Green routes for synthesis of zeolites

Acceleration of Zeolite Crystallization: Current Status, Mechanisms, and Perspectives

Zeolites are important classes of crystalline materials and possess well-defined channels and cages with molecular dimensions. They have been extensively employed as heterogeneous catalysts and gas adsorbents due to their relatively large specific surface areas, high pore volumes, compositional flexibility, definite acidity, and hydrothermal stability. The zeolite synthesis normally undergoes high-temperature hydrothermal treatments with a relatively long crystallization time, which exhibits low synthesis efficiency and high energy consumption. Various strategies, e.g., modulation of the synthesis gel compositions, employment of special silica/aluminum sources, addition of seeds, fluoride, hydroxyl (·OH) free radical initiators, and organic additives, regulation of the crystallization conditions, development of new approaches, etc., have been developed to overcome these obstacles. And, these achievements make prominent contributions to the topic of acceleration of the zeolite crystallization and promote the fundamental understanding of the zeolite formation mechanism. However, there is a lack of the comprehensive summary and analysis on them. Herein, we provide an overview of the recent achievements, highlight the significant progress in the past decades on the developments of novel and remarkable strategies to accelerate the crystallization of zeolites, and basically divide them into three main types, i.e., chemical methods, physical methods, and the derived new approaches. The principles/acceleration mechanisms, effectiveness, versatility, and degree of reality for the corresponding approaches are thoroughly discussed and summarized. Finally, the rational design of the prospective strategies for the fast synthesis of zeolites is commented on and envisioned. The information gathered here is expected to provide solid guidance for developing a more effective route to improve the zeolite crystallization and obtain the functional zeolite-based materials with more shortened durations and lowered cost and further promote their applications.

Zeolite-Templated Carbons Supported Rh and Ru Electrocatalysts for Highly Active Hydrogen Evolution Reaction

Here, we report the systematical synthesis of zeolite-templated carbon (ZTC) supported Ru and Rh mono- or bi-metallic electrocatalysts towards hydrogen evolution reaction (HER). The zeolite A or ZSM-5 derived ZTC supports and metal sites were adjusted, and all electrocatalysts outperformed the commercial Pt/C electrocatalyst for HER performance. In particular, the RhRu/(ZTC/ZSM5) sample exhibited superior catalytic performance with the overpotential of 24.8 mV@10 mA ⋅ cm-2, and outstanding stability with 1 mV drop after 20000 cyclic voltammetry circles. This work offers a simple impregnation method for the synthesis of highly performed HER electrocatalysts supported on porous zeolite-templated carbon.

Controlling Crystal Morphology of Anisotropic Zeolites with Elemental Composition

The morphology of zeolite crystals strongly affects their textural, catalytic, and mechanical attributes. However, controlling zeolite crystal morphology without using modifiers or structure-directing agents remains a challenging task because of our limited understanding of the relationships between zeolite crystal shape, crystallization mechanism, and composition of the starting synthesis mixture. In this study, we aimed at developing a general method for controlling the morphology of zeolites by assessing the impact of the Si/T molar ratio of the synthesis gel on the growth rate of zeolite crystals in various crystallographic directions and on the final crystal morphology of the UTL germanosilicate with a 2D system of intersecting 14- and 12-ring pores. Our results showed that flat UTL crystals progressively thicken with the Si/Ge molar ratio, demonstrating that Ge concentration controls the relative rate of crystal growth in the perpendicular direction to the pore system. The morphology of other zeolites and zeotypes with an anisotropic structure, including AFI (12R), IFR (12R), MWW (10-10R), and IWW (12-10-8R), can also be predicted based on their Si/T ratio, suggesting a systematic pattern across zeolite structures and in a wide range of zeolite framework elements. Combined, these findings introduce a facile and cost-efficient method for directly controlling crystal morphology of zeolites with anisotropic structures with a high potential for scale-up while providing further insights into the role of elemental composition in zeolite crystal growth.

