Control of Al Distribution in the CHA-Type Aluminosilicate Zeolites and Its Impact on the Hydrothermal Stability and Catalytic Properties

Formation of paired Ga sites in CHA-type zeolite frameworks via a transcription-induced method

Paired Ga sites represented by the Ga-O-Si-O-Ga sequence were firstly formed intentionally in CHA-type zeolite frameworks via the transcription of pre-formed paired Ga species in a Ga-rich amorphous silica-gallia under seed-assisted hydrothermal conditions. Such paired Ga sites behaved as ion-exchange sites for capturing divalent cation, Co2+.

Exploring the adsorption behavior of molecular hydrogen on CHA-zeolite by comparing the performance of various force field methods

Molecular hydrogen (H2) adsorption plays a crucial role in numerous applications, including hydrogen storage and purification processes. Understanding the interaction of H2 with porous materials is essential for designing efficient adsorption systems. In this study, we investigate H2 adsorption on CHA-zeolite using a combination of density functional theory (DFT) and force field-based molecular dynamics (MD) simulations. Firstly, we employ DFT calculations to explore the energetic properties and adsorption sites of H2 on the CHA-zeolite framework. The electronic structure and binding energies of H2 in various adsorption configurations are analyzed, providing valuable insights into the nature of the adsorption process. Subsequently, force field methods are employed to perform extensive MD simulations, allowing us to study the dynamic behavior of H2 molecules adsorbed on the CHA-zeolite surface. The trajectory analysis provides information on the diffusion mechanisms and mobility of H2 within the porous structure, shedding light on the transport properties of the adsorbed gas. Furthermore, the combination of DFT and MD results enables us to validate and refine the force field parameters used in simulations, improving the accuracy of the model, and enhancing our understanding of the H2-CHA interactions. Our comprehensive investigation into molecular hydrogen adsorption on CHA-zeolite using density functional theory and molecular dynamics simulations yields valuable insights into the fundamental aspects of the adsorption process. These findings contribute to the development of advanced hydrogen storage and separation technologies, paving the way for efficient and sustainable energy applications.

Regulation of the Si/Al ratios and Al distributions of zeolites and their impact on properties

Zeolites are typically a class of crystalline microporous aluminosilicates that are constructed by SiO4 and AlO4 tetrahedra. Because of their unique porous structures, strong Brönsted acidity, molecular-level shape selectivity, exchangeable cations, and high thermal/hydrothermal stability, zeolites are widely used as catalysts, adsorbents, and ion-exchangers in industry. The activity, selectivity, and stability/durability of zeolites in applications are closely related to their Si/Al ratios and Al distributions in the framework. In this review, we discussed the basic principles and the state-of-the-art methodologies for regulating the Si/Al ratios and Al distributions of zeolites, including seed-assisted recipe modification, interzeolite transformation, fluoride media, and usage of organic structure-directing agents (OSDAs), etc. The conventional and newly developed characterization methods for determining the Si/Al ratios and Al distributions were summarized, which include X-ray fluorescence spectroscopy (XRF), solid state 29Si/27Al magic-angle-spinning nuclear magnetic resonance spectroscopy (29Si/27Al MAS NMR), Fourier-transform infrared spectroscopy (FT-IR), etc. The impact of Si/Al ratios and Al distributions on the catalysis, adsorption/separation, and ion-exchange performance of zeolites were subsequently demonstrated. Finally, we presented a perspective on the precise control of the Si/Al ratios and Al distributions of zeolites and the corresponding challenges.

Synthesis strategies to control the Al distribution in zeolites: thermodynamic and kinetic aspects

