

Single-crystalline hierarchical Beta zeolites were synthesized by the l-lysine-assisted kinetic regulation method, exhibiting improved catalytic performance in both gas- and liquid-phase reactions.

K-Chabazite Zeolite Nanocrystal Aggregates for Highly Efficient Methane Separation

Methane (CH₄ ) enrichment and purification is of great significance for increasing the heating value of unconventional natural gas sources and curtailing its effect on global warming. For a long time, commercial adsorbents for CH₄ separation have been hampered by low adsorption capacities, sub-optimal adsorption selectivities, or slow diffusion rates, which have significantly restricted separation productivity. Herein, we report a facile and green seed-passaging method to fabricate donut-like macro-meso-micro hierarchical zeolite K-Chabazite nanocrystal aggregates. This consecutive seed-inducing method requires no organic template. By utilizing this unique nanocrystallization technique, the CH₄ adsorption capacity, gas diffusion rate, and separation productivity of the resultant material are dramatically increased compared with those of commercially available adsorbents, thus setting a new benchmark in CH₄ /N₂ separation. More importantly, production of this adsorbent can be easily scaled-up to the order of 100 kg using readily available raw materials in this environmentally friendly synthetic route, enabling potential industrial implementation.

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.

A review of sustainable biodiesel production using biomass derived heterogeneous catalysts

The production of biodiesel through chemical production processes of transesterification reaction depends on suitable catalysts to hasten the chemical reactions. Therefore, the initial selection of catalysts is critical although it is also dependent on the quantity of free fatty acids in a given sample of oil. Earlier forms of biodiesel production processes relied on homogeneous catalysts, which have undesirable effects such as toxicity, high flammability, corrosion, by-products such as soap and glycerol, and high wastewater. Heterogeneous catalysts overcome most of these problems. Recent developments involve novel approaches using biomass and bio-waste resource derived heterogeneous catalysts. These catalysts are renewable, non-toxic, reusable, offer high catalytic activity and stability in both acidic and base conditions, and show high tolerance properties to water. This review work critically reviews biomass-based heterogeneous catalysts, especially those utilized in sustainable production of biofuel and biodiesel. This review examines the sustainability of these catalysts in literature in terms of small-scale laboratory and industrial applications in large-scale biodiesel and biofuel production. Furthermore, this work will critically review natural heterogeneous biomass waste and bio-waste catalysts in relation to upcoming nanotechnologies. Finally, this work will review the gaps identified in the literature for heterogeneous catalysts derived from biomass and other biocatalysts with a view to identifying future prospects for heterogeneous catalysts.

Seed-sol-assisted construction of a coffin-shaped multilamellar ZSM-5 single crystal using CTAB

A coffin-shaped multilamellar ZSM-5 single crystal (CMZS) composed of orderly stacked 2D nanosheets (70-100 nm) was synthesized via the use of cetyltrimethylammonium bromide (CTAB) in the presence of silicalite-1 seed sol. This crystallization strategy opens a facile approach for industrial applications using CMZS in the catalytic conversion of bulky molecules.

Rice-like and rose-like zinc silicates anchored on amorphous carbon derived from natural reed leaves for high-performance supercapacitors

3D N, S, P-doped rice-like C-Zn4Si2O7(OH)2·H2O (C-ZnSi-N2) and rose-like C-Zn2SiO4 (C-ZnSi-CO2) are derived from reed leaves and used for application in supercapacitors. The as-prepared C-ZnSi architectures with a large number of hierarchical pores and high specific surface area from reed leaves have outstanding electrochemical performance. The obtained C-ZnSi-N2 shows 341 F g-1 at the current density of 0.5 A g-1, while the C-ZnSi-CO2 exhibits 498 F g-1, and both of the C-ZnSi materials significantly retain above 99% of their capacitance after 10 000 cycles. Furthermore, the flexible solid-state asymmetric supercapacitors (ASCs) synthesized from C-ZnSi and activated carbon (denoted as C-ZnSi-N2//AC and C-ZnSi-CO2//AC) achieve a high capacitance (405 and 194 mF cm-2 at the current density of 2 mA cm-2, respectively). Besides, the ASC devices show good cycling stability for 7300 cycles with 73% and 77% capacitance retention. The results presented in this study indicate that the N, S, P-doped C-ZnSi architectures from natural reed leaves are promising and efficient materials for manufacturing high performance supercapacitors.

