Transmission Electron Microscopy Study of the Formation of FAU-Type Zeolite at Room Temperature

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.

Understanding formation thermodynamics of structurally diverse zeolite oligomers with first principles calculations

The mechanisms of many zeolitic processes, including nucleation and interzeolite transformation, are not fully understood owing to complex growth mixtures that obfuscate in situ monitoring of molecular events. In this work, we provide insights into zeolite chemistry by investigating the formation thermodynamics of small zeolitic species using first principles calculations. We systematically study how formation energies of pure-silicate and aluminosilicate species differ by structure type and size, temperature, and the presence of alkali or alkaline earth metal cations (Na⁺, K⁺, and Ca²⁺). Highly condensed (cage-like) species are found to be strongly preferred to simple rings in the pure-silicate system, and this thermodynamic preference increases with temperature. Introducing aluminum leads to more favorable formation thermodynamics for all species. Moreover, for species with a low Si/Al ratio (≤2), a thermodynamic preference does not exist among structure types; instead, a pool of diverse aluminosilicate structures compete in formation. Metal cation effects strongly depend on the presence of aluminum, cage size, cation type, and location, since each of these factors can alter electrostatic interactions between cations and zeolitic species. We reveal that confined metal cations may destabilize pure-silicate cages due to localized interactions; conversely, they stabilize aluminosilicates due to strong cation-framework attractions in sufficiently large cages. Importantly, this work rationalizes a series of experimental observations and can potentially guide efforts for controlling zeolite nucleation/crystallization processes.

In Situ Imaging of Faujasite Surface Growth Reveals Unique Pathways of Zeolite Crystallization

Zeolite crystallization occurs by complex processes involving a variety of possible mechanisms. The sol gel media used to prepare zeolites leads to heterogeneous mixtures of solution and solid states with diverse solute species. At later stages of zeolite synthesis when growth occurs predominantly from solution, classical two-dimensional nucleation and spreading of layers on crystal surfaces via the addition of soluble species is the dominant pathway. At earlier stages, these processes occur in parallel with nonclassical pathways involving crystallization by particle attachment (CPA). The relative roles of solution- and solid-state species in zeolite crystallization have been a subject of debate. Here, we investigate the growth mechanism of a commercially relevant zeolite, faujasite (FAU). In situ atomic force microscopy (AFM) measurements reveal that supernatant solutions extracted from a conventional FAU synthesis at various times do not result in growth, indicating that FAU growth predominantly occurs from the solid state through a disorder-to-order transition of amorphous precursors. Elemental analysis shows that supernatant solutions are significantly more siliceous than both the original growth mixture and the FAU zeolite product; however, in situ AFM studies using a dilute clear solution with a lower Si/Al ratio revealed three-dimensional growth of surfaces that is distinct from layer-by-layer and CPA pathways. This unique mechanism of growth differs from those observed in studies of other zeolites. Given that relatively few zeolite frameworks have been the subject of mechanistic investigation by in situ techniques, these observations of FAU crystallization raise the question whether its growth pathway is characteristic of other zeolite structures.

Strategy for Synthesis of Zeolite Y by Artificial Fish Reef Breeding Negative Crystals

Y zeolite is presently used to be an important active component in oil refining catalysts. The efficient synthesis of NaY zeolite remains many huge challenges. Herein, a novel method of...

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.

FAU-Type Zeolite Synthesis from Clays and Its Use for the Simultaneous Adsorption of Five Divalent Metals from Aqueous Solutions

In this research, a vermiculite-kaolinite clay (VK) was used to prepare faujasite zeolites via alkaline fusion and hydrothermal crystallisation. The optimal synthesis conditions were 1 h fusion with NaOH at 800 °C, addition of deionised water to the fused sample at a sample to deionised water mass ratio of 1:5, 68 h of non-agitated ageing of the suspension, and 24 h of hydrothermal treatment at 90 °C. The efficacy of the prepared faujasite was compared to raw clay and a reference zeolite material through adsorption experiments of aqueous solutions containing five divalent cations—Cd, Co, Cu, Pb, and Zn. The results showed that in the presence of competing cations at concentrations of 300 mg L⁻¹ and adsorbent loading of 5 g L⁻¹, within the first 10 min, about 99% of Pb, 60% of Cu, 58% of Cd, 28% of Zn, and 19% of Co were removed by the faujasite prepared from clay. Two to four parameter nonlinear adsorption isotherms were used to fit the adsorption data and it was found that overall, three and four parameter isotherms had the best fit for the adsorption process.

