MWW and MFI Frameworks as Model Layered Zeolites: Structures, Transformations, Properties, and Activity

Multifunctional Catalysts for Cascade Reactions in Biomass Processing

Multifunctional catalysts have received considerable attention in the cascade reactions of biomass processing. A cascade (or tandem) reaction is realized when multiple reaction steps that require different catalysts are performed in a one-step process. These reactions require bi- or multifunctional catalysts or catalyst mixtures to serve successfully at each reaction step. In this review article, we discuss the major factors of the catalyst design influencing the structure-property relationships, which could differ depending on the catalyst type. The major factors include the amounts and strengths of acidic and basic sites, interactions between those and metal sites, synergetic effects, nanoparticle sizes and morphology, nanostructures, porosity, etc. The catalysts described in this review are based on zeolites, mesoporous solids, MOFs, and enzymes. The importance of continuous cascade processes is also examined.

Tuning the morphology and textural properties of ZSM-5 additive for co-cracking of waste plastics with vacuum gas oil to light olefins

Typical cracking catalysts, called equilibrium catalyst (E-Cat) are ultra-stable Y (USY) zeolite often used with 15% commercial ZSM-5 zeolite additive (ZSM-5(COM)) to boost olefin yield. In this study, similar additive zeolites with different pore sizes and acidic character were synthesized by rapid ageing of precursor solution and used in the co-cracking of low-density polyethylene (LDPE) and heavy vacuum gas oil (HVGO). Three ZSM-5 zeolites additives with Si/Al ratio 25 (ZSM-5(25)), 50 (ZSM-5(50)) and 75 (ZSM-5(75)) were synthesized and combined with E-Cat to form E-Cat/ZSM-5(25), E-Cat/ZSM-5(50) and E-Cat/ZSM-5(75) respectively. The E-Cat/ZSM-5(50) has slightly better endothermic conversion (cracking) of a mixture of dissolved LDPE and HVGO into H2, C1 to C4 gases and C2-C4 light olefins (total conversion of E-Cat 80.0%, E-Cat/ZSM-5(COM) 75.0% and E-Cat/ZSM-5(50) 83.7% respectively), with different gas, liquid and coke distributions. The E-Cat/ZSM-5(75) has 81% conversion, and highest yield of light olefins (38.4%). Structural (surface area, pore size) and chemical (acid sites) characteristics of the synthetized ZSM-5(75) zeolite explain the observed higher light olefin selectivity by different and competing catalytic routes. The ZSM-5(75) has demonstrated to be a good zeolite additive for converting dissolved plastic in HVGO into light olefins.

Enhanced production of jet fuel precursors via furfural/cyclopentanone aldol condensation by synergistic pairing TiO2 with nano-ZSM-5 zeolite

Aldol condensation of biomass-derived compounds offers a sustainable route to jet fuel precursors. This study explores catalysts based on nanocrystalline ZSM-5 zeolite (n-ZSM-5) modified with various metals (Ca, Mg, Sn, Ti, Zr) for the aldol condensation of furfural (FFL) and cyclopentanone (CPO). While both reactants can enter the ZSM-5 micropores, the resulting C10 (FC) and C15 (F2C) adducts are too large to be formed within or to exit the microporosity, being instead produced over the external acid sites. Metal modification significantly impacts catalytic activity: Ca and Mg reduce conversion, Sn is neutral, whereas Zr and Ti leads to enhanced performance. The TiO2/n-ZSM-5 catalyst shows by far the best behavior, doubling FFL conversion and sharply increasing the FC + F2C yield, which is attributed to a synergistic effect arising from the generation of accessible weak Lewis acid sites by highly dispersed TiO2 that complement the external Brønsted acidity of ZSM-5.