The activity and selectivity of acid-catalyzed chemistry is highly dependent on the Brønsted and Lewis acid sites generated by Al substitutions in a zeolite framework with the desired pore architecture. The siting of two Al atoms in close proximity in the framework of high-silica zeolites can also play a decisive role in improving the performance of redox catalysts by producing exchangeable positions for extra-framework multivalent cations. Thus, considerable attention has been devoted to controlling the Al incorporation through direct synthesis approaches and post-synthesis treatments to optimize the performance as (industrial) solid catalysts and to develop new acid- and redox-catalyzed reactions. This Feature Article highlights bottom-up synthetic strategies to fine-tune the Al incorporation in zeolites, interpreted with respect to thermodynamic and kinetic aspects. They include (i) variation in extra-framework components in zeolite synthesis, (ii) isomorphous substitution of other heteroatoms in the zeolite framework, and (iii) control over the (alumino)silicate network in the initial synthesis mixture via in situ and ex situ methods. Most synthetic approaches introduced here tentatively showed that the energy barriers associated with Al incorporation in zeolites can be variable during zeolite crystallization processes, occurring in complex media with multiple chemical interactions. Although the generic interpretation of each strategy and underlying crystallization mechanism remains largely unknown (and often limited to a specific framework), this review will provide guidance on more efficient methods to prepare fine-tuned zeolites with desired chemical properties.

Recent progress in performance optimization of Cu-SSZ-13 catalyst for selective catalytic reduction of NO x

Nitrogen oxides (NO x ), which are the major gaseous pollutants emitted by mobile sources, especially diesel engines, contribute to many environmental issues and harm human health. Selective catalytic reduction of NO x with NH3 (NH3-SCR) is proved to be one of the most efficient techniques for reducing NO x emission. Recently, Cu-SSZ-13 catalyst has been recognized as a promising candidate for NH3-SCR catalyst for reducing diesel engine NO x emissions due to its wide active temperature window and excellent hydrothermal stability. Despite being commercialized as an advanced selective catalytic reduction catalyst, Cu-SSZ-13 catalyst still confronts the challenges of low-temperature activity and hydrothermal aging to meet the increasing demands on catalytic performance and lifetime. Therefore, numerous studies have been dedicated to the improvement of NH3-SCR performance for Cu-SSZ-13 catalyst. In this review, the recent progress in NH3-SCR performance optimization of Cu-SSZ-13 catalysts is summarized following three aspects: 1) modifying the Cu active sites; 2) introducing the heteroatoms or metal oxides; 3) regulating the morphology. Meanwhile, future perspectives and opportunities of Cu-SSZ-13 catalysts in reducing diesel engine NO x emissions are discussed.

Fluoride-free synthesis of high-silica CHA-type aluminosilicates by seed-assisted aging treatment for starting gel

High-silica CHA-type aluminosilicates (Si/Al molar ratio >100) were synthesized hydrothermally in the absence of fluoride media, where the seed-assisted aging treatment played an important role on the crystallization. These aluminosilicates showed a long catalytic lifetime with high selectivity toward lower olefins in the methanol-to-olefins reaction.

Comparison of Industrial and Lab-Scale Ion Exchange for the DeNOx-SCR Performance of Cu Chabazites: A Case Study

The efficiency and robustness of selective catalytic reduction (SCR) by NH3 catalysts for exhaust gas purification, especially of heavy-duty diesel engines, will continue to play a major role, despite the increasing electrification of powertrains. With that in mind, the effect of the synthesis scale on commercially available Cu-exchanged chabazite catalysts for SCR was investigated through physicochemical characterizations and catalytic tests. During hydrothermal aging, both industrial and lab-scale prepared catalysts underwent structural dealumination of the zeolite framework and redistribution of the Al sites. Although both catalysts demonstrated similar NO conversion activity under SCR conditions, the lab-scale catalyst showed higher selectivity and lower activity in NH3 oxidation. Variations in N2O formation and NH3 oxidation rate were found to correlate with the formation of different copper species, and the compositions become less controllable in industrial-scale process. This case study focused on routes of ion exchange, and the results provide new insights into catalytic performance of the industrially-produced zeolites.

Dealumination of small-pore zeolites through pore-opening migration process with the aid of pore-filler stabilization

Small-pore zeolites are gaining increasing attention owing to their superior catalytic performance. Despite being critical for the catalytic activity and lifetime, postsynthetic tuning of bulk Si/Al ratios of small-pore zeolites has not been achieved with well-preserved crystallinity because of the limited mass transfer of aluminum species through narrow micropores. Here, we demonstrate a postsynthetic approach to tune the composition of small-pore zeolites using a previously unexplored strategy named pore-opening migration process (POMP). Acid treatment assisted by stabilization of the zeolite framework by organic cations in pores is proven to be successful for the removal of Al species from zeolite via POMP. Furthermore, the dealuminated AFX zeolite is treated via defect healing, which yields superior hydrothermal stability against severe steam conditions. Our findings could facilitate industrial applications of small-pore zeolites via aluminum content control and defect healing and could elucidate the structural reconstruction and arrangement processes for inorganic microporous materials.

