Thermochemistry of microporous and mesoporous 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.

Illuminating the Black Box: A Perspective on Zeolite Crystallization in Inorganic Media

ConspectusSince the discovery of synthetic zeolites in the 1940s and their implementation in major industrial processes involving adsorption, catalytic conversion, and ion exchange, material scientists have targeted the rational design of zeolites: controlling synthesis to crystallize zeolites with predetermined properties. Decades later, the fundamentals of zeolite synthesis remain largely obscured in a black box, rendering rational design elusive. A major prerequisite to rational zeolite design is to fully understand, and control, the elementary processes governing zeolite nucleation, growth, and stability. The molecular-level investigation of these processes has been severely hindered by the complex multiphasic media in which aluminosilicate zeolites are typically synthesized. This Account documents our recent progress in crystallizing zeolites from synthesis media based on hydrated silicate ionic liquids (HSIL), a synthesis approach facilitating the evaluation of the individual impacts of synthesis parameters such as cation type, water content, and alkalinity on zeolite nucleation, growth, and phase selection. HSIL-based synthesis allows straightforward elucidation of the relationship between the characteristics of the synthesis medium and the properties and structure of the crystalline product. This assists in deriving new insights in zeolite crystallization in an inorganic aluminosilicate system, thus improving the conceptual understanding of nucleation and growth in the context of inorganic zeolite synthesis in general. This Account describes in detail what hydrated silicate ionic liquids are, how they form, and how they assist in improving our understanding of zeolite genesis on a molecular level. It describes the development of ternary phase diagrams for inorganic aluminosilicate zeolites via a systematic screening of synthesis compositions. By evaluating obtained crystal structure properties such as framework composition, topology, and extraframework cation distributions, critical questions are dealt with: Which synthesis variables govern the aluminum content of crystallizing zeolites? How does the aluminum content in the framework determine the expression of different topologies? The crucial role of the alkali cation, taking center stage in all aspects of crystallization, phase selection, and, by extension, transformation is also discussed. New criteria and models for phase selection are proposed, assisting in overcoming the need for excessive trial and error in the development of future synthesis protocols.Recent progress in the development of a toolbox enabling liquid-state characterization of these precursor media has been outlined, setting the stage for the routine monitoring of zeolite crystallization in real time. Current endeavors on and future needs for the in situ investigation of zeolite crystallization are highlighted. Finally, experimentally accessible parameters providing opportunities for modeling zeolite nucleation and growth are identified. Overall, this work provides a perspective toward future developments, identifying research areas ripe for investigation and discovery.

Does Water Enable Porosity in Aluminosilicate Zeolites? Porous Frameworks versus Dense Minerals

Recently identified zeolite precursors consisting of concentrated, hyposolvated homogeneous alkalisilicate liquids, hydrated silicate ionic liquids (HSIL), minimize correlation of synthesis variables and enable one to isolate and examine the impact of complex parameters such as water content on zeolite crystallization. HSIL are highly concentrated, homogeneous liquids containing water as a reactant rather than bulk solvent. This simplifies elucidation of the role of water during zeolite synthesis. Hydrothermal treatment at 170 °C of Al-doped potassium HSIL with chemical composition 0.5SiO₂:1KOH:xH₂O:0.013Al₂O₃ yields porous merlinoite (MER) zeolite when H₂O/KOH exceeds 4 and dense, anhydrous megakalsilite when H₂O/KOH is lower. Solid phase products and precursor liquids were fully characterized using XRD, SEM, NMR, TGA, and ICP analysis. Phase selectivity is discussed in terms of cation hydration as the mechanism, allowing a spatial cation arrangement enabling the formation of pores. Under water deficient conditions, the entropic penalty of cation hydration in the solid is large and cations need to be entirely coordinated by framework oxygens, leading to dense, anhydrous networks. Hence, the water activity in the synthesis medium and the affinity of a cation to either coordinate to water or to aluminosilicate decides whether a porous, hydrated, or a dense, anhydrous framework is formed.

Metal cations as inorganic structure-directing agents during the synthesis of phillipsite and tobermorite

Metal cation identity determines the zeolite topology. Framework topology determines the total zeolite cationic content. Potassium predominantly counterbalances Al anions; sodium and calcium are predominantly structure-directing agents.