Designed functions of oxide/hydroxide nanosheets via elemental replacement/doping

Partial replacement of one structural element in a solid with another of a similar size was conducted to impart functionality to the solids and modify their properties. This phenomenon is found in nature in coloured gemstones and clay minerals and is used in materials chemistry and physics, endowing materials with useful properties that can be controlled by incorporated heteroelements and their amounts. Depending on the area of research (or expected functions), the replacement is referred to as "isomorphous substitution", "doping", etc. Herein, elemental replacement in two-dimensional (2D) oxides and hydroxides (nanosheets or layered materials) is summarised with emphasis on the uniqueness of their preparation, characterisation and application compared with those of the corresponding bulk materials. Among the 2D materials (graphene, metallenes, transition metal chalcogenides, metal phosphate/phosphonates, MXenes, etc.), 2D oxides and hydroxides are characterised by their presence in nature, facile synthesis and storage under ambient conditions, and possible structural variation from atomic-level nanosheets to thicker nanosheets composed of multilayered structures. The heteroelements to be doped were selected depending on the target application objectively; however, there are structural and synthetic limitations in the doping of heteroelements. In the case of layered double hydroxides (single layer) and layered alkali silicates (from single layer to multiple layers), including layered clay minerals (2 : 1 layer), the replacement (commonly called isomorphous substitution) is discussed to understand/design characteristics such as catalytic, adsorptive (including ion exchange), and swelling properties. Due to the variation in their main components, the design of layered transition metal oxide/hydroxide materials via isomorphous substitution is more versatile; in this case, tuning their band structure, doping both holes and electrons, and creating impurity levels are examined by the elemental replacement of the main components. As typical examples, material design for the photocatalytic function of an ion-exchangeable layered titanate (lepidocrocite-type titanate) and a perovskite niobate (KCa2Nb3O10) is discussed, where elemental replacement is effective in designing their multiple functions.

Unraveling the Nanosheet Zeolite-Catalyzed Combustion of Aluminum Nanoparticles-Doped exo-Tetrahydrodicyclopentadiene (JP-10) Energetic Fuel

Nanosheet MFI zeolites (Zeolite Socony Mobil, five) have grown in popularity in cracking catalysis considering their tunability in porous topologies, acidic sites, and sheet thickness, thus allowing them to selectively adsorb molecules of specific sizes, shapes, and polarities, resulting in improved cracking performance for a specific fuel. Five different MFI zeolites in the form of a mesoporous nanosheet structure with a controlled concentration of acidic sites denoted as NSMFI(y), where y is Si/Al ratio, have been synthesized. The effects of the relative acidity content of these NSMFI(y) samples on the zeolite-catalyzed combustion of aluminum nanoparticles (AlNPs)-aided exo-tetrahydrodicyclopentadiene (JP-10) mixed energetic fuel droplets levitated in an oxygen-argon atmosphere were investigated using time-resolved imaging (optical and thermal infrared) and spectroscopic techniques (UV-vis and FTIR). The addition of 1.0 wt % of NSMFI(y) zeolites to AlNPs-JP-10 fluid fuel results in critically reduced ignition delays (9 ± 2 ms), elevated ignition temperatures (2800 ± 170 K), and prolonged burning times (60 ± 10 ms) with an enhanced combustion efficiency. The NSMFI(y) zeolites, which possess high acidity and significant mesoporosity, play a crucial role in improving the combustion efficiency by effectively catalyzing the chemical activation of JP-10 and prolonging the burning of the igniting droplet. The NSMFI (60) variant with the highest acidic site content achieved a maximum combustion efficiency of 80 ± 6%. A comprehensive catalytic combustion mechanism has been elucidated based on the detected reactive intermediates such as hydroxyl radical (OH) and aluminum monoxide (AlO). These findings will help to critically advance the development of next-generation, sustainable, and innovative mixed nanofluid fuels.

Zeolite-based chiral ion-exchangers for chromatographic enantioseparations and potential applications in membrane separation processes

Chiral resolution of racemic compounds represents an important task in research and development and, most importantly, in the large-scale production of pharmaceuticals. Zeolites, which are already frequently utilized for their unique properties, represent materials that can be used for the development of new chiral stationary phases for liquid chromatography, simulated moving bed or enantioselective membranes. The aim of this study was to modify a series of MWW zeolites by a chiral anion-exchange type selector thereby creating a chiral stationary phase for enantiomeric resolution of acidic compounds. To evaluate the applicability of the prepared chiral stationary phase in liquid chromatography, we used N-protected amino acids as model analytes. First, we tested the new sorbents preferential sorption using N-(3,5-dinitrobenzoyl)leucine. We observed outstanding sorption properties of a zeolite-based sorbent (MCM-36), which were comparable to spherical chromatographic silica. This particular material was subsequently packed into a chromatographic column, which was tested under polar organic mode HPLC conditions facilitating baseline resolution of 5 out of 8 N-protected amino acids. Although the chromatographic performance shows several drawbacks (high backpressure, low column efficiency), it clearly documents the potential of the novel materials in chiral separation. To the best of our knowledge, this is the first example of the preparation of the chiral stationary phase based on MWW zeolites ever.

