Zeolites in Adsorption Processes: State of the Art and Future Prospects

Zeolites have been widely used as catalysts, ion exchangers, and adsorbents since their industrial breakthrough in the 1950s and continue to be state-of the-art adsorbents in many separation processes. Furthermore, their properties make them materials of choice for developing and emerging separation applications. The aim of this review is to put into context the relevance of zeolites and their use and prospects in adsorption technology. It has been divided into three different sections, i.e., zeolites, adsorption on nanoporous materials, and chemical separations by zeolites. In the first section, zeolites are explained in terms of their structure, composition, preparation, and properties, and a brief review of their applications is given. In the second section, the fundamentals of adsorption science are presented, with special attention to its industrial application and our case of interest, which is adsorption on zeolites. Finally, the state-of-the-art relevant separations related to chemical and energy production, in which zeolites have a practical or potential applicability, are presented. The replacement of some of the current separation methods by optimized adsorption processes using zeolites could mean an improvement in terms of sustainability and energy savings. Different separation mechanisms and the underlying adsorption properties that make zeolites interesting for these applications are discussed.

Control of zeolite framework flexibility for ultra-selective carbon dioxide separation

Molecular sieving membranes with uniform pore size are highly desired for carbon dioxide separation. All-silica zeolite membranes feature well-defined micropores, but the size-exclusion effect is significantly compromised by the non-selective macro-pores generated during detemplation. Here we propose a template modulated crystal transition (TMCT) approach to tune the flexibility of Decadodecasil 3 R (DD3R) zeolite to prepare ultra-selective membranes for CO₂/CH₄ separation. An instantaneous overheating is applied to synchronize the template decomposition with the structure relaxation. The organic template molecules are transitionally converted to tight carbon species by the one-minute overheating at 700 °C, which are facilely burnt out by a following moderate thermal treatment. The resulting membranes exhibit CO₂/CH₄ selectivity of 157~1,172 and CO₂ permeance of (890~1,540) × 10⁻¹⁰mol m⁻² s⁻¹ Pa⁻¹. The CO₂ flux and CO₂/CH₄ mixture selectivity reach 3.6 Nm³ m⁻² h⁻¹ and 43 even at feed pressure up to 31 bar. Such strategy could pave the way of all-silica zeolite membranes to practical applications.

All-silica zeolite membranes are highly desired for natural gas upgrading but the size-exclusion effect is compromised by defects generated during high-temperature detemplation. Here, the authors develop a strategy to fabricate ultra-selective DD3R zeolite membranes via tuning the zeolite flexibility under rapid template decomposition.

A Hybrid Zeolite Membrane-Based Breakthrough for Simultaneous CO2 Capture and CH4 Upgrading from Biogas

Biogas is an environmentally friendly and sustainable energy resource that can substitute or complement conventional fossil fuels. For practical uses, biogas upgrading, mainly through the effective separation of CO₂ (0.33 nm) and CH₄ (0.38 nm), is required to meet the approximately 90-95% purity of CH₄, while CO₂ should be concomitantly purified. In this study, a high CO₂ perm-selective zeolite membrane was synthesized by heteroepitaxially growing a chabazite (CHA) zeolite seed layer with a synthetic precursor that allowed the formation of all-silica deca-dodecasil 3 rhombohedral (DDR) zeolite (with a pore size of 0.36 × 0.44 nm²). The resulting hydrophobic DDR@CHA hybrid membrane on an asymmetric α-Al₂O₃ tube was thin (ca. 2 μm) and continuous, thus providing both high flux and permselectivity for CO₂ irrespective of the presence or absence of water vapor (the third largest component in the biogas streams). To the best of our knowledge, the CO₂ permeance of (2.9 ± 0.3) × 10^-7 mol m^-2 s^-1 Pa^-1 and CO₂/CH₄ separation factor of ca. 274 ± 73 at a saturated water vapor partial pressure of ca. 12 kPa at 50 °C have the highest CO₂/CH₄ separation performance yet achieved. Furthermore, we explored the membrane module properties of the hybrid membrane in terms of the recovery and purity of both CO₂ and CH₄ under dry and wet conditions. Despite the high intrinsic membrane properties of the current hybrid membrane, reflected by the high permeance and SF, the corresponding module properties indicated that high-performance separation of CO₂ and CH₄ for the desired biogas upgrading was achieved at a limited processing capacity. This supports the importance of understanding the correlation between the membrane and module properties, as this will provide guidance for the optimal operating conditions.

