The Role of Organic and Inorganic Structure-Directing Agents in Selective Al Substitution of Zeolite

Synthetic Placement of Active Sites in MFI Zeolites for Selective Toluene Methylation to para-Xylene

Brønsted acidic zeolites are ubiquitous catalysts in fuel and chemical production. Broadening the catalytic diversity of a given zeolite requires strategies to manipulate the acid site placement at framework positions within distinct microporous locations. Here, we combine experiment and theory to elucidate how intermolecular interactions between organic structure-directing agents (OSDAs) and framework Al centers influence the placement of H+ sites in distinct void environments of MFI zeolites and demonstrate the catalytic consequences of active site location on kinetically controlled (403 K) toluene methylation to xylene regioisomers. Kinetic measurements, interpreted using mechanism-derived rate expressions and transition state theory, alongside density functional theory (DFT) calculations show that larger intersection environments similarly stabilize all three xylene isomer transition states without altering well-established aromatic substitution patterns (ortho/para/meta ∼ 60%:30%:10%), while smaller channel environments preferentially destabilize transition states that form bulkier ortho- and meta-isomers, thereby resulting in high intrinsic para-xylene selectivity (∼80%). DFT calculations reveal that the flexibility of nonconventional OSDAs (e.g., 1,4-diazabicyclo[2.2.2]octane) to reorient within MFI intersections and their ability to hydrogen-bond to form protonated complexes favor the placement of Al in smaller channel environments compared to conventional quaternary OSDAs (e.g., tetra-n-propylammonium). These molecular-level insights establish a mechanistic link between OSDA structure, active site placement, and transition state stability in MFI zeolites and provide active site design strategies that are orthogonal to crystallite design approaches harnessing complex reaction-diffusion phenomena to enhance regioisomer selectivity in the industrial production of valuable polymer precursors.

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.

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.

Driving the Active Site Incorporation in Zeolitic Materials via the Organic Structure-Directing Agent Through Development of H-Bonds with Hydroxyl Groups

(1S,2S)-N-methyl-pseudoephedrine (MPS) was used as organic structure-directing agent (OSDA) for the synthesis of Mg-doped nanoporous aluminophosphates. This molecule displays a particular conformational behavior, where the presence of H-bond donor and acceptor groups provide a rigid conformational space with one asymmetric conformation preferentially occurring. MPS drives the crystallization of Mg-containing AFI materials. Characterization of these materials shows that the OSDA incorporate as protonated species, arranged as head-to-tail monomers. Combination of three-dimensional electron diffraction with high-resolution synchrotron powder X-ray diffraction allowed to locate both the Mg and the organic species. Interestingly, results showed that the spatial incorporation of Mg is driven by the hydroxyl groups of the organic cation through the development of H-bonds with negatively-charged MgO4 tetrahedra. This work demonstrates that H-bond forming groups can be used to drive the spatial incorporation of low-valent dopants within zeolitic frameworks, a highly desired aim in order to control their catalytic activity and selectivity.

Quantitatively Mapping the Distribution of Intrinsic Acid Sites in Mordenite Zeolite by High-Field 23Na Solid-State Nuclear Magnetic Resonance

It is of great significance to accurately quantify the Brønsted acid sites (BASs) at different positions of mordenite (MOR) zeolite. However, H-MOR obtained from Na-MOR can hardly avoid dealumination under hydrothermal conditions, which causes difficulty in the acid characterization. Herein, 23Na-27Al D-HMQC was performed combined with high-field 23Na MQ MAS NMR and DFT calculation, which provided an unambiguous attribution of the 23Na chemical shifts and further helped to improve the resolution of 27Al MAS NMR. By fitting the 23Na and 1H MAS NMR spectra of Na/H-MOR, the intrinsic BAS contents in different T-sites were measured by characterizing the location and content of sodium ions. These Na/H-MOR zeolites with various acid distributions were used for DME carbonylation and showed that the amount of BASs in the T3 site was proportional to the activity of carbonylation. This study provides a new method for investigating the intrinsic acid properties of zeolites.

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.