Synthesis Route to Single-Walled Zeolite Nanotubes Enabled by Tetrabutylammonium Hydroxide

Single-walled zeolite nanotubes (ZNT) were recently synthesized in a narrow compositional window. ZNT structural features-thin zeolitic walls and large mesopores-can allow for easy access of small molecules to zeolite micropores, but they also impart processing limitations for these materials, such as challenges with conventional aqueous ion-exchange conditions. Conventional solid- and liquid-phase ion exchange of calcined NaOH-derived ZNT (NaH-ZNT) results in structural degradation to either 2D sheet-like phases, 3D nanocrystals, or amorphous phases, motivating different direct synthesis routes and unconventional ion-exchange procedures of uncalcined ZNT precursors. Here, a modified synthesis route for ZNT synthesis is introduced that facilitates facile ion exchange as well as incorporation of additional non-Al heteroatoms in the zeolite framework. Tetrabutylammonium hydroxide (TBAOH) is used as a hydroxide source and co-OSDA, enabling synthesis of new compositions of ZNT, otherwise unachievable by post-modification of previously reported NaH-ZNT. By varying the gel composition, synthesis temperature, crystallization time, hydroxide source, silicon source, and aluminum source, productive conditions for the new TBAOH synthesis are developed, leading to increased strong acid site density in the ZNT. The collected results demonstrate the sensitivity of the ZNT synthesis to many key parameters and show that the ZNT forms only when Si/(Al + T) ∼ 30 in these synthesis gels and with specific Si and Al sources, and always in the presence of trace Na+. Catalytic testing, via the tandem CO2 hydrogenation to methanol and methanol to aromatics reaction, shows that ZNTs provide adequate catalytic activity (acidity), relative to their conventional 3D counterparts in converting methanol to aromatic compounds.

Interchain-expanded extra-large-pore zeolites

Stable aluminosilicate zeolites with extra-large pores that are open through rings of more than 12 tetrahedra could be used to process molecules larger than those currently manageable in zeolite materials. However, until very recently1-3, they proved elusive. In analogy to the interlayer expansion of layered zeolite precursors4,5, we report a strategy that yields thermally and hydrothermally stable silicates by expansion of a one-dimensional silicate chain with an intercalated silylating agent that separates and connects the chains. As a result, zeolites with extra-large pores delimited by 20, 16 and 16 Si tetrahedra along the three crystallographic directions are obtained. The as-made interchain-expanded zeolite contains dangling Si-CH3 groups that, by calcination, connect to each other, resulting in a true, fully connected (except possible defects) three-dimensional zeolite framework with a very low density. Additionally, it features triple four-ring units not seen before in any type of zeolite. The silicate expansion-condensation approach we report may be amenable to further extra-large-pore zeolite formation. Ti can be introduced in this zeolite, leading to a catalyst that is active in liquid-phase alkene oxidations involving bulky molecules, which shows promise in the industrially relevant clean production of propylene oxide using cumene hydroperoxide as an oxidant.

Epitaxial Growth of Two-Dimensional MWW Zeolite

Two-dimensional (2D) zeolite, with a high aspect ratio, has more open skeletons and accessible active sites than its three-dimensional (3D) counterpart. However, traditional methods of obtaining 2D zeolites often cause structural damage and widespread skeleton defects, hindering efficient selectivity in molecular separation. In this study, we present, for the first time, a direct epitaxial synthesis of 2D zeolite (Epi-MWW) guided by hexagonal boron nitride (h-BN) with a coincidence matching of site lattices to MWW zeolite. The as-grown Epi-MWW zeolite possesses a high crystallinity and intact hexagonal 2D morphology, with an average thickness of 10 nm and an aspect ratio of over 50. Thanks to its excellent molecular accessibility, the diffusion time constants of o-xylene (OX) and p-xylene (PX) are as 12 and 133 times higher than those of conventional MCM-22, respectively; the PX/OX selectivity of Epi-MWW is 7.4 times better than MCM-22 as calculated by the ideal adsorbed solution theory.

