Synthesis of aluminosilicate and gallosilicate zeolites via a charge density mismatch approach and their characterization

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.

Highly efficient synthesis of zeolite chabazite using cooperative hydration-mismatched inorganic structure-directing agents

Chabazite (CHA type) zeolite is notoriously difficult to synthesize in the absence of organic structure-directing agents owing to long synthesis times and/or impurity formation. The ability to tailor organic-free syntheses of zeolites is additionally challenging due to the lack of molecular level understanding of zeolite nucleation and growth pathways, particularly the role of inorganic cations. In this study, we reveal that zeolite CHA can be synthesized using six different combinations of inorganic cations, including the first reported seed- and organic-free synthesis without the presence of potassium. We show that lithium, when present in small quantities, is an effective accelerant of CHA crystallization; and that ion pairings can markedly reduce synthesis times and temperatures, while expanding the design space of zeolite CHA formation in comparison to conventional methods utilizing potassium as the sole structure-directing agent. Herein, we posit the effects of cation pairings on zeolite CHA crystallization are related to their hydrated ionic radii. We also emphasize the broader implications for considering the solvated structure and cooperative role of inorganic cations in zeolite synthesis within the context of the reported findings for chabazite.

Atom-Selective Analyses Reveal the Structure-Directing Effect of Cs Cation on the Synthesis of Zeolites

To understand the crystallization mechanism of zeolites, it is important to clarify the detailed role of the structure-directing agent, which is essential for the crystallization of zeolite, interacting with an amorphous aluminosilicate matrix. In this study, to reveal the structure-directing effect, the evolution of the aluminosilicate precursor which causes the nucleation of zeolite is analyzed by the comprehensive approach including atom-selective methods. The results of total and atom-selective pair distribution function analyses and X-ray absorption spectroscopy indicate that a crystalline-like coordination environment gradually forms around Cs cations. This corresponds to the fact that Cs is located at the center of the d8r units in the RHO structure whose unit is unique in this zeolite, and a similar tendency is also confirmed in the ANA system. The results collectively support the conventional hypothesis that the formation of the crystalline-like structure before the apparent nucleation of the zeolite.

Computational elucidation of the aging time effect on zeolite synthesis selectivity in the presence of water and diquaternary ammonium iodide

An example of zeolite selectivity (MFI → MOR) driven by synthesis aging time has been studied. Using N,N,N',N'-tetramethyl-N,N'-dipropyl-ethylenediammonium diiodide (TMDP) as an organic structure-directing agent (OSDA), the zeolite phases obtained at 2 h (MFI 97%), 8 h (MFI 84%, MOR 16%) and 24 h (MFI 43%, MOR 57%) have been characterized by powder X-ray diffraction. The results suggest that at intermediate aging time, namely 8 h and 24 h, the dominant phase (MFI) is displaced by MOR. Different techniques (FT-IR, Raman, ¹³C MAS NMR, TGA/DTG and HC microanalysis) have been employed to verify the OSDA integrity and occlusion inside the zeolite micropores as well as to quantify the water and OSDA loading. The ¹H MAS NMR of the as-made occluded zeolite was compared with the spectra of TMDP and the recovered OSDA from the sample by extraction with water. The comparison indicated that TMDP was not structurally intact, indicating the chemical transformation of TMDP to imidazolinium homologues through the Hofmann degradation process. Furthermore, careful acidic breakdown of the aluminosilicate shell, covered on the zeolite samples by hydrofluoric acid, revealed that the remaining OSDA had been partially degraded to lower molecular weight ammonium salt, confirmed by ¹H NMR and mass spectrometry measurements. A computational study was performed by using a force field based methodology, including accurate loading of water and OSDA in the zeolite (MFI and MOR) unit cells. The results show an important contribution of the presence of water. The samples with larger aging time (8 h and 24 h) incorporate less water and show partial TMDP degradation, whilst at the shortest aging time (2 h), there is a larger water content and TMDP remains intact. The larger accessible volume of MFI justifies that this is the dominant phase at short aging times (large water content) since it can accommodate a larger number of water molecules than MOR. The OSDA partial degradation also plays a role. At longer aging times the partial OSDA decomposition has been considered in the models by including TMDP + Imidaz, which is more stabilized by MOR, whilst at shorter aging times the only OSDA present, TMDP, is better stabilized by MFI.

3D-3D topotactic transformation in aluminophosphate molecular sieves and its implication in new zeolite structure generation

Zeolites have unique pore structures of molecular dimensions and tunable compositions, making them ideal for shape selective catalysis and separation. However, targeted synthesis of zeolites with new pore structures and compositions remains a key challenge. Here, we propose an approach based on a unique 3D-3D topotactic transformation, which takes advantage of weak bonding in zeolites. This is inspired by the structure transformation of PST-5, a new aluminophosphate molecular sieve, to PST-6 by calcination. The structure of nano-sized PST-5 crystals is determined by 3D electron diffraction. We find that the 3D-3D topotactic transformation involves two types of building units where penta- or hexa-coordinated Al is present. We apply this approach to several other zeolite systems and predict a series of new zeolite structures that would be synthetically feasible. This method provides a concept for the synthesis of targeted zeolites, especially those which may not be feasible by conventional methods.

