Tracking Sub-Nano-Scale Structural Evolution in Zeolite Synthesis by In Situ High-Energy X-ray Total Scattering Measurement with Pair Distribution Function Analysis

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.

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.

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.

Revealing the evolution of local structures in the formation process of alkaline earth metal cation-containing zeolites from glasses

Alkaline earth metal cations are ubiquitously present in natural zeolites but less exploited in synthetic zeolites due to their low solubility in water, and hence it remains elusive how they contribute to zeolite formation. Herein, harmotome, a PHI-type zeolite with Ba2+, is readily synthesized from a Ba-containing aluminosilicate glass. This glass-to-zeolite transformation process, in particular the structure-regulating role of Ba2+, is investigated by anomalous X-ray scattering and high-energy X-ray total scattering techniques. The results demonstrate that the steady Ba2+-aluminosilicate interactions not only help prevent the precipitation of barium species under alkaline synthetic conditions, but also dictate the local structures with distinct interatomic distances between the Ba2+ and the surrounding aluminosilicate species throughout the transformation process, which lead to the successful formation of harmotome without detectable impurities. This study highlights the usefulness of the comprehensive X-ray scattering techniques in revealing the formation scheme of the zeolites containing specific metal species. In addition, a promising alternative approach to design and synthesize zeolites with unique compositions and topologies by using well-crafted glasses with suitable metal cation dopants is demonstrated.

Fluoride- and Seed-Free Synthesis of Pure-Silica Zeolite Adsorbent and Matrix Using OSDA-Mismatch Approach

The pure-silica zeolite plays a crucially important role in the gas separation of alkane/alkene, the low-k dielectric material, and the robust matrix for confining metal species during catalysis. However, the environmentally friendly synthesis of pure-silica zeolites is still challenging since (1) the toxic fluoride or dealuminum seeds are inevitably utilized through the hydrothermal synthesis and (2) it will also take a longer crystallization time. Herein, we present an efficient method called the OSDA-mismatch approach for the fluoride- and seed-free synthesis of pure-silica zeolites using Si-SOD (enriched 4-rings) as the sole silica source. This approach allows for the rapid and green synthesis of 15 pure-silica zeolites (CHA, *BEA, EUO, SFF, STF, -SVR, *-SVY, DOH, MTN, NON, *MRE, MEL, MFI, MTW, and *STO). Furthermore, distinct crystallization mechanisms of two significant pure-silica CHA- and *BEA-type zeolites (denoted as Si-CHA and Si-BEA) are investigated in detail by advanced characterization techniques such as FIB, 3D ED, 4D-STEM, HRTEM, Raman, and 29Si MAS NMR. More importantly, Si-CHA displays promising propane/propylene separation performance even better than the one synthesized in the presence of toxic HF. In addition, the incorporation of Zn species within Si-BEA fabricated by this approach also renders superior performance on propane dehydrogenation.