Accelerated Synthesis of Nanolayered MWW Zeolite by Interzeolite Transformation

Hierarchical zeolites can offer substantial benefits over bulk zeolites in catalysis. A drawback towards practical implementation is their lengthy synthesis, often requiring complex organic templates. This work describes an accelerated synthesis of nanolayered MWW zeolite based on the combination of interzeolite transformation (IZT) with a dual-templating strategy. FAU zeolite, hexamethyleneimine (HMI), and cetyltrimethylammonium bromide (CTAB) were respectively employed as Al source and primary zeolite, structure directing agent, and exfoliating agent. This approach allowed to reduce the synthesis of nanolayered MWW to 48 h, which is a considerable advance over the state of the art. Tracking structural, textural, morphological, and chemical properties during crystallization showed that 4-membered-ring (4MR) units derived from the FAU precursor are involved in the faster formation of MWW in comparison to a synthesis procedure from amorphous precursor. CTAB restricts the growth of the zeolite in the c-direction, resulting in nanolayered MWW. Moreover, we show that this approach can speed up the synthesis of nanolayered FER. The merits of nanolayered MWW zeolites are demonstrated in terms of improved catalytic performance in the Diels-Alder cycloaddition of 2,5-dimethylfuran and ethylene to p-xylene compared to bulk reference MWW sample.

Design of Bifunctional Nanocatalysts Based on Zeolites for Biomass Processing

Bifunctional catalysts consisting of metal-containing nanoparticles (NPs) and zeolite supports have received considerable attention due to their excellent catalytic properties in numerous reactions, including direct (biomass is a substrate) and indirect (platform chemical is a substrate) biomass processing. In this short review, we discuss major approaches to the preparation of NPs in zeolites, concentrating on methods that allow for the best interplay (synergy) between metal and acid sites, which is normally achieved for small NPs well-distributed through zeolite. We focus on the modification of zeolites to provide structural integrity and controlled acidity, which can be accomplished by the incorporation of certain metal ions or elements. The other modification avenue is the adjustment of zeolite morphology, including the creation of numerous defects for the NP entrapment and designed hierarchical porosity for improved mass transfer. In this review, we also provide examples of synergy between metal and acid sites and emphasize that without density functional theory calculations, many assumptions about the interactions between active sites remain unvalidated. Finally, we describe the most interesting examples of direct and indirect biomass (waste) processing for the last five years.

Enhanced Oxidation of p-Toluidine Using Supported Zeolite Nanoparticles

Supported nanomaterials are becoming increasingly important in many industrial processes because of the need to improve both the efficiency and environmental acceptability of industrial processes. The unique properties of supported nanomaterials have attracted researchers to develop efficient catalytic materials in nanoscale. The extremely small size of the particles maximizes the surface area exposed to the reactant, allowing more reactions to occur. The environmental hazards resulting from the conventional manufacturing procedures for organic fine chemicals and intermediates by classical oxidation catalysis using mineral acids have forced chemical industries to seek less polluting processes. The present study aimed to oxidize p-toluidine by hydrogen peroxide in the presence of magnetite supported on nanocrystalline titanium silicalite-1 (M/NTS) zeolite at ambient temperature. The products detected are 4,4'-dimethylazobenzene as major product and 4,4'-dimethylazoxybenzene as minor product. Good selectivity, low cost, low wastage of materials and enhanced environmental friendliness of heterogeneous magnetite nanoparticle supported zeolite catalysts were observed. The effect of various reaction parameters such as mole ratio, catalyst weight and reusability of catalyst were studied. At the optimum reaction conditions, the oxidation activity of M/NTS catalyst was compared with M/NS catalyst, and it was found that titanium in the framework of M/NTS provided higher activity and selectivity.

