TPA−Silicalite Crystallization from Homogeneous Solution: Kinetics and Mechanism of Nucleation and Growth

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.

High yield synthesis of nanoscale high-silica ZSM-5 zeolites via interzeolite transformation with a new strategy

An “OSDA-confined” interzeolite transformation strategy was employed successfully to synthesize nanoscale high-silica ZSM-5 with high yield.

Controlled aggregation of core(amorphous silica)@shell(TPA+-polysilicate) nanoparticles at room temperature by selective removal of TPA+ ions from the nanoparticle shell

Displacement of TPA⁺ ions from the nanoparticle shell exposes the terminal silanol groups, which enables the aggregation of the collided nanoparticles.

Sailing into uncharted waters: recent advances in the in situ monitoring of catalytic processes in aqueous environments

This review presents recent advances inin situstudies of catalytic processes in the aqueous environment with an outlook of mesoscale imaging.

Tailoring the physicochemical properties of zeolite catalysts

Here we summarize our recent findings in the area of zeolite synthesis, focusing on pathways to control crystallization in the absence of organics, tailoring crystal habit with growth modifiers, and pioneering techniques in zeolite surface science to elucidate the mechanisms of growth.

Effects of ultrasound on the synthesis of silicalite-1 nanocrystals

Application of power ultrasound, offers potential in the degree of control over the preparation and properties of nanocrystalline zeolites, which have become increasingly important due to their diverse emerging applications. Synthesis of silicalite-1 nanocrystals from a clear solution was carried out at 348 K in the absence and presence of ultrasound of 300 and 600 W, in an attempt to investigate the effects of sonication, in this respect. Variation of the particle size and particle size distribution was followed with respect to time using a laser light scattering device with a detector set to collect back-scattered light at an angle of 173°. Product yield was determined and the crystallinity was analyzed by X-ray diffraction for selected samples collected during the syntheses. Nucleation, particle growth and crystallization rates all increased as a result of the application of ultrasound and highly crystalline silicalite-1 of smaller average particle diameter could be obtained at shorter synthesis times. The particle size distributions of the product populations, however, remained similar for similar average particle sizes. The rate of increase in yield was also speeded up in the presence of ultrasound, while the final product yield was not affected. Increasing the power of ultrasound, from 300 to 600 W, increased the particle growth rate and the crystalline domain size, and decreased both the final particle diameter and the time required for the particle growth to reach completion, while its effect on nucleation was unclear.

PFG NMR investigations of TPA-TMA-silica mixtures

Pulsed-field gradient (PFG) NMR studies of tetrapropylammonium (TPA)-tetramethylammonium (TMA)-silica mixtures are presented, and the effect of TMA as a foreign ion on the TPA-silica nanoparticle interactions before and after heating has been studied. Dynamic light scattering (DLS) results suggest that silica nanoparticles in these TPA-TMA systems grow via a ripening mechanism for the first 24 h of heating. PFG NMR of mixtures before heating show that TMA can effectively displace TPA from the nanoparticle surface. The binding isotherms of TPA at room temperature obtained via PFG NMR can be described by Langmuir isotherms, and indicate a decrease in the adsorbed amount of TPA upon addition of TMA. PFG NMR also shows a systematic increase in the self-diffusion coefficient of TPA in both the mixed TPA-TMA systems and pure TPA systems with heating time, indicating an increased amount of TPA in solution upon heating. By contrast, a much smaller amount of TMA is observed to desorb from the nanoparticles upon heating. These results point to the desorption of TPA from the nanoparticles being a kinetically controlled process. The apparent desorption rate constants were calculated from fitting the desorbed amount of TPA with time via a pseudosecond-order kinetic model. This analysis show the rate of TPA desorption in TPA-TMA mixtures increases with increasing TMA content, whereas for pure TPA mixtures the rate of TPA desorption is much less sensitive to the TPA concentration.