A nanoprecursor method for successfully synthesizing clinoptilolite with high-crystallinity and resultant effects on CO2/CH4 selective adsorption

Nanoprecursors used as a structural promoter (SP) were prepared by a hydrothermal method and named sol-SP. After centrifugation, the supernatant and precipitate were denoted as solution-SP and solid-SP, respectively. The effect of the additive amount on the structures and properties of the synthesized clinoptilolite was investigated using various characterization techniques. The activation energies of crystallization kinetics during induction and growth periods were calculated. The results showed that the induction period is the control step during the synthesis of clinoptilolite, while additive sol-SP or solid-SP was beneficial to shorten the induction period and therefore enhance the formation of the crystal nucleus. When their pre-crystallization time was too long or the additive amount was too much, the impure phase (phillipsite) in the synthesized clinoptilolite was easily generated. Although the addition of solution-SP had no obvious effect on the induction period, it promoted the growth of crystals after nucleation. Finally, the adsorption performances for CO₂ and CH₄ were preliminarily assessed using synthetic clinoptilolite as the adsorbent, showing the promising application for the separation of CO₂/CH₄.

Nanoprecursors used as a structural promoter (SP) were prepared by a hydrothermal method and named sol-SP.

Selective Conversion of Glucose to 5-Hydroxymethylfurfural by Using L-Type Zeolites with Different Morphologies

In the present work, the morphology of L-type zeolite (LTL topology) has been modified in order to evaluate the influence of several protonated-form LTL-zeolites with different morphologies on their stability and catalytic performance in the conversion of glucose into 5-hydroxymethylfurfural (5-HMF). Physico-chemical characterization of the LTL-based catalysts has revealed that the three types of morphologies (needle, short rod and cylinder) are active, providing complete glucose conversion and high 5-HMF yield values. The addition of CaCl2 had a positive influence on the catalytic performance. It was found that morphology influences the textural and acid properties of LTL-zeolites, and hence their catalytic performance. The best catalytic results have been obtained with the NEEDLE-LTL, showing nanoparticles with a length of 4.46 μm and a width of 0.63 μm, which attains a 5-HMF yield of 63%, at 175 °C after 90 min of reaction, and a glucose conversion of 88%. The reusability study has revealed a progressive decrease in 5-HMF yield after each catalytic cycle. Different regeneration methods have been essayed without recovering the initial catalytic activity. The presence of organic molecules in micropores has been demonstrated by TG analysis, which are difficult to remove even after a regeneration process at 550 °C.

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.

Micro- and macroscopic observations of the nucleation process and crystal growth of nanosized Cs-pollucite in an organotemplate-free hydrosol

Nucleation and crystal growth of a nanosized cesium pollucite zeolite from an organotemplate-free hydrosol under mild conditions (low pressure and temperature) are followed and reported.

From 3D to 2D zeolite catalytic materials

Research activities and recent developments in the area of three-dimensional zeolites and their two-dimensional analogues are reviewed. Zeolites are the most important industrial heterogeneous catalysts with numerous applications. However, they suffer from limited pore sizes not allowing penetration of sterically demanding molecules to their channel systems and to active sites. We briefly highlight here the synthesis, properties and catalytic potential of three-dimensional zeolites followed by a discussion of hierarchical zeolites combining micro- and mesoporosity. The final part is devoted to two-dimensional analogues developed recently. Novel bottom-up and top-down synthetic approaches for two-dimensional zeolites, their properties, and catalytic performances are thoroughly discussed in this review.