Structural Aspects Affecting Phase Selection in Inorganic Zeolite Synthesis

A guideline for zeolite phase selection in inorganic synthesis media is proposed, based on a systematic exploration of synthesis from inorganic media using liquid Na⁺, K⁺, and Cs⁺ aluminosilicate. Although the Si/Al ratio of the zeolites is a continuous function of the synthesis conditions, boundaries between topologies are sharp. The here-derived phase selection criterion relates the obtained zeolite topology to the Si/Al ratio imposed by the synthesis medium. For a given Si/Al ratio, the framework with the highest occupation of topologically available cation sites is favored. The large number of published zeolite syntheses supporting the observation provides strong indication that the concept is applicable in a larger context. The proposed criterion explains how minor variations in the composition of inorganic synthesis media induce the commonly occurring, abrupt changes in topology. It highlights underlying reasons causing the strict demarcation of stability fields of the as-synthesized zeolites experimentally observed in inorganic synthesis.

Ion-Pairs in Aluminosilicate-Alkali Synthesis Liquids Determine the Aluminum Content and Topology of Crystallizing Zeolites

Using hydrated silicate ionic liquids, phase selection and framework silicon-to-aluminum ratio during inorganic zeolite synthesis were studied as a function of batch composition. Consisting of homogeneous single phasic liquids, this synthesis concept allows careful control of crystallization parameters and evaluation of yield and sample homogeneity. Ternary phase diagrams were constructed for syntheses at 90 °C for 1 week. The results reveal a cation-dependent continuous relation between batch stoichiometry and framework aluminum content, valid across the phase boundaries of all different zeolites formed in the system. The framework aluminum content directly correlates to the type of alkali cation and gradually changes with batch alkalinity and dilution. This suggests that the observed zeolites form through a solution-mediated mechanism involving the concerted assembly of soluble cation-oligomer ion pairs. Phase selection is a consequence of the stability for a particular framework at the given aluminum content and alkali type.

Hierarchical Catalysts Prepared by Interzeolite Transformation

Interzeolite transformation has been used to produce a novel family of hierarchical catalysts featuring excellent textural properties, strong acidity, and superior catalytic performance for the Friedel-Crafts alkylation of indole with benzhydrol, the Claisen-Schmidt condensation of benzaldehyde and hydroxyacetophenone, and the cracking of polystyrene. Intermediate solids of the FAU interzeolite transformation into BEA display both increased accessibility─due to the development of mesoporosity─and strong acidity─caused by the presence of ultrasmall crystals or zeolitic fragments in their structure. The use of surfactants allows for the development of the hierarchical catalysts with very narrow pore size distribution. The properties of interzeolite transformation intermediates (ITIs) can be fine-tuned simply by stopping the interconversion at different times.

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.

Revealing scenarios of interzeolite conversion from FAU to AEI through the variation of starting materials

Interzeolite conversion, which refers to the synthesis of zeolites using a pre-made zeolite as the starting material, has enabled promising outcomes that could not be easily achieved by the conventional synthesis from a mixture of amorphous aluminum and silicon sources. Understanding the mechanism of interzeolite conversion is of particular interest to exploit this synthesis route for the preparation of tailor-made zeolites as well as the discovery of new structures. It has been assumed that the structural similarity between the starting zeolite and the target one is crucial to a successful interzeolite conversion. Nevertheless, an image as to how one type of zeolite evolves into another one remains unclear. In this work, a series of dealuminated FAU zeolites were created through acid leaching and employed as the starting zeolites in the synthesis of AEI zeolite under various conditions. This experimental design allowed us to create a comprehensive diagram of the interzeolite conversion from FAU to AEI as well as to figure out the key factors that enable this kinetically favourable crystallization pathway. Our results revealed different scenarios of the interzeolite conversion from FAU to AEI and pinpointed the importance of the structure of the starting FAU in determining the synthesis outcomes. A prior dealumination was proven effective to modify the structure of the initial FAU zeolite and consequently facilitate its conversion to the AEI zeolite. In addition, this strategy allowed us to directly transfer the knowledge obtained from the interzeolite conversion to a successful synthesis of the AEI zeolite from dealuminated amorphous aluminosilicate precursors. These results offer new insights to the design and fabrication of zeolites via the interzeolite conversion as well as to the understandings of the crystallization mechanisms.

