Diverse Physical States of Amorphous Precursors in Zeolite Synthesis

Aluminosilicate colloidal gels: from the early age to the precipitation of zeolites

Aluminosilicate hydrogels are often considered to be precursors for the crystallisation of zeolites carried out under hydrothermal conditions. The preparation of mechanically homogeneous aluminosilicate gels enables the study of these materials through bulk rheology and observation of the aging dynamics until the precipitation of crystalline zeolites. The first part of this study deals with the establishment of ternary state diagrams, in order to identify the range of chemical formulations that enable preparation of single-phase homogeneous gels. Then, by studying the viscoelastic moduli during the gelation reaction, and by yielding the gel under large deformation, we propose an empirical law considering the partial order of reaction on each chemical element, to predict the gelation time according to the chemical formulation. The scaling behavior of the elastic properties of this colloidal gel shows a transition from a strong link behavior to a weak link regime. Long term aging results in the shrinkage of the gel, accompanied by syneresis of interstitial liquid at the surface. Zeolites precipitate through crystallisation by a particle attachment mechanism, when thermodynamic equilibrium is reached. The stoichiometry of the precipitated zeolites is not only consistent with the concentration of the remaining species in the supernatant but, surprisingly, it is also very close to the partial order of the reaction of the chemical elements involved in the determination of the critical gel point. This indicates a strong correlation between the morphology of the soft amorphous gel network that is formed at an early age and those of the final solid precipitated crystals.

Enhanced Catalytic Activity of Crystalline Phosphorus Nanosheets Fabricated via Solvothermal Phase Transformation

The newly reported crystalline phosphorus nanosheets (cryst-P NSs) exhibit promising features for industrial applications, including outstanding air-water stability and facile large-scale production. However, their complex crystallization impedes a priori tailoring. Herein, the temporal evolution of cryst-P NSs was investigated with the optimized synthesis parameters. The occurrence of self-assembly and solid-state rearrangement unveiled the existence of an intermediate phase as the bulk crystalline precursor and the predominance of nonclassical crystallization pathway(s). With the upgraded synthesis protocol simultaneously strengthening the merits of cryst-P NSs, their catalytic performances were evaluated in various electro- and/or photocatalytic reactions spanning hydrogen and oxygen evolution, full water splitting, CO2 reduction, and organic pollutant decomposition. Superior catalytic activities and orders of magnitude longer lifetimes were consistently discerned compared with the widely employed black phosphorus nanosheets with similar size and thickness. The exciting discoveries in both fundamental crystallization and catalytic applications drastically thrust the comprehension of elemental phosphorus, shedding light on the encouraging capabilities of solvothermal synthesis strategies in the design and systematic tailoring of phosphorus materials.

The Current Understanding of Mechanistic Pathways in Zeolite Crystallization

Zeolite catalysts and adsorbents have been an integral part of many commercial processes and are projected to play a significant role in emerging technologies to address the changing energy and environmental landscapes. The ability to rationally design zeolites with tailored properties relies on a fundamental understanding of crystallization pathways to strategically manipulate processes of nucleation and growth. The complexity of zeolite growth media engenders a diversity of crystallization mechanisms that can manifest at different synthesis stages. In this review, we discuss the current understanding of classical and nonclassical pathways associated with the formation of (alumino)silicate zeolites. We begin with a brief overview of zeolite history and seminal advancements, followed by a comprehensive discussion of different classes of zeolite precursors with respect to their methods of assembly and physicochemical properties. The following two sections provide detailed discussions of nucleation and growth pathways wherein we emphasize general trends and highlight specific observations for select zeolite framework types. We then close with conclusions and future outlook to summarize key hypotheses, current knowledge gaps, and potential opportunities to guide zeolite synthesis toward a more exact science.