Fabrication of a ZIF-on-lamella-zeolite architecture as a highly efficient catalyst for aldol condensation

Designing composite catalysts that harness the strengths of individual components while mitigating their limitations is a fascinating yet challenging task in catalyst engineering. In this study, we aimed to enhance the catalytic performance by anchoring ZIF-67 nanoparticles of precise sizes onto lamella Si-MWW zeolite surfaces through a stepwise regrowth process. Co ions were initially grafted onto the zeolite surface using ultrasonication, followed by a seed-assisted secondary growth method. Si-MWW proved to be the ideal zeolite support due to its thin layered structure, large external surface area and substantial lateral dimensions. The abundant Si-OH groups on its surface played a crucial role in securely binding Co ions, limiting size growth and preventing undesirable ZIF-67 aggregation. The resulting ZIF-67/MWW composite with finely dispersed nano-scale ZIF-67 particles exhibited a remarkable catalytic performance and stability in the aldol condensation reactions involving acetone and various aldehydes. This approach holds promise for designing MOF/zeolite composite catalysts.

Porous Ionic Liquids Go Green

This Perspective points toward pathways to prepare porous ionic liquids using easily accessible materials, aiming for reduced environmental impact. We demonstrate that suspensions of porous solids are stable in eutectic mixtures, underscoring their potential for the preparation of porous ionic liquids. Porous ionic liquids retain the wide electrochemical window observed in their precursor pure ionic liquids, rendering them well-suited for green electrochemical reactions, particularly those involving gases whose solubility is enhanced in the porous suspensions. Moreover, their capacity as gas-rich media points to sustainable biomedical and pharmaceutical applications, provided nontoxic, biocompatible ionic liquids and porous solids are utilized.

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.

Realizing of ZSM-5 microspheres with enhanced catalytic properties prepared from iron ore tailings via solid-phase conversion method

The comprehensive utilization of iron ore tailings (IOTs) not only resolved environmental problems but also brought huge economic benefits. In this study, the synthetic route presented herein provides a novel method for the synthesis of ZSM-5 microspheres from IOTs. The effects of Si/Al molar ratios and the pH of the precursor solution on the formation of zeolite was evaluated by various analytical methods. The catalytic performance of the catalyst prepared by the solid-phase conversion method (denoted as MP-ZSM-5) was evaluated by methanol-to-propylene (MTP) reaction. Compared with the zeolite catalyst that synthesized via the conventional hydrothermal method (denoted as HM-ZSM-5), MP-ZSM-5 not only prolongs catalytic lifetime from 18.7 to 36.0 h but also has higher selectivity for propylene by MP-ZSM-5 (43.7%) than that for HM-ZSM-5 (38.6%). In addition, Kissinger-Akahira-Sunose (KAS) model is applied to the TG result to study the template removal process kinetics. The average activation energy values required for the removal of CTAB and TPABr are 201.11 ± 13.42 and 326.88 ± 16.91 kJ∙mol^-1, respectively. Furthermore, this result is well coupled with the model-free kinetic algorithms to determine the conversion and isoconversion of the TPABr and CTAB decomposition in ZSM-5, which serves as important guidelines for the industrial production process.

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.

Synthesized Zeolite Based on Egyptian Boiler Ash Residue and Kaolin for the Effective Removal of Heavy Metal Ions from Industrial Wastewater