Clarification of acid site location in MSE-type zeolites by spectroscopic approaches combined with catalytic activity: comparison between UZM-35 and MCM-68

MSE-type zeolites synthesized by different organic structure-directing agents (OSDAs), UZM-35 and MCM-68, were prepared. The location of Brønsted acid sites derived from the framework Al atoms and acidic properties were investigated based on ²⁷Al MQMAS NMR and in situ IR techniques combined with the evaluation of the catalytic activity. We have successfully found a significant difference in the location of Brønsted acid sites in the MSE-type framework; 61 and 33% of acid sites were located at the 12-ring channel for MCM-68 and UZM-35, respectively. The differences in the location of the acid sites yielded their unique catalytic activities for the hydrocarbon cracking reactions, indicating that a well-chosen type of OSDAs for the synthesis is one of the possibilities for controlling the distribution of the framework Al atoms in the MSE-type framework.

Understanding the superior NH3-SCR activity on CHA zeolite synthesized via template-free interzeolite transformation

Synthesizing CHA-type zeolite via template-free interzeolite transformation has been considered as a green manner, but the resultant zeolite exhibits low activity in selective catalytic reduction of NOx by ammonia (NH3-SCR)....

Dynamic evolution of Al species in the hydrothermal dealumination process of CHA zeolite

The hydrothermal stability of zeolites is an important factor being considered which could restrict their scope of industrial application. Revealing the water-induced dealumination mechanism is crucial for improving the hydrothermal...

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.

Transcription-induced formation of paired Al sites in high-silica CHA-type zeolite framework using Al-rich amorphous aluminosilicate

The paired Al species pre-formed in Al-rich amorphous aluminosilicates were transcribed into high-silica CHA-type zeolite frameworks under hydrothermal conditions, which offers a new approach to creating paired Al sites in zeolite frameworks. This Al-pair-rich CHA exhibited a higher Sr²⁺ uptake than the control CHA zeolite synthesized by the conventional procedure.

Recent progress in the improvement of hydrothermal stability of zeolites

Zeolites have been successfully employed in many catalytic reactions of industrial relevance. The severe conditions required in some processes, where high temperatures are frequently combined with the presence of steam, highlight the need of considering the evolution of the catalyst structure during the reaction. This review attempts to summarize the recently developed strategies to improve the hydrothermal framework stability of zeolites.

Control of location and distribution of heteroatoms substituted isomorphously in framework of zeolites and zeotype materials

Well-controlled incorporation of heteroatoms in frameworks of zeolites and zeotype materials has been achieved by a variety of new synthetic approaches, generating outstanding catalysts compared to uncontrolled materials.

Synthesis, Structure and Properties of an Extra-Large-Pore Aluminosilicate Zeolite NUD-6

Pure silica zeolites possessing uniform micropores, large surface area and high thermal and chemical stability have been widely studied and used in the fields of fine chemicals and oil industry. The incorporation of aluminium into the framework of silica zeolites changes their properties, making them more industrially useful as adsorbents and catalysts. Herein, we report the synthesis and characterization of an extra-large-pore aluminosilicate zeolite NUD-6 with a 16-membered-ring pore channel. Aluminium was directly incorporated into the zeolite NUD-6 framework, as confirmed by ²⁷ Al MAS NMR studies and ammonia temperature-programmed desorption probes. Al-NUD-6 was not stable when heated at 550 °C to remove the organic templates. However, the organic templates in Al-NUD-6 could be removed by oxidation in nitric acid at room temperature. The obtained Al-NUD-6H retained the crystalline structure and possessed both micropores and mesopores despite the occurrence of severe structural distortions due to the presence of the corner-sharing Q³ Si₂ O₇ units. The incorporation of aluminium resulted in both medium and strong acid sites in Al-NUD-6H, and could facilitate its use in adsorption and catalysis.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

CHA-Type Zeolite Prepared by Interzeolite Conversion Method Using FAU and LTL-Type Zeolite: Effect of the Raw Materials on the Crystallization Mechanism, and Physicochemical and Catalytic Properties