Nascent zeolite frameworks grown from amorphous gels – identification and prospects for crystal engineering

From the standpoint of designing microporous frameworks with desired pore diameter and dimensionality, and, especially, the optimization of crystal habit, the crystal engineering of new zeolites must be based on concepts/procedures different from those appropriate for the design of organic crystals. This is because the structure building units proposed by Barrer and co-workers are probably not instrumental for framework construction, thus eliminating the important ‘synthon’ approach used for the construction of innovative organic solids. With some variant of the Flanigen model for crystal growth via one SiO2 unit at a time, the best approach to zeolite crytal growth engineering appears to occur indirectly via structure directing agents that can also be modified to influence the emergent crystal habit. Prospects for identifying frameworks emerging from synthesis gels are also discussed in this review, revealing that the use of radial distribution functions is less informative than for the analysis of silicate glasses.

Kinetics of intermediate-mediated self-assembly in nanosized materials: a generic model

We propose in this paper a generic model of a nonstandard aggregation mechanism for self-assembly processes of a class of materials involving the mediation of intermediates consisting of a polydisperse population of nanosized particles. The model accounts for a long induction period in the process. The proposed mechanism also gives insight on future experiments aiming at a more comprehensive picture of the role of self-organization in self-assembly processes.

Viscosity sensing in heated alkaline zeolite synthesis media

A quartz disc resonator operating in thickness shear mode was used for the in situ monitoring of the viscosity during zeolite crystal formation.

Evolution of self-assembled silica-tetrapropylammonium nanoparticles at elevated temperatures

The time evolution of silica nanoparticles in solutions of tetrapropylammonium (TPA) has been studied using a combination of small-angle scattering, conductivity, and pH measurements to provide the first comprehensive analysis of nanoparticle structural and compositional changes at elevated temperatures. We have found that silica-TPA nanoparticles subjected to hydrothermal treatment (70-90 degrees C) grow via an Ostwald ripening mechanism with growth rates that depend on both pH and temperature. Small-angle X-ray (SAXS) and neutron (SANS) scattering confirm that the core-shell structure of the particles, initially present at room temperature, is maintained during heating, but an evolution toward sphericity is evidenced especially at high values of pH. SAXS absolute intensity calculations were utilized to calculate the changes in nanoparticle composition and concentration over time. These changes along with the conductivity and pH measurements and SANS contrast matching studies indicate that, upon heating, TPA becomes embedded in the core of nanoparticles giving rise to more zeolitic-looking nanomaterials.

Synthesis, Characterization, and Growth Rates of Aluminum- and Ge,Al-Substituted Silicalite-1 Materials Grown from Clear Solutions

The synthesis, characterization, and growth rates of aluminum- and germanium,aluminum-substituted silicalite-1 (Al-silicalite-1, Ge,Al-silicalite-1) materials grown from clear solutions are reported. In the case of aluminum substitution, the crystallinity of the materials as determined by powder X-ray diffraction (PXRD) decreases with increasing aluminum content, as does the micropore volume determined by nitrogen adsorption and the growth rate determined by in situ small-angle X-ray scattering (SAXS). The final materials possess slightly lower Si/Al ratios than the initial synthesis mixtures based on X-ray fluorescence analysis. In the case of simultaneous incorporation of germanium and aluminum, the final materials have a slightly lower Si/Al ratio than the synthesis mixture but a much higher Si/Ge ratio, indicating the aluminum is more readily incorporated in the zeolite as compared to germanium. This result is consistent with studies of individual heteroatom substitution behavior. Germanium incorporation in the final material increases at higher heteroatom contents (Si/(Ge+Al) = 50 and 25). The promoting effect of germanium on the growth rate of silicalite-1 dominates at low heteroatom content (Si/(Ge+Al) = 100), leading to enhanced zeolite growth rates as compared to pure silicalite-1. This promoting effect is insensitive to the Ge/Al ratio at a Si/(Ge+Al) = 100. The influence of aluminum on the growth rate, as well as the crystallinity of final materials, becomes observable when the heteroatom content is increased (Si/(Ge+Al) = 50 and 25). This is the first study we are aware of that reports the synthesis of Ge,Al-substituted silicalite-1 phases formed in hydroxide media or from clear solutions and has implications for the synthesis of nanoparticulate zeolitic materials for catalysis.