ZeoSyn: A Comprehensive Zeolite Synthesis Dataset Enabling Machine-Learning Rationalization of Hydrothermal Parameters

Zeolites, nanoporous aluminosilicates with well-defined porous structures, are versatile materials with applications in catalysis, gas separation, and ion exchange. Hydrothermal synthesis is widely used for zeolite production, offering control over composition, crystallinity, and pore size. However, the intricate interplay of synthesis parameters necessitates a comprehensive understanding of synthesis-structure relationships to optimize the synthesis process. Hitherto, public zeolite synthesis databases only contain a subset of parameters and are small in scale, comprising up to a few thousand synthesis routes. We present ZeoSyn, a dataset of 23,961 zeolite hydrothermal synthesis routes, encompassing 233 zeolite topologies and 921 organic structure-directing agents (OSDAs). Each synthesis route comprises comprehensive synthesis parameters: 1) gel composition, 2) reaction conditions, 3) OSDAs, and 4) zeolite products. Using ZeoSyn, we develop a machine learning classifier to predict the resultant zeolite given a synthesis route with >70% accuracy. We employ SHapley Additive exPlanations (SHAP) to uncover key synthesis parameters for >200 zeolite frameworks. We introduce an aggregation approach to extend SHAP to all building units. We demonstrate applications of this approach to phase-selective and intergrowth synthesis. This comprehensive analysis illuminates the synthesis parameters pivotal in driving zeolite crystallization, offering the potential to guide the synthesis of desired zeolites. The dataset is available at https://github.com/eltonpan/zeosyn_dataset.

Silanol-Engineered Nonclassical Growth of Zeolite Nanosheets from Oriented Attachment of Amorphous Protozeolite Nanoparticles

Zeolite nonclassical growth via particle attachment has been proposed for two decades, yet the attachment mechanism and kinetic regulation remain elusive. Here, nonclassical growth of an MFI-type zeolite has been achieved by using amorphous protozeolite (PZ) nanoparticles containing encapsulated TPA+ templates and abundant silanols (Si-OH) as sole precursors under hydrothermal conditions. The silanol characteristics of the precursor were studied by two-dimensional (2D) solid-state nuclear magnetic resonance (NMR) correlation spectroscopy, which were proven to play critical roles in determining precursor attachment behavior and crystal growth orientation. Under mechanical ball-milling or tablet-pressing process, pressure drove the fusion of spherical PZ into platelet-like integrated PZ (IPZ) coupled with transformations of external silanols from evenly distributed to curvature-dependent distributed and internal silanols from isolated to spatially proximate. Compared to isolated silanols, the spatially proximate silanols possessed a stronger correlation with TPA+, benefiting the formation of Si-O-Si bonds via silanol condensation. Subsequently, driven by minimization of surface energy, particle attachment of the platelet-like IPZ precursor preferentially occurred at high-curvature surfaces with high-density silanols, leading to anisotropic rates of nonclassical growth and thus the formation of high-aspect-ratio MFI-type zeolite nanosheets. Advanced electron microscopy provided direct evidence of attachment of amorphous IPZ precursors to crystalline intermediate surfaces along the c-axis direction with the formation of amorphous-crystalline interfaces, followed by interface elimination and structural evolution to a single-crystalline phase. Our findings not only unravel the zeolite nonclassical growth mechanism but also reveal the critical role of silanol chemistry in kinetic regulation, which is of great importance for pursuing a tailored zeolite synthesis.

Engineering Lewis Acidity in Zeolite Catalysts by Electrochemical Release of Heteroatoms during Synthesis

The creation of heteroatom nodes in zeolite frameworks is a challenging but rewarding pathway to superior materials for numerous catalytic applications. Here, we present a novel method for precise control over heteroatom incorporation by in situ anodic release of a desired metal during hydrothermal zeolite synthesis. The generic character of the technique and the applicability of the new synthesis reactor are shown across 3 zeolite structures crystallized and 4 electrode metals in two pH zones and by offering access to a new mixed-metal zeolite. The timed and voltage-controlled metal release offers a minimized interference between the metal precursor state and critical events in the zeolite's crystallization. A mechanistic study for Sn-MFI revealed the key importance of controlled release: while keeping its concentration lower than in batch, a lot more Sn can be incorporated into the framework. The method grants access to 10× increased framework Lewis acid site densities (vs batch controls) for the most relevant stannosilicates. As a proof, the electro-made materials demonstrate higher productivity than their classic counterparts in lactate catalysis. This innovative approach effectively expands the synthesis space of zeolites.