Preparation of Al-Containing ZSM-58 Zeolite Membranes Using Rapid Thermal Processing for CO2/CH4 Mixture Separation

The synthesis of DDR-type zeolite membranes faces the problem of cracks that occur on the zeolite membrane due to differences in the thermal expansion coefficient between zeolite and the porous substrate during the detemplating process. In this study, Al-containing ZSM-58 zeolite membranes with DDR topology were prepared by rapid thermal processing (RTP), with the aim of developing a reproducible method for preparing DDR zeolite membrane without cracks. Moreover, we verified the influence of RTP before performing conventional thermal calcination (CTC) on ZSM-58 membranes with various silica-to-aluminum (Si/Al) molar ratios. Using the developed method, an Al-containing ZSM-58 membrane without cracks was obtained, along with complete template removal by RTP, and it had higher CO₂/CH₄ selectivity. An all-silica ZSM-58 membrane without cracks was obtained by only using the ozone detemplating method. ZSM-58 crystals and membranes with various Si/Al molar ratios were analyzed by using Fourier-transform infrared (FTIR) spectroscopy to confirm the effects of RTP treatment. Al-containing ZSM-58 zeolites had higher silanol concentrations than all-silica zeolites, confirming many silanol condensations by RTP. The condensation of silanol forms results in the formation of siloxane bonds and stronger resistance to thermal stress; therefore, RTP caused crack suppression in Al-containing ZSM-58 membranes. The results demonstrate that Al-containing ZSM-58 zeolite membranes with high CO₂ permeance and CO₂/CH₄ selectivity and minimal cracking can be produced by using RTP.

Isolable 1-Butene Copper(I) Complexes and 1-Butene/Butane Separation Using Structurally Adaptable Copper Pyrazolates

Non-porous small molecule adsorbents such as {[3,5-(CF₃ )₂ Pz]Cu}₃ (where Pz=pyrazolate) are an emerging class of materials that display attractive features for ethene-ethane separation. This work examines the chemistry of fluorinated copper(I) pyrazolates {[3,5-(CF₃ )₂ Pz]Cu}₃ and {[4-Br-3,5-(CF₃ )₂ Pz]Cu}₃ with much larger 1-butene in both solution and solid state, and reports the isolation of rare 1-butene complexes of copper(I), {[3,5-(CF₃ )₂ Pz]Cu(H₂ C=CHC₂ H₅ )}₂ and {[4-Br-3,5-(CF₃ )₂ Pz]Cu(H₂ C=CHC₂ H₅ )}₂ and their structural, spectroscopic, and computational data. The copper-butene adduct formation in solution involves olefin-induced structural transformation of trinuclear copper(I) pyrazolates to dinuclear mixed-ligand systems. Remarkably, larger 1-butene is able to penetrate the dense solid material and to coordinate with copper(I) ions at high molar occupancy. A comparison to analogous ethene and propene complexes of copper(I) is also provided.