Synthesis, Characterization, and Growth Rates of Germanium Silicalite-1 Grown from Clear Solutions

The synthesis, characterization, and growth of Ge-silicalite-1 from optically clear solutions are reported. Ge-silicalite-1 is readily formed from optically clear solutions of TEOS, TPAOH, water, and a germanium source at 368 K. X-ray fluorescence (XRF) is used to determine the Si/Ge ratio and indicates that germanium inclusion is typically 30-50% of that in the actual mixture. Adsorption, power X-ray diffraction (PXRD), and 29Si NMR indicate the materials are crystalline and microporous. In situ small-angle X-ray scattering (SAXS) is applied to investigate the influences of germanium source (GeO2 and Ge(OC2H5)4) and content (Si/Ge 100:5) on the growth of Ge-silicalite-1 from clear solutions at 368 K. The in situ SAXS investigations show that for solutions with Si/Ge ratios of 100, 50, and 25 using Ge(OC2H5)4 the induction periods are approximately 6 h and the particle growth rates are 1.82 +/- 0.04, 2.52 +/- 0.13, and 2.85 +/- 0.08 nm/h, respectively, at 368 K, compared to those of pure silicalite-1 (6 h induction period, 1.93 +/- 0.1 nm/h growth rate). Further increasing the Si/Ge ratio to 15 and 5 shortens the induction period to approximately 4.5 h, and the growth rates are 3.07 +/- 0.16 and 2.05 +/- 0.10 nm/h, respectively, indicating the Si/Ge ratio that maximizes Ge-silicalite-1 growth is between 25 and 15. Similar trends are obtained with germanium oxide; however, the growth rates are all consistently larger than those for syntheses with Ge(OC2H5)4. The results indicate that Ge-silicalite-1 growth rates in the presence of germanium are increased as compared to those of pure-silica syntheses.

Silica Nanoparticle Formation in the TPAOH−TEOS−H2O System: A Population Balance Model

A model describing the kinetics of silica nanoparticle formation in the TPAOH-TEOS-H(2)O system is presented. These nanoparticles are an important intermediate in the clear-solution synthesis of silicalite-1, so understanding the mechanisms by which they are formed and stabilized is a key step in determining the crystallization behavior of pure-silica zeolites. The model presented here is based on the mass-conserving form of the Becker-Döring population balance equations, describing growth and fragmentation by addition or removal of monomeric units, and modified to account for rapid equilibration of small silicate species and electrostatic and/or template stabilization of nanoparticles. The model predictions compare favorably with the experimental results. It is found that nanoparticle evolution exhibits distinct time regimes consisting of TEOS hydrolysis, condensation, nanoparticle formation, Ostwald ripening, and a self-sharpening mechanism in particle size distribution toward equilibrium due to stabilization during which no apparent changes in average particle size and pH are observed. Finally, the model provides an alternative, to a recent hypothesis, kinetics point of view to explain the enhanced stability of nanoparticles over extended periods of time.

29Si NMR Studies of Zeolite Precursor Solutions

Solution 29Si NMR spectroscopy results of zeolite precursor solutions of composition 1 SiO2:4 C2H5OH:0.36/n R+n[OH-]n:20 H2O are reported. This work employs isotopically enriched 29Si materials to aid in spectral interpretation. Using both 1D and 2D methods, spectra of solutions containing tetrapropylammonium hydroxide are wholly consistent with the existing silicate chemistry literature and indicate that the majority of the species are high-symmetry silicate clusters previously observed in aqueous solutions. The results are inconsistent with the nanoblock or nanoslab model proposed by Kirschhock and co-workers. Mixtures containing the 4,4'-trimethylene-bis(1,1'-dimethylpiperidinium) dihydroxide cation were also studied. These mixtures have similar speciation to the TPA solutions, although the relative populations of the species are different. Preliminary variable temperature 29Si NMR of these mixtures shows that the exchange properties of the high-symmetry silicate species, most notably the tetrahedral tetramer, depend on the organocation identity.