The increase of global environmental restrictions concerning solid and liquid industrial waste, in addition to the problem of climate change, which leads to a shortage of clean water resources, has raised interest in developing alternative and eco-friendly technologies for recycling and reducing the amount of these wastes. This study aims to utilize Sulfuric acid solid residue (SASR), which is produced as a useless waste in the multi-processing of Egyptian boiler ash. A modified mixture of SASR and kaolin was used as the basic component for synthesizing cost-effective zeolite using the alkaline fusion-hydrothermal method for the removal of heavy metal ions from industrial wastewater. The factors affecting the synthesis of zeolite, including the fusion temperature and SASR: kaolin mixing ratios, were investigated. The synthesized zeolite was characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), particle size analysis (PSD) and N₂ adsorption-desorption. The SASR: kaolin weight ratio of 1:1.5 yields faujasite and sodalite zeolite with 85.21% crystallinity, which then shows the best composition and characteristics of the synthesized zeolite. The factors affecting the adsorption of Zn²⁺, Pb²⁺, Cu²⁺, and Cd²⁺ ions from wastewater on synthesized zeolite surfaces, including the effect of pH, adsorbent dosage, contact time, initial concentration, and temperature, have been investigated. The obtained results indicate that a pseudo-second-order kinetic model and Langmuir isotherm model describe the adsorption process. The maximum adsorption capacities of Zn²⁺, Pb²⁺, Cu²⁺, and Cd²⁺ ions onto zeolite at 20 °C were 12.025, 15.96, 12.247, and 16.17 mg·g^-1, respectively. The main mechanisms controlling the removal of these metal ions from aqueous solution by synthesized zeolite were proposed to be either surface adsorption, precipitation, or ion exchange. The quality of the wastewater sample obtained from the Egyptian General Petroleum Corporation (Eastern Desert, Egypt) was highly improved using the synthesized zeolite and the content of heavy metal ions was significantly reduced, which enhances the utilization of the treated water in agriculture.

Solid-State Synthesis of Aluminophosphate Zeotypes by Calcination of Amorphous Precursors

Because of the growing interest in the applications of zeolitic materials and the various challenges associated with traditional synthesis methods, the development of novel synthesis approaches remains of fundamental importance. Herein, we report a general route for the synthesis of aluminophosphate (AlPO) zeotypes by simple calcination of amorphous precursors at moderate temperatures (250-450 °C) for short reaction times (3-60 min). Accordingly, highly crystalline AlPO zeotypes with various topologies of AST, SOD, LTA, AEL, AFI, and -CLO, ranging from ultra-small to extra-large pores, have been successfully synthesized. Multinuclear multidimensional solid-state NMR techniques combined with complementary operando mass spectrometry (MS), powder X-ray diffraction, high-resolution transmission electron microscopy, and Raman characterizations reveal that covalently bonded fluoride in the intermediates catalyze the bond breaking and remaking processes. The confined organic structure-directing agents with high thermal stability direct the ordered rearrangement. This novel synthesis strategy not only shows excellent synthesis efficiency in terms of a simple synthesis procedure, a fast crystallization rate, and a high product yield, but also sheds new light on the crystallization mechanism of zeolitic materials.

Greenly synthesized zeolites as sustainable materials for corrosion protection: Design, technology and application

The progress and use of effective and economic anticorrosive resources are in high mandate due to huge safety and economic concerns about corrosion. Significant advancements have already been achieved that help in minimizing corrosion costs up to US $375 to US $875 billion annually. The use of zeolites in anticorrosive and self-healing coatings is well-studied and documented in many reports. The self-healing property of zeolite-based coatings is attributed to their ability to provide anticorrosive protection in the defected areas through forming protective oxide films i.e. passivation. The synthesis of zeolites from the traditional hydrothermal method is associated with several drawbacks including their high cost and discharge of harmful gases such as oxides of nitrogen (NO_x) and greenhouse gases (CO₂ and CO). In view of this, some green approaches such as solvent-free, organotemplate-free, use of safer organic templates, green solvents (e.g. ILs) and energy efficient (MW and US) heating, one-step reactions (OSRs) etc. are adopted in the green synthesis of zeolites. Recently, the self-healing properties of greenly synthesized zeolites are documented along with their mechanism of corrosion inhibition.