The effect of the raw materials including parent zeolite as aluminosilicate sources and organic structure-directing agents (OSDAs) on the crystallization mechanism, and physicochemical and catalytic properties of the CHA-type aluminosilicate zeolite was investigated. For this purpose, the FAU-type and the LTL-type zeolites were used as raw material, and trymethyladamantyl ammonium hydroxide and tetraethyl ammonium hydroxide were used as OSDAs. We firstly found that the CHA-type aluminosilicate zeolite was crystallized from the combination of the LTL-type zeolite and tetraethyl ammonium hydroxide as raw materials. The crystallization behaviors were also monitored in detail. The crystallization was delayed by using the LTL-type zeolite as the starting material regardless of the type of OSDA because of the low solubility of the LTL-type zeolite compared to the FAU-type zeolite. We have found that the Al distribution in the CHA framework was dependent on the raw materials. Thus, the prepared CHA-type aluminosilicate zeolite from the LTL-type zeolite exhibited a high thermal stability and catalytic performance in the methanol to olefins reaction.

High-quality synthesis of a nanosized CHA zeolite by a combination of a starting FAU zeolite and aluminum sources

A chabazite (CHA zeolite) was synthesized using high-silica faujasite (FAU) zeolites with a Si/Al ratio of 93, an additional alumina source (aluminum hydroxide) combined with seed crystals, and N,N,N-trimethyl-1-adamantammonium hydroxide. We compared the crystallization behavior of the starting material (HSY + Al) with that of other combinations of silica/alumina sources (high-silica and low-silica FAU, fumed silica, and aluminum hydroxide). HSY + Al rapidly yielded nanosized CHA zeolites with a crystal size of approximately 70 nm, exhibited high product crystallinity and high yield and offered a wide synthesis window. A combination of analytic experiments using electrospray-ionization mass spectrometry and nuclear magnetic resonance (NMR) suggested that in the early stage, the pre-introduced CHA seeds provide a crystal nucleus and the FAU zeolites decompose to form oligomer species in the liquid phase. Meanwhile, aluminum hydroxide retains its solid phase. Subsequent crystallization of the zeolites is accelerated by the liquid silicate oligomer and solid aluminate sources, resulting in a high yield and rapid synthesis of nanosized CHA zeolites. We observed that phosphorus-modified CHA zeolites synthesized using HSY + Al perform well as a catalyst for ethanol conversion reactions. Controlled Si/Al ratios and additional phosphorus modifications improve catalytic durability, thereby exhibiting a higher propylene yield from the reaction within the zeolite pore system.

Metal cation-exchanged zeolites with the location, state, and size of metal species controlled

Rh ion-exchanged MFI-type aluminosilicate zeolites with different Al distributions were prepared for controlling the location, state, and size of Rh species. The MFI-type aluminosilicate zeolite with the framework Al atoms predominantly located inside the channel intersections leads to the formation of relatively large Rh species, which were confirmed by ultraviolet-visible (UV-vis) and infrared (IR) spectroscopies. Moreover, this catalyst showed a high catalytic activity for the oxidative reforming reaction of methane.

Template-induced Al distribution in MOR and enhanced activity in dimethyl ether carbonylation

As the activity of dimethyl ether (DME) carbonylation over mordenite proportionally correlates with the Brønsted acid sites (BAS) in 8-membered ring (8-MR), enhancing the concentration of BAS in the 8-MR of MOR is important to improve the efficiency of the reaction. Herein, we report that the distribution of the BAS in the zeolite catalyst H-MOR can be altered by the synthesis of H-MOR with different cyclic amine structure-directing templates, several of which have not been reported previously for MOR synthesis. By combining FTIR, ICP, TG analysis and DFT calculations, it is verified that the strength of the interaction between amine or sodium cations and [AlO₄]^- in the zeolite framework plays a decisive role in Al distribution, owing to the competitive effect between Na⁺ and the cyclic amine compensating negative charges from the framework [AlO₄]^-. Quantitative analysis of the BAS in the 12-MR and 8-MR identifies the optimum template for maximizing the BAS in the 8-MR. It is shown that the enhanced activity of the H-MOR for the DME carbonylation to methyl acetate correlates with the increase in the BAS in the 8-MR. Our finding thus provides a facile strategy to direct Al location within different channels of the zeolite, which must benefit spatially confined reaction systems.