Template-Aluminosilicate Structures at the Early Stages of Zeolite ZSM-5 Formation. A Combined Preparative, Solid-state NMR, and Computational Study

Species at three stages in the self-assembly of zeolite ZSM-5 have been studied with one- and two-dimensional magic-angle-spinning 13C, 27Al, 29Si, and 1H NMR spectroscopy and compared with the earlier proposed structures: (1) precursor species containing 33-36 T sites around a tetrapropylammonium (TPA) cation, (2) nanoslabs consisting of a flat 4 x 3 array of such precursors, and (3) the final TPA-ZSM-5 zeolite. Synthesis was carried out in D2O to suppress the water and silanol protons. Under such conditions, the effective Si-H and Al-H distances measured with 29Si-{1H} and 27Al-{1H} rotational echo double resonance (REDOR) reflect the interactions between TPA cations and the surrounding aluminosilica. The 29Si-{1H} REDOR curves for Q4-type silicon atoms at the three mentioned stages are closely similar, as well as the observed 27Al-1H REDOR curve for the precursor species compared to that for the TPA-ZSM-5. This indicates that in addition to externally attached TPA, there is also internal TPA already incorporated at an early stage into the aluminosilicate in a similar way as in the final zeolite, in accordance with the earlier proposed MFI self-assembly pathway (Kirschhock et al. Angew. Chem. Int. Ed. 2001, 40, 2637). However, the effective distances extracted from the initial REDOR curvatures are significantly (10-15%) larger than those computed for the model. Since there is no temperature effect, we tentatively assign this difference to a reduction of the 29Si-1H and 27Al-1H interactions by multispin decoherence effects or self-decoupling caused by proton spin diffusion. By assuming the computed model distances and fitting Anderson-Weiss curves to the observed REDOR data, we obtain similar "decoherence times" in the order of 0.1 ms. The observed 29Si-{1H} REDOR dephasing for the Q3 sites in the precursors is significantly faster than that for the Q4 sites. This is tentatively ascribed to a partial deuteron-proton back exchange at the silanol positions.

Evidences for Zeolite Nucleation at the Solid−Liquid Interface of Gel Cavities

The entire sequence of crystallization events, starting with formation of the initial organic-cation-free gel, proceeding through the zeolite nucleation stage, and finishing with complete transformation into LTA-type zeolite crystals, has been monitored by means of high-resolution transmission electron microscopy. Formation and development of voids, containing highly hydrated material transformed later into negative crystals, has been discovered in the solid part of the system. The evolution of these areas has been found to be an integral and noteworthy part of the chemical transformation of the gel that preceded the nucleation in the system. These void structures and, in particular, their solid-liquid interfaces have been identified as the specific locations where the formation of protozeolite nuclei took place. Further development of the system followed the classical for zeolite-yielding systems of crystallization that could be described by the autocatalytic model.

Observations on clear solution silicalite-1 growth by nanoslabs

Several research groups have reported the presence of nanometer-sized particles (nanoslabs) in clear solutions, which precipitate the crystalline MFI (ZSM-5) structure. Debate about the growth mechanism for Al-free ZSM-5 (silicalite-1) has revolved around growth by small silicate units (monomers, dimers, etc.) from solution vs growth by nanoslab addition. A model developed for precipitation of uniform sized colloids by addition of sub-colloidal precursor units has been adapted for this zeolite synthesis system. Parameter values were adjusted for the simulation results to match experimental observations from work reported previously, at least to the extent possible. The model involved the simultaneous solution of up to 6000 ordinary differential equations, and required computation times of up to 24 h. The results shed light on the crystal growth mechanism, but pose questions for further investigations of the nucleation mechanism.