Green synthesis of nanocrystalline faujasite zeolite

In this work, the synthesis of 28 and 38 nm Na-Y zeolite nanocrystals is reported. The process was performed via green synthesis without any organic structure directing agents (SDAs), at low temperature and applying ultrasound-assisted aging. The zeolite nanoparticles obtained were characterized by X ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and N₂ adsorption - desorption isotherm at 77 K. A simple, fast, efficient and environmentally friendly procedure to synthetize nanocrystalline FAU zeolite is described in the present study. The sonochemical pretreatment was found to directly affect the Na-Y zeolite properties. The final product obtained via ultrasound pretreatment shows high phase purity and crystallinity degree with crystal size smaller than 38 nm and elevated surface area (S_BET ∼ 950 m² g^-1). The hierarchical micro- and mesoporous FAU zeolites exhibit a pore volume of ∼0.4 cm³ g^-1.

Synthesis and catalytic application of alumina@SAPO-11 composite via the in situ assembly of silicoaluminophosphate nanoclusters at an alumina substrate

An alumina@SAPO-11 composite with a core–shell structure has been synthesized via the in situ assembly and crystallization of silicoaluminophosphate nanoclusters.

Rapid screening of the antimicrobial efficacy of Ag zeolites

A semi-quantitative screening method was used to compare the killing efficacy of Ag zeolites against bacteria and yeast as a function of the zeolite type, crystal size and concentration. The method, which substantially reduced labor, consumables and waste and provided an excellent preliminary screen, was further validated by quantitative plate count experiments. Two pairs of zeolite X and zeolite beta with different sizes (ca. 200nm and 2μm for zeolite X and ca. 250 and 500nm for zeolite beta) were tested against Escherichia coli (E. coli) and Candida albicans (C. albicans) at concentrations in the range 0.05-0.5mgml^-1. Reduction of the zeolite crystal size resulted in a decrease in the killing efficacy against both microorganisms. The semi-quantitative tests allowed convenient optimization of the zeolite concentrations to achieve targeted killing times. Zeolite beta samples showed higher activity compared to zeolite X despite their lower Ag content, which was attributed to the higher concentration of silver released from zeolite beta samples. Cytotoxicity measurements using peripheral blood mononuclear cells (PBMCs) indicated that Ag zeolite X was more toxic than Ag zeolite beta. However, the trends for the dependence of cytotoxicity on zeolite crystal size at different zeolite concentrations were different for the two zeolites and no general conclusions about zeolite cytotoxicity could be drawn from these experiments. This result indicates a complex relationship, requiring the necessity for individual cytotoxicity measurements for all antimicrobial applications based on the use of zeolites.

Pioneering In Situ Recrystallization during Bead Milling: A Top-down Approach to Prepare Zeolite A Nanocrystals

Top-down approach has been viewed as an efficient and straightforward method to prepare nanosized zeolites. Yet, the mechanical breaking of zeolite causes amorphization, which usually requires a post-milling recrystallization to obtain fully crystalline nanoparticles. Herein we present a facile methodology to prepare zeolite nanocrystals, where milling and recrystallization can be performed in situ. A milling apparatus specially designed to work under conditions of high alkalinity and temperature enables the in situ recrystallization during milling. Taking zeolite A as an example, we demonstrate its size reduction from ~3 μm to 66 nm in 30 min, which is quite faster than previous methods reported. Three functions, viz., miniaturization, amorphization and recrystallization were found to take effect concurrently during this one-pot process. The dynamic balance between these three functions was achieved by adjusting the milling period and temperature, which lead to the tuning of zeolite A particle size. Particle size and crystallinity of the zeolite A nanocrystals were confirmed by X-ray diffraction, scanning electron microscopy, transmission electron microscopy and water adsorption-desorption. This work presents a pioneering advancement in this field of nanosized zeolites, and will facilitate the mass production as well as boost the wide applications of nanosized zeolites.