Recent Advances in Tetra- (Ti, Sn, Zr, Hf) and Pentavalent (Nb, V, Ta) Metal-Substituted Molecular Sieve Catalysis

Metal substitution of molecular sieve systems is a major driving force in developing novel catalytic processes to meet current demands of green chemistry concepts and to achieve sustainability in the chemical industry and in other aspects of our everyday life. The advantages of metal-substituted molecular sieves include high surface areas, molecular sieving effects, confinement effects, and active site and morphology variability and stability. The present review aims to comprehensively and critically assess recent advances in the area of tetra- (Ti, Sn, Zr, Hf) and pentavalent (V, Nb, Ta) metal-substituted molecular sieves, which are mainly characterized for their Lewis acidic active sites. Metal oxide molecular sieve materials with properties similar to those of zeolites and siliceous molecular sieve systems are also discussed, in addition to relevant studies on metal-organic frameworks (MOFs) and some composite MOF systems. In particular, this review focuses on (i) synthesis aspects determining active site accessibility and local environment; (ii) advances in active site characterization and, importantly, quantification; (iii) selective redox and isomerization reaction applications; and (iv) photoelectrocatalytic applications.

Exfoliating layered zeolite MFI into unilamellar nanosheets in solution as precursors for the synthesis of hierarchical nanocomposites and oriented films

The separation of layered MFI into unilamellar nanosheets in solution confirms the general validity of soft-chemical exfoliation for zeolites and allows top-down production of films with potential applications in separation and catalysis.

c-Axis-penetrated mesoporous MWW zeolite nanosheets: preparation by H2O2-induced micro-explosion and their enhanced properties

A series of highly dispersed and c-axis-penetrated mesoporous MWW oligolayers with enhanced properties was prepared via an efficient, green, and controllable method through H2O2-induced micro-explosion.

Mechanistic kinetic modeling for catalytic conversion of DME to gasoline-range hydrocarbons over nanostructured ZSM-5

A new kinetic model for the synthesis of gasoline-range hydrocarbons from dimethyl ether over a nanostructured ZSM-5 catalyst was developed based on the dual-cycle reaction mechanism.

Synthesis of nanosheet epitaxial growth ZSM-5 zeolite with increased diffusivity and its catalytic cracking performance

The introduction of microporous substrate in the nanosheet zeolite reduces the “acid wall” barrier. The diffusional time constant of RP-120 is increased by 32%, and its TOF is increased by 54%.

MWW-type zeolite nanostructures for a one-pot three-component Prins–Friedel–Crafts reaction

One-pot Prins–Friedel–Crafts reaction of aldehydes, homoallylic alcohol and aromatics catalyzed by large-pore zeolites is an attractive environmentally friendly route towards valuable heterocyclic compounds containing 4 aryltetrahydropyran moiety. Herein, a catalytic...

Advances in the Synthesis of Crystalline Metallosilicate Zeolites via Interlayer Expansion

Given the numerous industrial applications of zeolites as adsorbents, catalysts, and ion-exchangers, the development of new zeolite structures is highly desired to expand their practical applications. Currently, a general route to develop new zeolite structures is to use interlayer expansion agents to connect layered silicates. In this review, we briefly summarize the novel zeolite structures constructed from the lamellar precursor zeolites MWW, RUB-36, PREFER, Nu-6(1), COK-5, and PLS-1 via interlayer expansion. The contents of the summary contain detailed experiments, physicochemical characterizations, possible expansion mechanisms, and catalytic properties. In addition, the insertion of metal heteroatoms (such as Ti, Fe, Sn) into the layered zeolite precursor through interlayer expansion, which could be helpful to modify the catalytic function, is discussed.