Fluoride-free and seed-free microwave-assisted hydrothermal synthesis of nanosized high-silica Beta zeolites for effective VOCs adsorption

High-silica Beta zeolites, typically synthesized by hydrothermal synthesis with the assistance of F^- or seeds, are highly important in volatile organic compounds (VOCs) adsorption. Fluoride-free or seed-free synthesis of high-silica Beta zeolites attracts great attention. Herein, highly dispersed Beta zeolites with a size of 25-180 nm and Si/Al ratios of 9-∞ were successfully synthesized by a microwave-assisted hydrothermal strategy. We have for the first time revealed that microwave irradiation can induce the formation of hydroxyl free radicals (˙OH), promoting the formation of the Si-O-Si bond. Thanks to the high total surface area, pore volume, and excellent hydrophobicity, the as-prepared pure-silica Beta zeolite presents a higher toluene adsorption capacity in VOCs adsorption compared to other pure-silica Beta zeolites prepared by traditional methods. This work provides a facile avenue for fluoride-free and seed-free synthesis of nanosized high-silica zeolites, promising their important applications in VOCs adsorption.

Direct synthesis of IDM-1 aluminosilicate nanosheets with improved MTP performance

Aluminosilicate nanosheets with pure IDM-1 structure, abbreviated as Al-I1, were rapidly synthesized by adjusting the F sources. Through preliminary aging, the length along the b-axis of Al-I1 was precisely tuned in the range of 40-200 nm and meanwhile the competitive growth to the MFI phase was suppressed. With improved mass transport owing to expanded pores and shortened diffusion path along the b-axis, the Al-I1 nanosheets exhibited superior catalytic performance to conventional b-axis oriented ZSM-5 in the methanol-to-propylene (MTP) reaction. The optimal Al-I1-40 catalyst with the thinnest thickness of 40 nm showed a long catalytic lifetime of 67 h and a high propylene selectivity of up to 57.1%.

Zeolites in Adsorption Processes: State of the Art and Future Prospects

Zeolites have been widely used as catalysts, ion exchangers, and adsorbents since their industrial breakthrough in the 1950s and continue to be state-of the-art adsorbents in many separation processes. Furthermore, their properties make them materials of choice for developing and emerging separation applications. The aim of this review is to put into context the relevance of zeolites and their use and prospects in adsorption technology. It has been divided into three different sections, i.e., zeolites, adsorption on nanoporous materials, and chemical separations by zeolites. In the first section, zeolites are explained in terms of their structure, composition, preparation, and properties, and a brief review of their applications is given. In the second section, the fundamentals of adsorption science are presented, with special attention to its industrial application and our case of interest, which is adsorption on zeolites. Finally, the state-of-the-art relevant separations related to chemical and energy production, in which zeolites have a practical or potential applicability, are presented. The replacement of some of the current separation methods by optimized adsorption processes using zeolites could mean an improvement in terms of sustainability and energy savings. Different separation mechanisms and the underlying adsorption properties that make zeolites interesting for these applications are discussed.

Zeolite greenly synthesized from fly ash and its resource utilization: A review

Fly ash is an incineration byproduct of thermal power plants. Due to the complex composition of fly ash, improper disposal will seriously harm the ecological environment. Therefore, how to effectively use fly ash to safely and environmentally replace landfills is a worldwide concern. Considering the high silicon and aluminum contents in fly ash, it has the potential to synthesize zeolite, which has a wide range of applications in sewage treatment, gas adsorption, etc. Therefore, the synthesis of zeolites from fly ash is consistent with the theme of sustainable development. The synthesis mechanism of zeolite, various synthetic methods of zeolite from fly ash and their advantages and disadvantages was introduced in detail. In addition, combined with the current research hotspots, the application of synthetic zeolite from fly ash in the fields of sewage treatment and gas adsorption was introduced. Finally, the future development prospects and research directions of synthetic zeolite from fly ash to improve the utilization rate of fly ash were considered.