Recognizing the Minimum Structural Units Driving the Crystallization of SAPO-34 in a Top-Down Process

Recognizing the structure and nature of the nuclei for zeolites crystallization on an atomic level is of great importance, which can provide guidance on the control of crystallization kinetics and the rational synthesis of zeolites. However, it remains a long-standing challenge due to the difficulty in characterization of amorphous precursor with limited crystal nuclei. Herein, a top-down synthesis system was designed for SAPO-34 molecular sieve and well investigated. A clear precursor solution with abundant SAPO-34 crystal nuclei was obtained under a depolymerization-dominant condition. The species in the liquid precursor were identified by FT-ICR MS, solid-state MAS NMR and atomic pair distribution function analyses. In combination with various designed experiments, it is revealed that both the formation of small species containing Si-O-Al bonds and reaching a certain concentration, is crucial for driving the crystallization of SAPO-34, rather than structural units with specific spatial conformation. This work provides an important understanding on the (pre)nucleation of SAPO-34 and sheds light on the synthesis control of SAPO molecular sieves.

Tracking Sub-Nano-Scale Structural Evolution in Zeolite Synthesis by In Situ High-Energy X-ray Total Scattering Measurement with Pair Distribution Function Analysis

The crystallization mechanism of zeolites remains unclarified to date because of lack of effective techniques in characterizing the local structures of amorphous precursors under synthetic conditions. Herein, in situ high-energy X-ray total scattering measurement with pair distribution function analysis is performed throughout the hydrothermal synthesis of SSZ-13 zeolite to investigate the amorphous-to-crystalline transformation at the sub-nano level in real time. Ordered four-membered rings (4Rs) are dominantly formed during the induction period, prior to the significant increase in the number of symmetric six- and eight-membered rings (6Rs and 8Rs) in the crystal growth stage. These preformed ordered 4Rs contribute to the formation of d6r and cha composite building units containing 6Rs and 8Rs with the assistance of the organic structure-directing agent, leading to the construction of embryonic zeolite crystallites, which facilitate the crystal growth through a particle attachment pathway. This work enriches the toolbox for better understanding the crystallization pathway of zeolites.

Influence of the Zeolite ZSM-22 Precursor on a UF-PES Selective Substrate Layer for Salts Rejection

Fabrication of the ZSM-22/Polyethersulfone (ZSM-22/PES) membranes as selective salt filters represent a growing membrane technological area in separation with the potential of high economic reward based on its low energy requirements. The incorporation of ZSM-22 zeolite material as additives into the PES polymer matrix has the prospective advantage of combining both the zeolite and polymer features while overcoming the limitations associated with both materials. This work investigated the influence of the nature of the silica precursor on ZSM-22 zeolite hydrothermally synthesised using colloidal (C60) and fumed (C60) silica to Si/Al of 60. The successful synthesis of the highly crystalline zeolitic materials was confirmed through XRD, FTIR, and SEM with EDX. The ZSM-22 additives were directly dispersed into a PES polymeric matrix to form a casting solution for the preparation of the ZSM-22/PES selective substrate layers via a phase inversion method for salts rejection. The polymeric PES was selected as an organic network in which the content of the ZSM-22 zeolite (ranging between 0 and 1.0 wt.%), was obtained and characterised by XRD, FTIR, and SEM analysis, as well as water contact angle (WCA) measurement and dead-end filtration cell. The phase inversion preparation method has induced the resulting ZSM-22/PES NF substrates anisotropy, as attributed to a high water flux to the above 700 L·m−2·h−1; high selectivity and rejection of salts to above 80% is revealed by the obtained results. The materials also exhibited improved antifouling behavior to above 70% flux recovery ratios. As such, the nature of the silica precursor influences ZSM-22 zeolite synthesis as a potential additive in the PES polymer matrix and led to the enhanced performance of the pure PES ultrafiltration membrane.