Overcoming Fundamental Limitations in Adsorbent Design: Alkene Adsorption by Non-porous Copper(I) Complexes

Purifying alkenes from alkanes requires cryogenic distillation. This consumes energy equivalent to countries of ca. 5 million people. Replacing distillation with adsorption processes would significantly increase energy efficiency. Trade-offs between kinetics, selectivity, capacity, and heat of adsorption have prevented production of an optimal adsorbent. We report adsorbents that overcome these trade-offs. [Cu-Br]₃ and [Cu-H]₃ are air-stable trinuclear complexes that undergo reversible solid-state inter-molecular rearrangements to produce dinuclear [Cu-Br⋅(alkene)]₂ and [Cu-H⋅(alkene)]₂ . The reversible solid-state rearrangement, confirmed in situ using powder X-ray diffraction, allows adsorbent design trade-offs to be overcome, coupling low heat of adsorption (-10 to -17 kJ mol^-1 _alkene ), high alkene:alkane selectivity (47; 29), and uptake capacity (>2.5 mol_alkene  mol^-1 _Cu3 ). Most remarkably, [Cu-H]₃ displays fast uptake and regenerates capacity within 10 minutes.

Comparative study on different strategies for synthesizing all-silica DD3R zeolite crystals with a uniform morphology and size

In the last three decades, the all-silica deca-dodecasil 3R (DD3R) zeolite has been extensively studied as a significant potential class of porous materials in adsorptive separations. However, the use of most existing synthesis methods is unable to produce pure DD3R crystals with a uniform morphology and size. The present research, is therefore intended to provide a facile protocol to synthesize pure DD3R crystals with a controllable morphology and size and with a high reproducibility and productivity. Special attention was focused on investigating the effects of the type of seeds and the mineralizing reagent on the phase-purity, morphology, and crystal size of the resultant DD3R crystals. Various techniques, such as X-ray diffraction (XRD), scanning electron microscopy (SEM), N2 adsorption-desorption at 77 K, and thermogravimetric analysis (TGA) were then used to characterize the synthesized samples. The results show that by adding a small amount of "amorphous" DD3R or "amorphous" ZSM-58 seeds, the pure DD3R crystals with a uniform morphology and size can be synthesized using 1-adamantanamine (1-ADA) as a structure-directing agent (SDA), KF was used as a mineralizing reagent, and LUDOX AS-30 as a silicon source at 443 K for 1 d. In addition, the pure, large and uniform hexahedron DD3R crystals can be prepared using fumed silica as seeds, although the crystallization time takes a longer period of 3 d. The present work could stimulate fundamental research and industrial applications of the all-silica DD3R zeolite.

Adsorptive Separation of Geometric Isomers of 2-Butene on Gallate-Based Metal-Organic Frameworks

The separation of mixed C₄ olefins is a highly energy-intensive operation in the chemical industry due to the close boiling points of the unsaturated C₄ isomers. In particular, the separation of trans/cis-2-butene is among the most challenging separation processes for geometric isomers and is of prime importance to increase the added value of C₄ olefins. In this work, we report a series of isostructural gallate-based metal-organic frameworks (MOFs), namely, M-gallate (M = Ni, Mg, Co), featuring oval-shaped pores, that are ideally suitable for shape-selective separation of trans/cis-2-butene through their differentiation in minimum molecular cross-section size. Significantly, Mg-gallate displays a record high trans/cis-2-butene uptake selectivity of 3.19 at 298 K, 1.0 bar in single-component adsorption isotherms. These gallate-based MOFs not only exhibit the highest selectivity for trans/cis-2-butene separation but also accomplish a highly efficient separation of 1,3-butadiene, 1-butene, and iso-butene. DFT-D study shows that Mg-gallate interacts strongly with trans-2-butene and 1,3-butadiene along with short distances of C···H-O cooperative supramolecular interaction of 2.57-2.83 and 2.45-2.79 Å, respectively. In breakthrough experiments, Mg-gallate not only displays prominent separation performance for trans/cis-2-butene but also realizes the clean separation of a ternary mixture of 1,3-butadiene/1-butene/iso-butene and a binary mixture of 1-butene/iso-butene. This work indicates that M-gallate are industrially promising materials for adsorption separation of geometric isomers of C₄ hydrocarbons.