Silicalite-1 Growth from Clear Solution: Effect of Alcohol Identity and Content on Growth Kinetics

In situ small-angle X-ray scattering (SAXS) is used to investigate the influence of alcohol identity and content on silicalite-1 growth from clear solutions at 368 K. Several tetraalkyl orthosilicates (Si(OR)4, R = Me, Pr, and Bu) are used to synthesize silicalite-1 from clear solution mixtures comparable to those previously investigated (i.e. 1:0.36:20 TEOS:TPAOH:H2O (TEOS = tetraethyl orthosilicate; TPAOH = tetrapropylammonium hydroxide), 368 K). All TPAOH-organosiloxane mixtures studied form silica nanoparticles after aging at room temperature for 24 h. Full-profile fitting analysis of the SAXS data indicates the particles are ellipsoidal and is inconsistent with the presence of "nanoslabs" or "nanoblocks". Synthesis using TEOS as the silica source have an induction period of approximately 7.5 h and a growth rate of 1.90 +/- 0.10 nm/h at 368 K. Changing the silica source to tetramethyl orthosilicate (TMOS) does not change the induction period; however the particle growth rate is decreased to 1.65 +/- 0.09 nm/h at 368 K. Variable-temperature SAXS measurements for syntheses with TEOS and TMOS show the activation energy for silicalite-1 growth is 60.0 +/- 2.9 and 73.9 +/- 2.8 kJ/mol, respectively, indicating the alcohol identity does influence the growth rate. By mixing tetrapropyl orthosilicate (TPOS) with TEOS (1.6:1.0 molar ratio) as the silica source, the precursor solution shows a shorter induction period (6.0 h) and a faster particle growth rate (2.16 +/- 0.06 nm/h). The alcohol identity effect is more pronounced when other organocations (e.g. alkyltripropylammonium cations) are used to make silicalite-1 at 368 K. Removing ethanol from the precursor solution decreases the induction period to approximately 4.5 h and increases the particle growth rate to 2.99 +/- 0.13 nm/h. Mixtures with 2 equiv of ethanol have an induction period and particle growth rate of 6.0 h and 2.04 +/- 0.03 nm/h, respectively. The results demonstrate the alcohol identity and content influence silicalite-1 growth kinetics. One possible explanation is varying the alcohol identity and content changes the strength of the hydrophobic hydration of the structure-directing agent and the water-alcohol interaction, resulting in less efficient interchange between clathrated water molecules and solvated silicate species.

Modeling Spontaneous Formation of Precursor Nanoparticles in Clear-Solution Zeolite Synthesis

We present a lattice model describing the formation of silica nanoparticles in the early stages of the clear-solution templated synthesis of silicalite-1 zeolite. Silica condensation/hydrolysis is modeled by a nearest-neighbor attraction, while the electrostatics are represented by an orientation-dependent, short-range interaction. Using this simplified model, we show excellent qualitative agreement with published experimental observations. The nanoparticles are identified as a metastable state, stabilized by electrostatic interactions between the negatively charged silica surface and a layer of organic cations. Nanoparticle size is controlled mainly by the solution pH, through nanoparticle surface charge. The size and concentration of the charge-balancing cation are found to have a negligible effect on nanoparticle size. Increasing the temperature allows for further particle growth by Ostwald ripening. We suggest that this mechanism may play a role in the growth of zeolite crystals.

Unraveling the Crystallization Mechanism of CoAPO-5 Molecular Sieves under Hydrothermal Conditions

The hydrothermal crystallization of CoAPO-5 molecular sieves has been studied using time-resolved in-situ SAXS/WAXS, UV-vis, Raman, and XAS. Data collected during heating to 180 degrees C allowed the observation of different steps occurring during the transformation of the amorphous gel into a crystalline material from a macroscopic and atomic perspective. Raman spectroscopy detected the initial formation of Al-O-P bonds, whereas SAXS showed that these gel particles had a broad size distribution ranging from ca. 7 to 20 nm before crystallization began. WAXS showed that this crystallization was sharp and occurred at around 160 degrees C. Analysis of the crystallization kinetics suggested a one-dimensional growth process. XAS showed that Co(2+) transformed via a two-stage process during heating involving (i) a gradual transformation of octahedral coordination into tetrahedral coordination before the appearance of Bragg peaks corresponding to AFI, suggesting progressive incorporation of Co(2+) into the poorly ordered Al-O-P network up to ca. 150 degrees C, and (ii) a rapid transformation of remaining octahedral Co(2+) at the onset of crystallization. Co(2+) was observed to retard crystallization of AFI but provided valuable information regarding the synthesis process by acting as an internal probe. A three-stage, one-dimensional crystallization mechanism is proposed: (i) an initial reaction between aluminum and phosphate units forming a primary amorphous phase, (ii) progressive condensation of linear Al-O-P chains forming a poorly ordered structure separated by template molecules up to ca. 155 degrees C, and (iii) rapid internal reorganization of the aluminophosphate network leading to crystallization of the AFI crystal structure.