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.

An intrinsic synthesis parameter governing the crystallization of silico(zinco)aluminophosphate molecular sieves

One of the most fundamental but yet unanswered questions in the synthesis of zeolites and zeolite-like materials is whether or not any parameter controlling the microporosity of the crystallized product from synthesis mixtures with feasible chemical compositions exists. Here we report that an experimentally optimized parameter (ca. 3.3 ≤ MOH/P₂O₅ ≤ 5.3, where M is alkali metal ions) is the criterion bringing about the successful formation of various high-charge-density silicoaluminophosphate (SAPO) and zincoaluminophosphate (ZnAPO) molecular sieves, without the aid of organic structure-directing agents. The materials obtained using this empirical concept include SAPO molecular sieves with CHA and LTA topologies, as well as a SAPO FAU/EMT intergrowth, and ZnAPO ones with CZP and SOD topologies. This study demonstrates the existence of an essential factor determining not only phase selectivity but also microporosity (0.3-2 nm) in the synthesis of zeotypes with charged frameworks which may offer interesting opportunities for more efficiently producing novel zeolite structures and/or compositions.

Thermodynamics of Water-Cationic Species-Framework Guest-Host Interactions within Transition Metal Ion-Exchanged Mordenite Relevant to Selective Anaerobic Oxidation of Methane to Methanol

Low-temperature anaerobic methane conversion to methanol (MTM) using copper ion-exchanged mordenite (Cu-MOR) as the catalyst and water as the sole source of oxygen is promising for sustainable utilization of methane. Integrating in situ calorimetric, spectroscopic, and structural methodologies, we report a systematic study on energetics of water-cationic species-framework guest-host interactions as a function of water loading for several mordenites relevant to low-temperature MTM. Notably, the near-zero coverage hydration enthalpy on Cu-MOR is -133.1 ± 6.0 kJ/mol water, which is related to Cu-MOR regeneration using water as oxidant. The copper oxo sites are thermally stable up to 915 °C and remain chemically intact as an oxygen source after complete hydration and dehydration. This study underscores the importance of manipulating the oxidation state and coordination chemistry of transition metal guest species in zeolites by fine-tuning the partial pressure of water as a strategy for rational design, synthesis, and modification of catalysts.

Self-organization of silicates on different length scales exemplified by amorphous mesoporous silica and mesoporous zeolite beta using multiammonium surfactants

In this study the structure directing effect of a gemini-type piperidine-based multi-ammonium surfactant during hydrothermal zeolite synthesis was investigated for two cases: with and without a source of aluminum. The absence of an aluminum source led to the formation of an amorphous mesoporous MCM-48 type silica material, while the presence of aluminum guaranteed the formation of zeolite beta with a hierarchical pore system. The two opposing cases were studied in a time and temperature-dependent manner. The mobility and through space interaction of these large surfactant molecules were studied by liquid state nuclear magnetic resonance (NMR) at a temperature relevant to hydrothermal synthesis (363 K) in pure water and upon addition of an aluminum and silicon source. In the gel state, at different stages of aging and hydrothermal synthesis, low angle X-ray diffraction (XRD) and solid state magic angle spinning nuclear magnetic resonance (¹H MAS NMR) spectrometry determined the developing order within the system. At each of these different synthesis steps the respective intermediate materials were calcined. Transmission electron microscopy then allowed closer inspection of the locally developing mesoscopic order, while N₂ physisorption was used to follow the evolution of porosity.

Reaction gels containing piperidine-based multi-ammonium OSDA yield hierarchical nano-beta zeolite in the presence of aluminum and amorphous mesoporous silica without aluminum, illustrating the highly complex thermodynamic course of zeolite formation.