Toward sustainability in zeolite manufacturing: An industry perspective

Conventional zeolite manufacturing processes are highly energy-intensive and come along with a significant carbon dioxide footprint. Here, we discuss the main energy consumers and potential alternatives toward a more sustainable production of zeolites: from simple optimization efforts on existing unit operations to new and novel manufacturing concepts such as the continuous crystallization and solidothermal route toward zeolites and their industrial applicability. These efforts contribute to the global effort into transitioning manufacturing of chemicals and catalysts to a net-zero environment by cutting greenhouse gas emissions to as close to zero as possible.

Recent advances in the synthesis of TS-1 zeolite

Heteroatomic zeolites as an important class of zeolites, have been widely applied in industrially catalytic processes due to their unique properties. As one of the most representative heteroatomic zeolites, titanosilicate zeolites have been extensively used in the selective oxidations of organic substrates with H2O2 such as cyclohexanone ammoximation, epoxidation of alkenes, and phenol hydroxylation. In this review, recent advances in the synthesis of TS-1 zeolite are briefly summarized, including use of low-cost raw materials (organic templates, silicon, and titanium sources), development of new synthesis routes (post-treatment synthesis, dry-gel conversion synthesis, solvent-free synthesis, and microwave-assisted synthesis), and new strategy for enhanced mass transfer in TS-1 crystals (synthesis of hierarchical and nanosized TS-1 zeolite). This review might help researchers to have a deep understanding on the synthesis of TS-1 zeolite and provide a new opportunity for the design and preparation of highly efficient TS-1 catalysts in the future.

Synthesis and Crystal Growth Mechanism of PST-2: An Aluminosilicate SBS/SBT Zeolite Intergrowth

The synthesis of PST-2, an aluminosilicate zeolite intergrowth of cage-based, large-pore SBS and SBT topologies, and its intergrowth characteristics are presented. With the Si/Al ratio and crystallization inorganic structure-directing agent in zeolite synthesis mixtures fixed to 8.0 and Cs⁺ ions, respectively, pure PST-2 is obtained at 120 °C using tetraalkylammonium ions with C/N⁺ ratios of 5-9 as a charge density mismatch (CDM) organic structure-directing agent (OSDA). More interestingly, the intergrowth ratio between SBS and SBT in PST-2 was found to vary notably not only with the type of CDM OSDA employed but also with the crystallization time, unlike the case of other well-known zeolite intergrowths such as β and MFI/MEL. When tetraethylammonium ions are used as a CDM OSDA at 100 °C in the presence of Cs⁺, the SBS portion in PST-2 decreases from over 60% to less than 45% with increasing crystallization time from 2.5 to 14 days, suggesting that SBS formation is kinetically more favorable than SBT formation. A thorough characterization of changes in the crystallite dimension of PST-2 with crystallization time, together with those in the chemical composition, allowed us to propose a plausible crystal growth mechanism of this large-pore zeolite intergrowth.

Crystalline chalcogenidometalate-based compounds from uncommon reaction media

Chalcogenides are one of the most versatile inorganic materials families, further subdivided into a large variety of specific groups of compounds, ranging from neat binary or multinary solids and nanoparticles of the same formal compositions, both in crystalline or non-crystalline form, to complicated open-framework structures and cluster compounds, also including organ(ometall)ic derivates of the latter. The large variety regarding both the compositions and the structures is associated with an enormous variety of properties, ranging from simple or high-tech pigments through a multitude of opto-electronic devices and electrolytes to materials for ion separation or high-sophisticated catalysts. Naturally, this also goes hand in hand with a corrosponding breadth of synthesis strategies. Traditionally, chalcogenides have been accessed via high-temperature methods, which continuously have been replaced by lower-temperature approaches for economical and ecological reasons. Moreover, more recent methods also showed that new types of chalcogenide materials can be obtained under such milder conditions that are not accessible via traditional routes. To shed light onto one of the numerous families of chalcogenides, this feature article summarizes current achievements in the generation of multinary chalcogenidometallate-based clusters and networks via non-classical routes, using ionic liquids, surfactants, or hydrazine as reaction media at moderately elevated termperature.