Physical basis for the formation and stability of silica nanoparticles in basic solutions of monovalent cations

The colloidal stability, phase behavior, and solubility of silica nanoparticles (3-10 nm) that are formed in basic solutions of monovalent cations (primarily tetrapropylammonium) are investigated using a combination of chemical equilibria and electrostatic models. The free-energy gain associated with the formation of an electric double layer surrounding the nanoparticle was obtained by solving the Poisson-Boltzmann equation. This free energy is an important contribution to the total free energy of the particle and is second only to the formation of Si-O-Si bonds. The free energy of formation of the nanoparticles becomes increasingly negative with an increase in particle size and density, which explains the lower solubility of nanoparticles compared to that of amorphous silica. There is a minimum in the free energy of condensation as a function of size that qualitatively explains why the formation of small particles with a uniform size (<5 nm) is energetically favorable. The electrostatic models provide an estimate for the nanoparticle surface potential, which is significantly higher (-120 to -170 mV) than that of zeolite silicalite-1 (-60 to -80 mV) prepared in similar solutions. This result explains the stability of such small particles in solution. It is also shown that a condensation model that is based on silica solubility can describe the phase diagram for nanoparticle formation reported by Fedeyko et al. (J. Phys. Chem. B 2004, 108, 12271) over a wide range of pH and, in conjunction with a complexation model, provides an approximate equilibrium constant (pKa = 8.4) for the dissociation of nanoparticle silanol groups.

Silicalite-1 Growth from Clear Solution: Effect of the Structure-Directing Agent on Growth Kinetics

Small-angle X-ray scattering (SAXS) has been used to quantify how perturbations of the tetrapropylammonium (TPA) cation structure affect the growth of silicalite-1 from clear solutions at 368 K. Alkyltripropylammonium (RN(C3H7)3 +OH-, R = Me, Et, Bu, and Pe), dialkyldipropylammonium (R2N(C3H7)2 +OH-, R = Et and Bu), and bis-1,6-(tripropylammonium)hexamethylene dihydroxide (TPA-dimer) cations are used as structure-directing agents (SDAs) to synthesize silicalite-1 from clear solution mixtures comparable to those that have been previously investigated for the TPAOH mediated synthesis (i.e., 1 TEOS:0.36 TPAOH:20 H2O, 368 K). All mixtures studied except those employing dialkyldipropylammonium cations lead to the formation of silicalite-1. The in-situ SAXS investigations show that TPA cations lead to the shortest reaction time as indicated by the observance of Bragg diffraction peaks (15 approximately 16.5 h) and the largest particle growth rate (1.9 +/- 0.1 nm/h). Substituting a propyl group of the TPA moiety with a different alkyl group significantly affects silicalite-1 nucleation and growth with the trend Bu > Et > Pe > Me. Synthesis mixtures containing the TPA-dimer also show a slower growth rate. All the solutions show a bimodal particle distribution throughout zeolite growth with the primary particle size being approximately 5 nm in all cases, independent of the SDA identity. Syntheses using diethyldipropylammonium hydroxide, dibutyldipropylammonium hydroxide, and 4,4'-trimethylenebis(1-methyl-1-hexyl-piperidinium) dihydroxide as the SDA do not result in silicalite-1 formation, showing that the nucleation of silicalite-1 from clear solution at 368 K is sensitive to the SDA geometry.