Cooperative and Competitive Occlusion of Organic and Inorganic Structure-Directing Agents within Chabazite Zeolites Influences Their Aluminum Arrangement

We combine experiment and theory to investigate the cooperation or competition between organic and inorganic structure-directing agents (SDAs) for occupancy within microporous voids of chabazite (CHA) zeolites and to rationalize the effects of SDA siting on biasing the framework Al arrangement (Al-O(-Si-O)_x-Al, x = 1-3) among CHA zeolites of essentially fixed composition (Si/Al = 15). CHA zeolites crystallized using mixtures of TMAda⁺ and Na⁺ contain one TMAda⁺ occluded per cage and Na⁺ co-occluded in an amount linearly proportional to the number of 6-MR paired Al sites, quantified by Co²⁺ titration. In contrast, CHA zeolites crystallized using mixtures of TMAda⁺ and K⁺ provide evidence that three K⁺ cations, on average, displace one TMAda⁺ from occupying a cage and contain predominantly 6-MR isolated Al sites. Moreover, CHA crystallizes from synthesis media containing more than 10-fold higher inorganic-to-organic ratios with K⁺ than with Na⁺ before competing crystalline phases form, providing a route to decrease the amount of organic SDA needed to crystallize high-silica CHA. Density functional theory calculations show that differences in the ionic radii of Na⁺ and K⁺ determine their preferences for siting in different CHA rings, which influences their energy to co-occlude with TMAda⁺ and stabilize different Al configurations. Monte Carlo models confirm that energy differences resulting from Na⁺ or K⁺ co-occlusion promote the formation of 6-MR and 8-MR paired Al arrangements, respectively. These results highlight opportunities to exploit using mixtures of organic and inorganic SDAs during zeolite crystallization in order to more efficiently use organic SDAs and influence framework Al arrangements.

The influence of adjacent Al atoms on the hydrothermal stability of H-SSZ-13: a first-principles study

The Al concentration and distribution have a great influence on the hydrothermal stability of the H-SSZ-13 zeolites in experiments. In this work, first-principles calculations are performed to clarify the decomposition mechanism of an H-SSZ-13 framework with adjacent Al atom pair distribution under hydrothermal conditions. It is found that the adjacent Al atoms have a tendency to occupy the para-sites of the 4-membered rings (4MRs) in the framework. Water molecules are chemisorbed onto the Al atom one by one, and the hydroxylation of the neighboring O atoms induces the breaking of the Al-O bonds, which causes the first dealumination in 4MRs. The other Al atom in the para-site can be easily removed from the framework once the first one is lost. The feasible subsequent dealumination of adjacent Al atoms would break the linker of 6MRs in the framework, which is responsible for the degraded hydrothermal stability. Moreover, the partial substitution of metal ions (such as Na⁺ and Cu⁺) for the protons in the framework will greatly stabilize the Al-O bonds and enlarge the energy barrier of para-site Al dealumination, which leads to the improved hydrothermal stability of H-SSZ-13.

Tracking the rearrangement of atomic configurations during the conversion of zeolite to zeolite

In order to realize designed synthesis, understanding the formation mechanism of zeolites at an atomic level has long been aspired, but remains challenging due to the fact that the knowledge of atomic configurations of the species formed during the process is limited. We focus on a synthesis system that crystallizes CHA zeolite from FAU zeolite as the sole source of tetrahedral atoms of Si and Al, so that end-to-end characterization can be conducted. Solid-state 29Si MAS NMR is followed by high-throughput computational modeling to understand how atomic configurations changed during the interzeolite conversion. This reveals that the structural motif commonly found in FAU and CHA is not preserved during the conversion; rather, there is a specific rearrangement of silicates and aluminates within the motif. The atomic configuration of CHA seems to be influenced by that of the starting FAU, considering that CHA synthesized without using FAU results in a random Al distribution. A Metropolis Monte-Carlo simulation combined with a lattice minimization technique reveals that CHA derived from FAU has energetically favorable, biased atomic locations, which could be a result of the atomic configurations of the starting FAU. These results suggest that by choosing the appropriate reactant, Al placement could be designed to enhance the targeted properties of zeolites for catalysis and adsorption.