Exfoliated Ferrierite-Related Unilamellar Nanosheets in Solution and Their Use for Preparation of Mixed Zeolite Hierarchical Structures

Direct exfoliation of layered zeolites into solutions of monolayers has remained unresolved since the 1990s. Recently, zeolite MCM-56 with the MWW topology (layers denoted mww) has been exfoliated directly in high yield by soft-chemical treatment with tetrabutylammonium hydroxide (TBAOH). This has enabled preparation of zeolite-based hierarchical materials and intimate composites with other active species that are unimaginable via the conventional solid-state routes. The extension to other frameworks, which provides broader benefits, diversified activity, and functionality, is not routine and requires finding suitable synthesis formulations, viz. compositions and conditions, of the layered zeolites themselves. This article reports exfoliation and characterization of layers with ferrierite-related structure, denoted bifer, having rectangular lattice constants like those of the FER and CDO zeolites, and thickness of approximately 2 nm, which is twice that of the so-called fer layer. Several techniques were combined to prove the exfoliation, supported by simulations: AFM; in-plane, in situ, and powder X-ray diffraction; TEM; and SAED. The results confirmed (i) the structure and crystallinity of the layers without unequivocal differentiation between the FER and CDO topologies and (ii) uniform thickness in solution (monodispersity), ruling out significant multilayered particles and other impurities. The bifer layers are zeolitic with Brønsted acid sites, demonstrated catalytic activity in the alkylation of mesitylene with benzyl alcohol, and intralayer pores visible in TEM. The practical benefits are demonstrated by the preparation of unprecedented intimately mixed zeolite composites with the mww, with activity greater than the sum of the components despite high content of inert silica as pillars.

From Colloidal Dispersions of Zeolite Monolayers to Effective Solid Catalysts in Transformations of Bulky Organic Molecules: Role of Freeze-Drying and Dialysis

We investigated the properties and catalytic activity of zeolites with MWW topology obtained by unprecedented liquid exfoliation of the MCM-56 zeolite into solutions of monolayers and isolation/reassembly of the dispersed layers by various methods, with optional purification by dialysis or ammonium exchange. The layers were recovered by flocculation with alcohol or ammonium nitrate and freeze-drying. Flocculation alone, even with ammonium nitrate, did not ensure removal of residual sodium cations resulting in catalysts with low activity. Dialysis of the solutions with dispersed monolayers proved to be efficient in removing sodium cations and preserving microporosity. The monolayers were also isolated as solids by freeze-drying. The highest BET area and pore volume obtained with the freeze-dried sample confirmed lyophilization efficiency in preserving layer structure. The applied test reaction, Friedel–Crafts alkylation of mesitylene, showed high benzyl alcohol conversion due to increased concentration of accessible acid centers caused by the presence of secondary mesoporosity. The applied treatments did not change the acid strength of the external acid sites, which are the most important ones for converting bulky organic molecules. Zeolite acidity was not degraded in the course of exfoliation into monolayers, showing the potential of such colloid dispersions for the formation of active catalysts.

Structure-Catalytic Properties Relationship in Friedel Crafts Alkylation Reaction for MCM-36-Type Zeolites Obtained by Isopropanol-Assisted Pillaring

MWW type zeolites are characterized by the presence of zeolitic layers of 2.5 nm thickness, containing 10-member ring sinusoidal channels inside and supercavities with 12-member ring openings located on their surfaces. Expansion and pillaring of layered zeolites increase the access to active sites and can enable or facilitate catalytic activity towards larger reactant molecules. This goal is explored in this work reporting the pillaring of layered zeolite MCM-56 with MWW topology by tetraethylorthosilicate (TEOS) treatment with the assistance of isopropanol, aimed at obtaining hierarchical micro-mesoporous systems. MCM-56 (Si/Al = 12) was synthesized with hexamethyleneimine as a structure-directing and aniline as a structure-promoting agent. Hierarchical porous systems were obtained using two different pillaring methods: (1) with TEOS only and (2) with TEOS mixed with isopropanol. The MWW framework was preserved during swelling/pillaring in both methods. Pillared zeolites obtained via alcohol-assisted pillaring possessed unique intermediate micro-mesopores with the size of about 2 nm. IR study revealed a decrease in the concentration of accessible acid centers upon pillaring. However, the fraction of acid sites on the external surface, accessible for adsorption of large molecules, increased by up to 90%. Catalytic activity was evaluated in the Friedel-Crafts alkylation of mesitylene with benzyl alcohol. Pillaring resulted in reduction of the acid site concentrations, but the materials retained high catalytic activity. Pillaring in the presence of alcohol produced increased turnover frequency values based on the concentrations of the external acid sites.