Recent Advances in the Seed-Directed Synthesis of Zeolites without Addition of Organic Templates

Zeolites have been widely employed in fields of petroleum refining, fine chemicals and environmental protection, but their syntheses are always performed in the presence of organic templates, which have many drawbacks such as high cost and polluted wastes. In recent years, the seed-directed synthesis of zeolites has been paid much attention due to its low-cost and environmentally friendly features. In this review, the seed-directed synthesis of Al-rich zeolites with homonuclear and heteronuclear features, the seed-directed synthesis of Si-rich zeolites assisted with ethanol and the utility of seed-directed synthesis have been summarized. This review could help zeolite researchers understand the recent progress of seed-directed synthesis.

First-Generation Organic Reaction Intermediates in Zeolite Chemistry and Catalysis

Zeolite chemistry and catalysis are expected to play a decisive role in the next decade(s) to build a more decentralized renewable feedstock-dependent sustainable society owing to the increased scrutiny over carbon emissions. Therefore, the lack of fundamental and mechanistic understanding of these processes is a critical "technical bottleneck" that must be eliminated to maximize economic value and minimize waste. We have identified, considering this objective, that the chemistry related to the first-generation reaction intermediates (i.e., carbocations, radicals, carbenes, ketenes, and carbanions) in zeolite chemistry and catalysis is highly underdeveloped or undervalued compared to other catalysis streams (e.g., homogeneous catalysis). This limitation can often be attributed to the technological restrictions to detect such "short-lived and highly reactive" intermediates at the interface (gas-solid/solid-liquid); however, the recent rise of sophisticated spectroscopic/analytical techniques (including under in situ/operando conditions) and modern data analysis methods collectively compete to unravel the impact of these organic intermediates. This comprehensive review summarizes the state-of-the-art first-generation organic reaction intermediates in zeolite chemistry and catalysis and evaluates their existing challenges and future prospects, to contribute significantly to the "circular carbon economy" initiatives.

Minute-Scale Synthesis of Nano Silicalite-1 Zeolites

Synthesis of zeolites in more efficient and greener methods is of great significance in both industrial and academic fields. However, the relative long time for zeolite crystallization and much consumption of water solvent make the target challengeable. Herein, a route for ultrafast synthesis of nano Silicalite-1 zeolites in 10 min with much less water consumption has been developed. Comprehensive characterizations, i.e., X-ray powder diffraction, N₂ sorption, scanning electron microscope, and NMR, confirm the high quality of such obtained Silicalite-1 zeolites. In the catalytic deoxygenation of O₂-containing ethylene (mixture of O₂ and ethylene), these reported Silicalite-1 zeolite samples show the comparable performance with the conventional Silicalite-1 zeolites synthesized under hydrothermal conditions. This research therefore provides a new trial toward the ultrafast synthesis of zeolite materials in an environment-friendly route.

Sn-Beta Catalyzed Transformations of Sugars—Advances in Catalyst and Applications

Beta zeolite modified with Sn in the framework (Sn-Beta) was synthesized and introduced as a heterogeneous catalyst for Baeyer–Villiger oxidations about twenty years ago. Since then, both syntheses strategies, characterization and understanding as well as applications with the material have developed significantly. Remarkably, Sn-Beta zeolite has been discovered to exhibit unprecedented high catalytic efficiency for the transformation of glucose to fructose (i.e., aldoses to ketoses) and lactic acid derivatives in both aqueous and alcoholic media, which has inspired an extensive interest to develop more facile and scalable syntheses routes and applications for sugars transformations. This review survey the progress made on both syntheses approaches of Sn-Beta and applications of the material within catalyzed transformations of sugar, including bottom-up and top-down syntheses and catalyzed isomerization, dehydration, and fragmentation of sugars.