Improving Olefin Purification Using Metal Organic Frameworks with Open Metal Sites

The separation and purification of light hydrocarbons is challenging in the industry. Recently, a ZJNU-30 metal-organic framework (MOF) has been found to have the potential for adsorption-based separation of olefins and diolefins with four carbon atoms [H. M. Liu et al. Chem.-Eur. J. 2016, 22, 14988-14997]. Our study corroborates this finding but reveals Fe-MOF-74 as a more efficient candidate for the separation because of the open metal sites. We performed adsorption-based separation, transient breakthrough curves, and density functional theory calculations. This combination of techniques provides an extensive understanding of the studied system. Using this MOF, we propose a separation scheme to obtain a high-purity product.

Sustainable Separations of C4 -Hydrocarbons by Using Microporous Materials

Petrochemical refineries must separate hydrocarbon mixtures on a large scale for the production of fuels and chemicals. Typically, these hydrocarbons are separated by distillation, which is extremely energy intensive. This high energy cost can be mitigated by developing materials that can enable efficient adsorptive separation. In this critical review, the principles of adsorptive separation are outlined, and then the case for C₄ separations by using zeolites and metal-organic frameworks (MOFs) is examined. By analyzing both experimental and theoretical studies, the challenges and opportunities in C₄ separation are outlined, with a focus on the separation mechanisms and structure-selectivity correlations. Zeolites are commonly used as adsorbents and, in some cases, can separate C₄ mixtures well. The pore sizes of eight-membered-ring zeolites, for example, are in the order of the kinetic diameters of C₄ isomers. Although zeolites have the advantage of a rigid and highly stable structure, this is often difficult to functionalize. MOFs are attractive candidates for hydrocarbon separation because their pores can be tailored to optimize the adsorbate-adsorbent interactions. MOF-5 and ZIF-7 show promising results in separating all C₄ isomers, but breakthrough experiments under industrial conditions are needed to confirm these results. Moreover, the flexibility of the MOF structures could hamper their application under industrial conditions. Adsorptive separation is a promising viable alternative and it is likely to play an increasingly important role in tomorrow's refineries.

Consequences of secondary zeolite growth on catalytic performance in DMTO studied over DDR and CHA

Zeolites with DDR (Sigma-1 and ZSM-58) and CHA (SSZ-13) topology were synthesized by seed assisted and direct hydrothermal synthesis in order to investigate the effects of fast crystal growth on catalytic performance.

Methanol-to-olefins process over zeolite catalysts with DDR topology: effect of composition and structural defects on catalytic performance

The effect of physicochemical properties on catalyst deactivation, overall olefin selectivity and ethylene/propylene ratio during the methanol-to-olefins (MTO) reaction is presented for two zeolites with the DDR topology, Sigma-1 and ZSM-58.

Methods Comparison for the Synthesis of Deca-Dodecasil 3 Rhombohedral (DDR3) Zeolite Crystals

In the present work, DDR3 zeolite crystals were synthesized using two different methods. The silica sources used to synthesize DDR3 crystals were tetramethoxysilane (TMOS) and Ludox-40. The resultant samples were characterized using X-ray Diffraction (XRD) and Field Emission Scanning Electron Microscope (FESEM). The XRD results showed that the peaks representing DDR3 structure were not obtained for the sample synthesized in 5 days at room temperature with ultrasonic pre-treatment of 3h using Ludox-40 as silica source. On the other hand, the XRD pattern obtained for the sample synthesized in 25 days at 160 o C using TMOS as a silica source were similar with the XRD peaks reported in the literature. From these results, it can be concluded that the synthesis conditions of 25 days at 160 o C using TMOS as silica source were the favorable conditions in obtaining DDR3 crystal structure.

Accelerated synthesis of deca-dodecasil 3 rhombohedral (DDR3) zeolite crystals via hydrothermal growth coupled with ultrasonic irradiation method

In the present work, DDR3 zeolite crystals were synthesized via hydrothermal heating coupled with ultrasonic irradiation method.