Linking synthesis and structure descriptors from a large collection of synthetic records of zeolite materials

Correlating synthesis conditions and their consequences is a significant challenge, particularly for materials formed as metastable phases via kinetically controlled pathways, such as zeolites, owing to a lack of descriptors that effectively illustrate the synthesis protocols and their corresponding results. This study analyzes the synthetic records of zeolites compiled from the literature using machine learning techniques to rationalize physicochemical, structural, and heuristic insights to their chemistry. The synthesis descriptors extracted from the machine learning models are used to identify structure descriptors with the appropriate importance. A similarity network of crystal structures based on the structure descriptors shows the formation of communities populated by synthetically similar materials, including those outside the dataset. Crossover experiments based on previously overlooked structural similarities reveal the synthesis similarity of zeolites, confirming the synthesis–structure relationship. This approach is applicable to any system to rationalize empirical knowledge, populate synthesis records, and discover novel materials.

Understanding zeolite synthesis-structure relationships remains challenging owing to the number of variables involved in their preparation. Here the authors analyze zeolite synthetic records from the literature via machine learning and find communities of synthetically related materials with previously overlooked similarities.

Thermochemistry of Surfactant-Templating of USY Zeolite

With the aim of understanding the thermochemistry of the introduction of mesoporosity in zeolites by using surfactants, high temperature oxide melt solution calorimetry was used to determine the change in the enthalpy of formation of USY zeolite before and after the introduction of mesoporosity. Our results confirm that this process only slightly destabilizes the zeolite by the additional surface area. However, this can be overcome by the stabilizing effect of the interactions between the surfactant and the zeolite framework.

A Machine Learning Approach to Zeolite Synthesis Enabled by Automatic Literature Data Extraction

Zeolites are porous, aluminosilicate materials with many industrial and "green" applications. Despite their industrial relevance, many aspects of zeolite synthesis remain poorly understood requiring costly trial and error synthesis. In this paper, we create natural language processing techniques and text markup parsing tools to automatically extract synthesis information and trends from zeolite journal articles. We further engineer a data set of germanium-containing zeolites to test the accuracy of the extracted data and to discover potential opportunities for zeolites containing germanium. We also create a regression model for a zeolite's framework density from the synthesis conditions. This model has a cross-validated root mean squared error of 0.98 T/1000 Å3, and many of the model decision boundaries correspond to known synthesis heuristics in germanium-containing zeolites. We propose that this automatic data extraction can be applied to many different problems in zeolite synthesis and enable novel zeolite morphologies.

Benchmarking the performance of approximate van der Waals methods for the structural and energetic properties of SiO2 and AlPO4 frameworks

Density functional theory (DFT) calculations using sixteen different approaches, fourteen of which were designed to include dispersion interactions [DFT + D and van der Waals (vdW)-DF methods], were performed for a set of sixteen framework compounds with either SiO₂ or AlPO₄ composition. The compounds include four dense structures (α-quartz, α-cristobalite, and their AlPO₄ analogues), eight all-silica zeolites, and four aluminophosphate zeotypes (AlPOs). We analyzed the performance in reproducing the equilibrium structure for all systems, and computed bulk moduli and relative stabilities were compared to experiments for those compounds where experimental data are available. We found that the results obtained with functionals that take into account dispersive interactions are closer to experiments than those obtained with a bare generalized gradient functional. However, the variation among individual methods is considerable, and functionals that perform well for one quantity may give rather large deviations for another. Taking together the whole body of results, it appears that the Perdew-Burke-Ernzerhof functional including a many-body dispersion correction and the rev-vdW-DF2 methods present the best performance for the description of SiO₂ and AlPO₄ materials.

Ultrafast synthesis of zeolites: breakthrough, progress and perspective

An ultrafast route was established to synthesize industrially important zeolites in several minutes, which represents a breakthrough in the field of zeolite synthesis.

Continuous flow synthesis of ordered porous materials: from zeolites to metal–organic frameworks and mesoporous silica

Herein we review the concepts, challenges and recent developments on the continuous flow synthesis of ordered porous materials.

The Energetics of Surfactant-Templating of Zeolites

Mesoporosity can be conveniently introduced into zeolites by treating them in basic surfactant solutions. The apparent activation energy involved in the formation of mesopores in USY by surfactant-templating was determined using a combination of in situ synchrotron X-ray diffraction and ex situ gas adsorption. Additionally, techniques such as pH measurement and thermogravimetry/differential thermal analysis were employed to determine OH^- evolution and cetyltrimethylammonium ion (CTA⁺ ) uptake during the development of mesoporosity, thereby providing information about the different steps involved. The combination of both in situ and ex situ techniques has allowed determination of the apparent activation energies of the different processes involved in the mesostructuring of USY zeolites for the first time. Apparent activation energies are of the same order of magnitude (30-65 kJ mol^-1 ) as those involved in the crystallization of zeolites. Hence, important mechanistic insight into the surfactant-templating method was obtained.