Lignin as a Bio-Sourced Secondary Template for ZSM-5 Zeolite Synthesis

The aim of this study was to investigate the effect of the addition of lignin as a sacrificial agent in ZSM-5 zeolite synthesis. Peculiar growths of ZSM-5 crystals leading to various textural properties were observed. Hence, the behavior in acid-catalyzed conversion of methanol into hydrocarbons (MTH) shifted from high selectivity toward olefins (>55%) to the sole formation of dimethyl ether (DME). Lignin acted as a bio-sourced secondary template (BSST), impacting the zeolite crystals’ shape and, thus, their physicochemical properties.

Insight into Crystallization Features of MOR Zeolite Synthesized via Ice-Templating Method

Hydrothermal, solvothermal or ionothermal routes are usually employed for the synthesis of zeolite, which is often accompanied by a high energy consumption, high cost and low efficiency. We have developed a novel route for the rapid and high yield synthesis of mordenite (MOR) zeolite via an ice-templating method. In comparison with traditional hydrothermal synthesis, not only the high yield, but also the superior crystallinity, large reduction in water level and reaction pressure, simple device and conventional silica sources by this route can have great potential for the commercial production of pure MOR zeolite. Moreover, the changed bonding environment of silicon atoms in MOR zeolite, that is, a relative decrease in the tetrahedrally coordinated Si–O–Si bond, and accordingly, an increase in the T–OH (T = Si, Al) groups and Si–O–Al sites, remarkably enhances its acid strength.

Efficient Etherification of 2,5-Bis(hydroxymethyl)furan to 2,5-Bis(propoxymethyl)furan by an Amorphous Silica-Alumina Catalyst in a Fixed-Bed Reactor

The efficient etherification of 2,5-bis(hydroxymethyl)furan (BHMF) to 2,5-bis(propoxymethyl)furan (BPMF) was achieved by using low-cost amorphous silica-aluminas (ASA) catalysts in a fixed-bed reactor. A considerable yield of BPMF up to 85.1 % was obtained over ASA-30 catalyst under the reaction conditions of 140 °C, 2.0 MPa of N2 , and 0.015 h-1 of WHSV. The excellent performance of ASA-30 catalyst could be attributed to the relatively stronger acidity (>375 °C) and larger mesoporous size (6 nm), thereby facilitating the conversion of BHMF to BPMF. In addition, the lower ratio of Brønsted/Lewis acid sites for ASA catalyst was found to efficiently suppress the occurrence of side reactions.

Investigation into the crystallization of molecular sieve DNL-6

Crystallization of DNL-6, a silicoaluminophosphate (SAPO) based molecular sieve with the RHO topology, was investigated under both the hydrothermal synthesis (HTS) and dry-gel conversion (DGC) conditions. Crystallization of DNL-6 under the HTS conditions is rather fast. But a combination of crystallization under the DGC conditions and reducing reaction temperature slow down the reactions, allowing for intermediates to be captured. Under the DGC conditions, DNL-6 crystallizes through a semi-crystalline layered phase. The nature of this intermediate is aluminophosphate (AlPO) rather than SAPO with most P atoms having a local environment of P(–O–Al)3(OH). The surfactant (cetyltrimethylammonium chloride) used for synthesis appears to be part of the layered intermediate. Si is directly incorporated in the DNL-6 framework via SM II mechanism when the semi-crystalline AlPO phase is transforming to DNL-6 with the assistance of a very small amount of water. Both the structure directing agent and the surfactant play a role in the formation of DNL-6, as they were found within the final synthesized products. SEM data show that hydrothermal synthesis produces a much more crystalline product. The facts that the semi-crystalline layered phase was also observed in the powder X-ray diffraction patterns of the solid samples obtained under the HTS conditions and that the evolution of the local structure around P and Al in the intermediate phases are similar imply that under the reaction conditions employed in the present study, the formation pathways of DNL-6 under the HTS and DGC conditions appear to have some similarities.