Zeolite Structure Direction: Identification, Strength and Involvement of Weak CH⋅⋅⋅O Hydrogen Bonds

We demonstrate that weak CH⋅⋅⋅O hydrogen bonds (HBs) are important host-guest interactions in zeolite assemblies involving structure directing organocations. This type of HB is identified between alkyl groups of the organic structure directing agent (OSDA) and the silica framework in as-synthesized silicalite-1 of complex topology (MFI) using a combination of experimental and theoretical data obtained at low and room temperatures. The 28 weak CH⋅⋅⋅O HBs, evidenced along dynamics simulation at room temperature, represent 30 % of the energy of the Coulomb electrostatic interaction between OSDA and the zeolite framework. The strongest and most stable HB found here connects the OSDA to the [4¹ 5² 6² ] cage containing F atoms and should contribute to preserve zeolite topology during crystal growth. An inspection of other as-synthesized zeolites of very different framework topology indicates that the directional CH⋅⋅⋅O HBs have to be considered when discussing zeolite structure directing phenomena.

New insights into the di-n-propylamine (DPA) molecule as an organic structural directing agent (OSDA) in the crystallization of AlPO4-11 molecular sieve

Di-n-propylamine (DPA) molecules induce the transformation from 4/6-MR chains to a 2D layered structure and then to 3D crystals of AlPO₄-11 molecular sieves.

Solid solution of a zeolite and a framework-bound OSDA-containing molecular sieve

The first solid-solution of a zeolite and a FOMS has been demonstrated and the overall results of this work strongly suggest that other families of zeolite–FOMS solid solutions can in principle exist.

The structure of the as-made, hydrated form of ECR-40C, synthesized in the presence of (2-hydroxyethyl)trimethylammonium (HTMA⁺) ions as an organic structure-directing agent (OSDA) and 2 wt% (relative to alumina in the synthesis mixture) of aluminosilicate zeolite UZM-22 with the MEI topology as seeds, has been determined using synchrotron powder X-ray diffraction and Rietveld analyses. Two different types of organic species were suggested to exist in ECR-40C: the encapsulated HTMA⁺ ions with one intramolecular C–H···O hydrogen bond, typical of OSDA molecules in as-made UZM-22, and the framework-bound cations. A combination of elemental and thermal analyses, Na⁺ ion exchange, and multinuclear MAS NMR and IR spectroscopies clearly shows the coexistence of the zeolite and framework-bound OSDA-containing molecular sieve (FOMS) domains with a proportion of approximately 3 : 2 in ECR-40C crystals. TEM elemental mapping reveals that the Na⁺ ions exchanged with the HTMA⁺ ions into as-made ECR-40C are uniformly distributed throughout the ECR-40C crystals. Therefore, ECR-40C is not a pure FOMS but a solid solution of a zeolite and a FOMS (i.e., UZM-22 and ECR-40-type FOMS), which has never been recognized or addressed before. The overall characterization results of this work demonstrate that the proportion of the zeolite domain in such solid-solutions varies significantly with the number of OH groups in OSDAs.

Synthesis of new zeolite structures

The advances in the synthesis of new zeolite structures in the past decade are presented, which are achieved by utilization of the synthetic strategies primarily based on pre-designed SDAs, heteroatom substitution, and topotactic transformations.

Charge density mismatch synthesis of MEI- and BPH-type zeolites in the TEA+–TMA+–Li+–Sr2+ mixed-structure-directing agent system

The charge density mismatch synthesis of MEI- and BPH-type zeolites in the TEA⁺–TMA⁺–Li⁺–Sr²⁺ mixed-structure-directing agent system is described.

Molecular gallosilicates and their group 4 multimetallic derivatives

Reaction between the silanediol (HO)(2)Si(OtBu)(2) and gallium amides, LGaCl(NHtBu) and LGa(NHEt)(2) (L = [HC{C(Me)N(Ar)}(2)](-), Ar = 2,6-iPr(2)C(6)H(3)), respectively, resulted in the facile isolation of molecular gallosilicates LGaCl(μ-O)Si(OH)(OtBu)(2) (1) and LGa(NHEt)(μ-O)Si(OH)(OtBu)(2) (2). Compound 2 easily reacts with 1 equiv of water to form the unique gallosilicate-hydroxide LGa(OH·THF)(μ-O)Si(OH)(OtBu)(2) (3). Compounds 1-3 contain the simple Ga-O-SiO(3) framework and are the first structurally authenticated molecular gallosilicates. These compounds may be used not only as models for gallosilicate-based materials but also as further reagents because of the presence of reactive functional groups attached to both gallium and silicon atoms. Accordingly, seven molecular heterometallic compounds were obtained from the reactions between compound 3 and group 4 amides M(NMe(2))(4) (M = Ti, Zr) or M(NEt(2))(4) (M = Ti, Zr, Hf). Hence, by tuning the reactions conditions and stoichiometries, it was possible to isolate and structurally characterize the complete 1:1 and 2:1 series (4-10). Completely inorganic cores of types M-O-Ga-O-Si-O and spiro M[O-Ga-O-Si-O](2) were obtained and characterized by common spectroscopic techniques.