Ultrasonic vs hydrothermal method: Different approaches to convert fly ash into zeolite. How they affect the stability of synthetic products over time?

The action of direct sonication (US) versus conventional hydrothermal method (HY) was investigated to determine the differences in the crystallization mechanism of zeolite formed from fly ash. The results showed that ultrasonic energy is decisive in very fast faujasite and A-type zeolite transformation into more stable sodalite phase. The data display the main presence of sodalite together with a low amount of faujasite and zeolite A after the first 3 h of sonication. The full transformation of the latter two phases into sodalite takes place after 1 h more of treatment. The samples incubated by hydrothermal process for 3 h, instead, are characterized by the main presence of faujasite and A-type zeolites. The progressive synthesis of sodalite at the expense of the other two phases begins only after 4 h of treatment. The conclusion is that the crystallization of zeolites by ultrasonic and hydrothermal method proceeds via two different mechanisms. The data also show that the two approaches affect the stability of the synthetic products in a different way over the years.

Selecting strong Brønsted acid zeolites through screening from a database of hypothetical frameworks

New candidate zeolites with potentially strong Brønsted acidity have been computationally selected from the Treacy/Foster database of prospective zeolites.

Enantiopure anion templated synthesis of a zeolitic metal-organic framework

Utilizing (R)-H3CIA as a chiral template, an unprecedented homochiral metal-organic framework (MOF) with zeotype GIS topology is obtained from achiral 1.4-DIB ligands and Zn(II) ions, which opens up a feasible approach to create zeolitic MOFs with homochirality.

Establishing hierarchy: the chain of events leading to the formation of silicalite-1 nanosheets

In applying a multi-scale spectroscopic and computational approach, we demonstrate that the synthesis of stacked zeolite silicalite-1 nanosheets, in the presence of a long-tail diquaternary ammonium salt surfactant, proceeds through a pre-organised phase in the condensed state. In situ small-angle X-ray scattering, coupled to paracrystalline theory, and backed by electron microscopy, shows that this phase establishes its meso-scale order within the first five hours of hydrothermal synthesis. Quasi in situ vibrational and solid-state NMR spectroscopy reveal that this meso-shaped architecture already contains some elementary zeolitic features. The key to this coupled organisation at both micro- and meso-scale, is a structure-directing agent that is ambifunctional in shaping silica at the meso-scale whilst involved in molecular recognition at the micro-scale. The latter feature is particularly important and requires the structure-directing agent to reside within the silica matrix already at early stages of the synthesis. From here, molecular recognition directs stabilization of precursor species and their specific embedding into a lattice, as shown by force-field molecular dynamics calculations. These calculations, in line with experiment, further show how it is possible to subtly tune both the zeolite topology and aspect ratio of the condensating crystals, by modifying the headgroup of the structure-directing agent.

Pegylated folate and peptide-decorated graphene oxide nanovehicle for in vivo targeted delivery of anticancer drugs and therapeutic self-monitoring

This work reports a graphene oxide-based nanovehicle with conjugation of pegylated folate for targeted delivery of anticancer drugs and fluorescein-labeled peptide for therapeutic self-monitoring in vitro and in vivo. The nanovehicle could absorb hydrophobic and aromatic drug molecules with high loading capacity and efficiency of more than 1.7 mg mg(-1) and 90%, respectively. MTT and flow cytometric assays demonstrated that the drug-loaded nanovehicle could specifically transport and release the drugs into the folate receptor high-expressed cancer cells, which ensured a high therapeutic efficiency to cancer cells and prevented the injury to normal cells. Moreover, confocal fluorescence imaging confirmed that the drug-induced cancer cell death could be visualized with the light-up fluorescence of fluorescein activated by caspase-3. The targeted delivery of drug and self-evaluation of therapeutic efficacy were further successfully realized by living imaging in tumor-bearing mice, which broaden the applications of this theranostic system in vivo and may offer new opportunities for precise cancer treatment.