Controlled direct synthesis of single- to multiple-layer MWW zeolite

The minimized diffusion limitation and completely exposed strong acid sites of the ultrathin zeolites make it an industrially important catalyst especially for converting bulky molecules. However, the structure-controlled and large-scale synthesis of the material is still a challenge. In this work, the direct synthesis of the single-layer MWW zeolite was demonstrated by using hexamethyleneimine and amphiphilic organosilane as structure-directing agents. Characterization results confirmed the formation of the single-layer MWW zeolite with high crystallinity and excellent thermal/hydrothermal stability. The formation mechanism was rigorously revealed as the balanced rates between the nucleation/growth of the MWW nanocrystals and the incorporation of the organosilane into the MWW unit cell, which is further supported by the formation of MWW nanosheets with tunable thickness via simply changing synthesis conditions. The commercially available reagents, well-controlled structure and the high catalytic stability for the alkylation of benzene with 1-dodecene make it an industrially important catalyst.

Acylation of Anisole With Benzoyl Chloride Over Rapidly Synthesized Fly Ash-Based HBEA Zeolite

Stable HBEA zeolite with high surface area and strong acid sites was synthesized from coal fly ash–based silica extract via indirect hydrothermal synthesis. The rapid HBEA hydrothermal crystallization times of 8, 10, and 12 h were achieved through a reduced molar water fraction in the synthesis composition. The HBEA zeolites prepared from fly ash silica extract exhibited well-defined spheroidal-shaped crystal morphology with uniform particle sizes of 192, 190, or 239 nm obtained after 8, 10, or 12 h of synthesis time, respectively. The high surface area and the microporous area of 702 and 722 m²/g were achieved as a function of shorter hydrothermal synthesis durations (10 and 24 h, respectively) compared to 48 or 72 h, which resulted in HBEA zeolites with lower surface areas of 538 and 670 m²/g. Likewise, temperature-programmed desorption measurements of fly ash–based HBEA zeolites revealed the presence of weak and strong acid sites in the zeolite. The submicron crystal sizes with a well-defined porosity of HBEA zeolites enhanced the diffusion of anisole and benzoyl chloride molecules toward the active acid sites and hence showed better conversion and selectivity in acylation products. High conversion of benzoyl chloride with anisole was achieved, reaching up to 83% with a 93–96% selectivity toward 4-methoxyacetophenone.

Hierarchical HZSM-5 for Catalytic Cracking of Oleic Acid to Biofuels

Solid acid catalyzed cracking of waste oil-derived fatty acids is an attractive route to hydrocarbon fuels. HZSM-5 is an effective acid catalyst for fatty acid cracking; however, its microporous nature is susceptible to rapid deactivation by coking. We report the synthesis and application of hierarchical HZSM-5 (h-HZSM-5) in which silanization of pre-crystallized zeolite seeds is employed to introduce mesoporosity during the aggregation of growing crystallites. The resulting h-HZSM-5 comprises a disordered array of fused 10–20 nm crystallites and mesopores with a mean diameter of 13 nm, which maintain the high surface area and acidity of a conventional HZSM-5. Mesopores increase the yield of diesel range hydrocarbons obtained from oleic acid deoxygenation from ~20% to 65%, attributed to improved acid site accessibility within the hierarchical network.