Manipulation of amorphous precursors to enhance zeolite nucleation

Crystallization in media comprised of amorphous precursors is becoming a more common phenomenon for numerous synthetic, biological, and natural materials that grow by a combination of classical and nonclassical pathways. Amorphous phases can exhibit a wide range of physicochemical properties that may evolve during the course of nucleation and crystal growth. This creates challenges for establishing causal relationships between amorphous precursor properties and their effect(s) on the selection of mechanistic pathways of crystallization and ultimately the properties of the crystalline product. In this study, we examine ways to manipulate the composition and colloidal stability of amorphous (alumino)silicate precursors that are prevalent in nanoporous zeolite syntheses. Changes in the amorphous precursor properties are evaluated on the basis of their ability to enhance rates of crystal formation. Here, we use fumed silica as the primary silicon source and examine the effects of infusing the source or growth medium with additional alkali metal, which serves as an inorganic structure-directing agent to facilitate the formation of porous crystal structures. We also assess the impact of adding a polymer additive, which reduces the colloidal stability of precursors, wherein we posit that the confined pockets of solution within the interstitial spaces of the precursor aggregates play an important role in regulating the rate of zeolite crystallization. Three commercially relevant zeolites (mordenite, SSZ-13, and ZSM-5) were selected for this study based on their diverse frameworks and methods of preparation. Our findings reveal that alkali infusion significantly reduces the crystallization times for mordenite and SSZ-13, but has little impact on ZSM-5 synthesis. Conversely, we find that polymer addition markedly enhanced the rates of crystallization among all three zeolites, suggesting that this method may be a general approach to reduce zeolite synthesis times. Given the relatively high costs associated with commercial zeolite production, identifying new methods to improve the efficiency of hydrothermal syntheses can have significant practical implications beyond the fundamental benefits of developing new routes to tailor nonclassical crystallization.

Accelerating the Crystallization of Zeolite SSZ-13 with Polyamines

Tailoring processes of nucleation and growth to achieve desired material properties is a pervasive challenge in synthetic crystallization. In systems where crystals form via nonclassical pathways, engineering materials often requires the controlled assembly and structural evolution of colloidal precursors. In this study, we examine zeolite SSZ-13 crystallization and show that several polyquaternary amines function as efficient accelerants of nucleation, and, in selected cases, tune crystal size by orders of magnitude. Among the additives tested, polydiallyldimethylammonium (PDDA) was found to have the most pronounced impact on the kinetics of SSZ-13 formation, leading to a 4-fold reduction in crystallization time. Our findings also reveal that enhanced nucleation occurs at an optimal PDDA concentration where a combination of light-scattering techniques demonstrate these conditions lead to polymer-induced aggregation of amorphous precursors and the promotion of (alumino)silicate precipitation from the growth solution. Here, we show that relatively low concentrations of polymer additives can be used in unique ways to dramatically enhance SSZ-13 crystallization rates, thereby improving the overall efficiency of zeolite synthesis.

Polymorph Selection in Zeolite Synthesis Occurs after Nucleation

Zeolites are porous crystals with extensive polymorphism. The hydrothermal synthesis of zeolites is a multistage process involving amorphous precursors that evolve continuously in solubility and local order toward those of the crystal. These results pose several questions: Why does a first-order transition appear as a continuous transformation? At which stage is the polymorph selected? How large are the barriers and critical sizes for zeolite nucleation? Here we address these questions using nucleation theory with experimental data. We find that the nucleation barriers and critical zeolite nuclei are extremely small at temperatures of hydrothermal synthesis, resulting in spinodal-like crystallization that produces a mosaic of tiny zeolitic crystallites that compete to grow inside each glassy precursor nanoparticle. The subnanometer size of the critical nuclei reveals that the selection between zeolite polymorphs occurs after the nucleation stage, during the growth and coarsening of the crystals around the excluded volume of the structure-directing agents.

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.

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.

The Promoter Role of Amines in the Condensation of Silicic Acid: A First-Principles Investigation

Though well-recognized, the molecular-level understanding of the multifunctional roles of amines in the condensation of polysilicic acids, which is one of the key processes in hydrothermal synthesis of zeolites, is still limited. Taking ethylamine as a prototype, we investigated the mechanism of polysilicic acid condensation in the existence of organic amines in aqueous solution with extensive first-principles-based calculations. Because of the high proton affinity, ethylamine exists as amine silicates and alters the subsequent condensation mechanisms from a 1-step lateral attack mechanism accompanied with simultaneous intermolecular proton transfer in neutral aqueous solution to a 2-step SN2-like mechanism. Specifically, the 5-coordinated Si species that were not observed on pathways of condensation in neutral solution are effectively stabilized by the ethylamine cations as intermediates, and the barriers for condensation of ortho-silicic acid are significantly reduced from 133 kJ/mol in neutral solution to 58 and 63 kJ/mol for formation of the 5-coordinated Si intermediate and proton transfer for water release, respectively. Similar variations of mechanisms and barriers for condensation were also observed in the formation of cyclic trimers as well as linear and cyclic tetramers of ortho-silicic acids. Based on these, it was proposed that apart from acting as structure-directing agents, pore fillers, and pH adjusters, organic amines can also function as promoters in the condensation of polysilicic acids.