Anion-promoted increase of the SiO2/Al2O3 ratio of zeolites

Increasing the SiO2/Al2O3 ratio (SAR) of zeolites is crucial for enhancing their acidic catalysis performance and thermal/hydrothermal stability. In this work, we reported a facile strategy to improve the SAR...

Steam-assisted crystallization of highly dispersed nanosized hierarchical zeolites from solid raw materials and their catalytic performance in lactide production

A solvent-free route based on solid raw materials affords higher product yield and lower waste production compared to the traditional hydrothermal synthesis. However, the as-made zeolites usually present blocky aggregation states, limiting their mass transfer and exposure of active sites in catalytic applications. Herein, highly dispersed nanosized hierarchical Beta zeolites with varied Si/Al ratios were prepared via steam-assisted crystallization from ball-milled solid raw materials. Thanks to the sufficient mixing of solid raw materials and favorable migration of solid mixture, nanosized Beta zeolites are obtained that are assembled from nanoparticles (∼15 nm) and possess abundant interconnected intraparticle mesopores. The strategy can also be extended to synthesize nanosized hierarchical ZSM-5 zeolites. The as-prepared Beta zeolite (Si/Al = 10) exhibits outstanding catalytic performance in conversion of lactic acid to lactide (as high as 77.5% in yield). This work provides avenues for simple and cost-efficient synthesis of highly dispersed nanosized hierarchical zeolites, promising their important catalytic applications.

A cost-effective synthesis strategy based on steam-assisted crystallization from ball-milled solid raw materials is developed to prepare a highly dispersed nanosized hierarchical Beta zeolite for conversion of lactic acid (LA) to lactide (LT).

Organotemplate-free synthesis of Al-rich ZSM-35 and ZSM-22 zeolites with the addition of ZSM-57 zeolite seeds

An organotemplate-free synthesis of Al-rich ZSM-35 (Si/Al ratio at about 5) and ZSM-22 (Si/Al ratio at about 20) zeolites has been successfully shown with the addition of ZSM-57 zeolite seeds in the absence of organic templates.

OUP accepted manuscript

The rational design synthesis of zeolite catalysts with effective, environmentally benign and atom-economic routes is a major topic in the field of microporous materials, as it would avoid the high labor cost and inefficiency of traditional trial-and-error methods in developing new structures and dispel environmental concerns regarding the industrial mass production of zeolites. Catalytic applications of zeolite materials have expanded from conventional single functionalities, such as solid acids or selective oxidation catalysts to bi/multifunctionalities through combination with metals or metal oxides. This is a response to new requirements from petrochemical and fine chemical industries, such as precise control of product distribution, conversion of low-carbon resources for chemical production, and solutions to increasingly severe environmental problems related to CO₂ and NO_x. Thus, based on the systematic knowledge of zeolite chemistry and science that researchers have acquired in the past half-century and the development requirements, remarkable progress has been made in zeolite synthesis and catalysis in the past 10 years. This includes the manipulation of zeolitic monolayers derived from layered zeolites and germanosilicates to construct novel zeolite materials and effective and green zeolite syntheses as well as the synergistic interaction of zeolites and metal/metal oxides with different space distributions in the conversion of low-carbon resources. With many zeolite catalysts and catalytic processes being developed, our understanding of the close relationship between zeolite synthesis, structure and catalytic properties has deepened. Researchers are gradually approaching the goal of rationally designing zeolite catalysts with precisely controlled activity and selectivity for particular applications.

Zeolites in catalysis: sustainable synthesis and its impact on properties and applications

Zeolites are versatile catalysts not only for large scale petrochemical processes but also in applications related to fine chemicals synthesis, biomass conversion and CO2 utilization. Introduction of mesopores and heteroatoms...