A Brief Review on Solvent-Free Synthesis of Zeolites

The traditional hydrothermal method to prepare zeolite will inevitably use a large amount of water as a solvent, which will lead to higher autogenous pressure, low efficiency, and wastewater pollution. The solvent-free method can be used to synthesize various types of zeolites by mechanical mixing, grinding, and heating of solid raw materials, which exhibits the apparent advantages of high yield, low pollution, and high efficiency. This review mainly introduces the development process of solvent-free synthesis, preparation of hierarchical zeolite, morphology control, synthesis mechanism and applications of solvent-free methods. It can be believed that solvent-free methods will become a research focus and have enormous industrial application potential.

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.

Local Structures of Two-Dimensional Zeolites-Mordenite and ZSM-5-Probed by Multinuclear NMR

Mesostructured pillared zeolite materials in the form of lamellar phases with a crystal structure of mordenite (MOR) and ZSM-5 (MFI) were grown using CTAB as an agent that creates mesopores, in a one-pot synthesis; then into the CTAB layers separating the 2D zeolite plates were introduced by diffusion the TEOS molecules which were further hydrolyzed, and finally the material was annealed to remove the organic phase, leaving the 2D zeolite plates separated by pillars of silicon dioxide. To monitor the successive structural changes and the state of the atoms of the zeolite framework and organic compounds at all the steps of the synthesis of pillared MOR and MFI zeolites, the nuclear magnetic resonance method (NMR) with magic angle spinning (MAS) was applied. The 27Al and 29Si MAS NMR spectra confirm the regularity of the zeolite frameworks of the as synthetized materials. Analysis of the 1H and 13C MAS NMR spectra and an experiment with variable contact time evidence a strong interaction between the charged "heads" -[N(CH3)3]+ of CTAB and the zeolite framework at the place of [AlO4]- location. According to 27Al and 29Si MAS NMR the evacuation of organic cations leads to a partial but not critical collapse of the local zeolite structure.

Revival of Zeolite-Templated Nanocarbon Materials: Recent Advances in Energy Storage and Conversion

Nanocarbon materials represent one of the hottest topics in physics, chemistry, and materials science. Preparation of nanocarbon materials by zeolite templates has been developing for more than 20 years. In recent years, novel structures and properties of zeolite-templated nanocarbons have been evolving and new applications are emerging in the realm of energy storage and conversion. Here, recent progress of zeolite-templated nanocarbons in advanced synthetic techniques, emerging properties, and novel applications is summarized: i) thanks to the diversity of zeolites, the structures of the corresponding nanocarbons are multitudinous; ii) by various synthetic techniques, novel properties of zeolite-templated nanocarbons can be achieved, such as hierarchical porosity, heteroatom doping, and nanoparticle loading capacity; iii) the applications of zeolite-templated nanocarbons are also evolving from traditional gas/vapor adsorption to advanced energy storage techniques including Li-ion batteries, Li-S batteries, fuel cells, metal-O2 batteries, etc. Finally, a perspective is provided to forecast the future development of zeolite-templated nanocarbon materials.

Two-Dimensional Zeolite Materials: Structural and Acidity Properties

Zeolites are generally defined as three-dimensional (3D) crystalline microporous aluminosilicates in which silicon (Si⁴⁺) and aluminum (Al³⁺) are coordinated tetrahedrally with oxygen to form large negative lattices and consequent Brønsted acidity. Two-dimensional (2D) zeolite nanosheets with single-unit-cell or near single-unit-cell thickness (~2-3 nm) represent an emerging type of zeolite material. The extremely thin slices of crystals in 2D zeolites produce high external surface areas (up to 50% of total surface area compared to ~2% in micron-sized 3D zeolite) and expose most of their active sites on external surfaces, enabling beneficial effects for the adsorption and reaction performance for processing bulky molecules. This review summarizes the structural properties of 2D layered precursors and 2D zeolite derivatives, as well as the acidity properties of 2D zeolite derivative structures, especially in connection to their 3D conventional zeolite analogues' structural and compositional properties. The timeline of the synthesis and recognition of 2D zeolites, as well as the structure and composition properties of each 2D zeolite, are discussed initially. The qualitative and quantitative measurements on the acid site type, strength, and accessibility of 2D zeolites are then presented. Future research and development directions to advance understanding of 2D zeolite materials are also discussed.