On the key role of aluminium and other heteroatoms during interzeolite conversion synthesis

Interzeolite conversion, a synthesis technique for several zeolite frameworks, has recently yielded a large amount of high-performing catalytic zeolites. Yet, the mechanisms behind the success of interzeolite conversion remain unknown. Conventionally, small oligomers with structural similarity between the parent and daughter zeolites have been proposed, despite the fact these have never been observed experimentally. Moreover, recent synthesis examples contradict the theory that structural similarity between the parent and daughter zeolites enhances interzeolite conversion. In this perspective it is proposed that heteroatoms, such as aluminium, are key players in the processes that determine the successful conversion of the parent zeolite. The role of Al during parent dissolution, and all consecutive stages of crystallization, are discussed by revising a vast body of literature. By better understanding the role of Al during interzeolite conversions, it is possible to elucidate some generic features and to propose some synthetic guidelines for making advantageous catalytic zeolites. The latter analysis was also expanded to the interconversion of zeotype materials where heteroatoms such as tin are present.

The crucial roles of aluminium in driving and controlling interzeolite conversion, a useful catalyst synthesis protocol, are put under scrutiny.

Mesoporogen-Free Strategy to Construct Hierarchical TS-1 in a Highly Concentrated System for Gas-Phase Propene Epoxidation with H2 and O2

Hierarchical TS-1 has attracted enormous attention from both academia and industry due to its remarkable catalytic performance in epoxidation reactions. However, sustainable synthesis of hierarchical-nanosized TS-1 without mesoporogens is still challenging. In this work, we report a facile and mesoporogen-free strategy to simultaneously manipulate pore structure and particle size of TS-1 employing the concentrated system. Taking advantage of the suspended nuclei in the concentrated system as confirmed by the DLS-PSD and atomic force microscopy, the novel TS-1 is demonstrated to have higher Ti concentration on surface, higher surface area (539 m²/g), abundant mesopores, and reduced crystal size (ca. 150 nm). Moreover, this Au-Ti bifunctional catalyst shows a good PO formation rate with enhanced catalytic stability due to the hierarchical structure. This strategy opens a novel way for the green synthesis of hierarchical-nanosized TS-1 and facilitates industrial development of the Au/TS-1 catalyst for propene epoxidation.

Titanosilicate zeolite precursors for highly efficient oxidation reactions

Titanosilicate zeolites are catalysts of interest in the field of fine chemicals. However, the generation and accessibility of active sites in titanosilicate materials for catalyzing reactions with large molecules is still a challenge. Herein, we prepared titanosilicate zeolite precursors with open zeolitic structures, tunable pore sizes, and controllable Si/Ti ratios through a hydrothermal crystallization strategy by using quaternary ammonium templates. A series of quaternary ammonium ions are discovered as effective organic templates. The prepared amorphous titanosilicate zeolites with some zeolite framework structural order have extra-large micropores and abundant octahedrally coordinated isolated Ti species, which lead to a superior catalytic performance in the oxidative desulfurization of dibenzothiophene (DBT) and epoxidation of cyclohexene. It is anticipated that the amorphous prezeolitic titanosilicates will benefit the catalytic conversion of bulky molecules in a wide range of reaction processes.

Titanosilicate zeolite precursors, with open structures of zeolite units and high amounts of catalytically active Ti species, show superior catalytic performance in the oxidative reactions.

Additive-free synthesis of house-of-card faujasite zeolite by utilizing aluminosilicate gel memory

The gel “memory” effect of aluminosilicate sols was used to tune the mesopore size of hierarchical house-of-card faujasite in the absence of additives, following earlier findings by Khaleel et al. demonstrating the use of pre- and post-nucleation trajectories for the synthesis of high FAU content faujasite nanocrystals.