3D Study of the Morphology and Dynamics of Zeolite Nucleation

The principle aspects and constraints of the dynamics and kinetics of zeolite nucleation in hydrogel systems are analyzed on the basis of a model Na-rich aluminosilicate system. A detailed time-series EMT-type zeolite crystallization study in the model hydrogel system was performed to elucidate the topological and temporal aspects of zeolite nucleation. A comprehensive set of analytical tools and methods was employed to analyze the gel evolution and complement the primary methods of transmission electron microscopy (TEM) and nuclear magnetic resonance (NMR) spectroscopy. TEM tomography reveals that the initial gel particles exhibit a core-shell structure. Zeolite nucleation is topologically limited to this shell structure and the kinetics of nucleation is controlled by the shell integrity. The induction period extends to the moment when the shell is consumed and the bulk solution can react with the core of the gel particles. These new findings, in particular the importance of the gel particle shell in zeolite nucleation, can be used to control the growth process and properties of zeolites formed in hydrogels.

A top-down methodology for ultrafast tuning of nanosized zeolites

We herein present a top-down methodology to prepare nanosized zeolites with tunable size by combining post-synthesis milling and fast recrystallization of several minutes (10 min for SSZ-13 and 5 min for AlPO4-5). A continuous-flow recrystallization process is demonstrated to further enhance the overall product efficiency.

Template-free nanosized faujasite-type zeolites

Nanosized faujasite (FAU) crystals have great potential as catalysts or adsorbents to more efficiently process present and forthcoming synthetic and renewable feedstocks in oil refining, petrochemistry and fine chemistry. Here, we report the rational design of template-free nanosized FAU zeolites with exceptional properties, including extremely small crystallites (10-15 nm) with a narrow particle size distribution, high crystalline yields (above 80%), micropore volumes (0.30 cm(3) g(-1)) comparable to their conventional counterparts (micrometre-sized crystals), Si/Al ratios adjustable between 1.1 and 2.1 (zeolites X or Y) and excellent thermal stability leading to superior catalytic performance in the dealkylation of a bulky molecule, 1,3,5-triisopropylbenzene, probing sites mostly located on the external surface of the nanosized crystals. Another important feature is their excellent colloidal stability, which facilitates a uniform dispersion on supports for applications in catalysis, sorption and thin-to-thick coatings.

Silver zeolite-loaded silicone elastomers: a multidisciplinary approach to synthesis and antimicrobial assessment

The fabrication of silicone elastomers containing organo-silane modified Ag-zeolites with potential for applications as antibacterial medical devices is demonstrated.

Na2HPO4-modified NaY nanocrystallites: efficient catalyst for acrylic acid production through lactic acid dehydration

An acrylic acid yield of 74.3% and a formation rate of 12.0 mmol g_cat⁻¹ h⁻¹ have been achieved at 340 °C by lactic acid dehydration over Na₂HPO₄-modified NaY nanocrystallites (NaY-n) due to appropriate surface acidity together with the unique structural features of NaY-n.

Investigation of the crystallization of zeolite A from hydrogels aged under high pressure

Aging of hydrogels under high pressure can result in the formation of zeolites with small particle sizes and narrow particle size distribution.

Low temperature synthesis of nanosized NaY zeolite crystals from organic-free gel by using supported seeds

Zeolite crystals having faujasite-type (FAU) topology and particle size distribution in the nanometer range have been successfully prepared by a room temperature, short duration synthesis, in the absence of organic structure directing agents (SDAs).

Advances in nanosized zeolites

This review highlights recent developments in the synthesis of nanosized zeolites. The strategies available for their preparation (organic-template assisted, organic-template free, and alternative procedures) are discussed. Major breakthroughs achieved by the so-called zeolite crystal engineering and encompass items such as mastering and using the physicochemical properties of the precursor synthesis gel/suspension, optimizing the use of silicon and aluminium precursor sources, the rational use of organic templates and structure-directing inorganic cations, and careful adjustment of synthesis conditions (temperature, pressure, time, heating processes from conventional to microwave and sonication) are addressed. An on-going broad and deep fundamental understanding of the crystallization process, explaining the influence of all variables of this complex set of reactions, underpins an even more rational design of nanosized zeolites with exceptional properties. Finally, the advantages and limitations of these methods are addressed with particular attention to their industrial prospects and utilization in existing and advanced applications.