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

For zeolite catalysts, the regulation of active site and pore structure plays an important role in the enhancement of their catalytic performance. In this work, a one-pot and organic template-free co-regulation route is proposed to straightforwardly synthesize basic mesoporous ZSM-5 zeolites with adjustable alkaline-earth metal species. The synthesis pathway combines two decisive strategies: 1) the seed-induced interface assembly growth method and 2) the acidic co-hydrolysis/condensation of aluminosilicate species and alkaline-earth metal (e.g., Mg, Ca, Sr, or Ba) sources. It is interesting that the mesoporous structure was self-evolved through particle-attached seed-interfacial crystallization without the assistance of any template. Meanwhile, the incorporation of alkaline-earth metals species is homogeneous and highly dispersed in the solid products during the whole crystallization process, and finally generate the superior basicity. Catalysis tests of the as-synthesized samples displayed their novel performance in the typical base reaction of Knoevenagel condensation, even for bulky substrates owing to the enhanced diffusion arising from the meso/microporous network. This finding opens new possibilities for facile, cost-effective, and environmentally friendly synthesis of mesoporous high-silica zeolites with tunable acid/base properties, and deepens our understanding of the particle-attached crystallization.

Aluminosilicate Nanocomposites from Incinerated Chinese Holy Joss Fly Ash: A Potential Nanocarrier for Drug Cargos

An incredible amount of joss fly ash is produced from the burning of Chinese holy joss paper; thus, an excellent method of recycling joss fly ash waste to extract aluminosilicate nanocomposites is explored. The present research aims to introduce a novel method to recycle joss fly ash through a simple and straightforward experimental procedure involving acidic and alkaline treatments. The synthesized aluminosilicate nanocomposite was characterized to justify its structural and physiochemical characteristics. A morphological analysis was performed with field-emission transmission electron microscopy, and scanning electron microscopy revealed the size of the aluminosilicate nanocomposite to be ~25 nm, while also confirming a uniformly spherical-shaped nanostructure. The elemental composition was measured by energy dispersive spectroscopy and revealed the Si to Al ratio to be 13.24 to 7.96, showing the high purity of the extracted nanocomposite. The roughness and particle distribution were analyzed using atomic force microscopy and a zeta analysis. X-ray diffraction patterns showed a synthesis of faceted and cubic aluminosilicate crystals in the nanocomposites. The presence of silica and aluminum was further proven by X-ray photoelectron spectroscopy, and the functional groups were recognized through Fourier transform infrared spectroscopy. The thermal capacity of the nanocomposite was examined by a thermogravimetric analysis. In addition, the research suggested the promising application of aluminosilicate nanocomposites as drug carriers. The above was justified by an enzyme-linked apta-sorbent assay, which claimed that the limit of the aptasensing aluminosilicate-conjugated ampicillin was two-fold higher than that in the absence of the nanocomposite. The drug delivery property was further justified through an antibacterial analysis against Escherichia coli (gram-negative) and Bacillus subtilis (gram-positive).

The mechanism of promoter-induced zeolite nanosheet crystallization under hydrothermal and microwave irradiation conditions

The mechanism of MFI zeolite nanosheet formation was established under accelerated conditions using perchlorate ions and fresh zeolite seeds as promoters.

Exploring the impact of synthetic strategies on catalytic cracking in hierarchical beta zeolites via hydrothermal desilication and organosilane-templated synthesis

Hierarchical zeolites can be synthesized by different strategies, resulting in the creation of mesoporosity with different configurations (inter-crystalline or intra-crystalline) in addition to unique porous and catalytic properties.

High-performing Ir- and Pt-containing catalysts based on mesoporous beta zeolite for the selective ring opening of decalin

Iridium dispersed on mesoporous beta zeolite obtained by desilication exhibits outstanding catalytic performance in the selective ring opening of decalin.