Advances and challenges in designing active site environments in zeolites for Brønsted acid catalysis

Zeolites contain proton active sites in diverse void environments that stabilize the reactive intermediates and transition states formed in converting hydrocarbons and oxygenates to chemicals and energy carriers. The catalytic diversity that exists among active sites in voids of varying sizes and shapes, even within a given zeolite topology, has motivated research efforts to position and quantify active sites within distinct voids (synthesis-structure) and to link active site environment to catalytic behavior (structure-reactivity). This Feature Article describes advances and challenges in controlling the position of framework Al centers and associated protons within distinct voids during zeolite synthesis or post-synthetic modification, in identifying and quantifying distinct active site environments using characterization techniques, and in determining the influence of active site environments on catalysis. During zeolite synthesis, organic structure directing agents (SDAs) influence Al substitution at distinct lattice positions via intermolecular interactions (e.g., electrostatics, hydrogen bonding) that depend on the size, structure, and charge distribution of organic SDAs and their mobility when confined within zeolitic voids. Complementary post-synthetic strategies to alter intrapore active site distributions include the selective removal of protons by differently-sized titrants or unreactive organic residues and the selective exchange of framework heteroatoms of different reactivities, but remain limited to certain zeolite frameworks. The ability to identify and quantify active sites within distinct intrapore environments depends on the resolution with which a given characterization technique can distinguish Al T-site positions or proton environments in a given zeolite framework. For proton sites in external unconfined environments, various (post-)synthetic strategies exist to control their amounts, with quantitative methods to distinguish them from internal sites that largely depend on using stoichiometric or catalytic probes that only interact with external sites. Protons in different environments influence reactivity by preferentially stabilizing larger transition states over smaller precursor states and influence selectivity by preferentially stabilizing or destabilizing competing transition states of varying sizes that share a common precursor state. We highlight opportunities to address challenges encountered in the design of active site environments in zeolites by closely integrating precise (post-)synthetic methods, validated characterization techniques, well-defined kinetic probes, and properly calibrated theoretical models. Further advances in understanding the molecular details that underlie synthesis-structure-reactivity relationships for active site environments in zeolite catalysis can accelerate the predictive design of tailored zeolites for desired catalytic transformations.

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.

Driving the Active Site Incorporation in Zeolitic Materials via the Organic Structure-Directing Agent Through Development of H-Bonds with Hydroxyl Groups

(1S,2S)-N-methyl-pseudoephedrine (MPS) was used as organic structure-directing agent (OSDA) for the synthesis of Mg-doped nanoporous aluminophosphates. This molecule displays a particular conformational behavior, where the presence of H-bond donor and acceptor groups provide a rigid conformational space with one asymmetric conformation preferentially occurring. MPS drives the crystallization of Mg-containing AFI materials. Characterization of these materials shows that the OSDA incorporate as protonated species, arranged as head-to-tail monomers. Combination of three-dimensional electron diffraction with high-resolution synchrotron powder X-ray diffraction allowed to locate both the Mg and the organic species. Interestingly, results showed that the spatial incorporation of Mg is driven by the hydroxyl groups of the organic cation through the development of H-bonds with negatively-charged MgO4 tetrahedra. This work demonstrates that H-bond forming groups can be used to drive the spatial incorporation of low-valent dopants within zeolitic frameworks, a highly desired aim in order to control their catalytic activity and selectivity.

Polymorph Selection in Zeolite Synthesis Occurs after Nucleation

Zeolites are porous crystals with extensive polymorphism. The hydrothermal synthesis of zeolites is a multistage process involving amorphous precursors that evolve continuously in solubility and local order toward those of the crystal. These results pose several questions: Why does a first-order transition appear as a continuous transformation? At which stage is the polymorph selected? How large are the barriers and critical sizes for zeolite nucleation? Here we address these questions using nucleation theory with experimental data. We find that the nucleation barriers and critical zeolite nuclei are extremely small at temperatures of hydrothermal synthesis, resulting in spinodal-like crystallization that produces a mosaic of tiny zeolitic crystallites that compete to grow inside each glassy precursor nanoparticle. The subnanometer size of the critical nuclei reveals that the selection between zeolite polymorphs occurs after the nucleation stage, during the growth and coarsening of the crystals around the excluded volume of the structure-directing agents.

Constructing single-crystalline hierarchical plate-like ZSM-5 zeolites with short b-axis length in the synthesis for catalyzing MTO reaction

ZSM-5 zeolite with hierarchical and lamellar structure is highly desired in industrial application. This paper reports an efficient additive, tetramethylguanidine (TMG), modifying crystal growth of the zeolite to this morphology....

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.

Factors controlling the molecular modification of one-dimensional zeolites

Interactions between organic molecules and inorganic materials are ubiquitous in many applications and often play significant roles in directing pathways of crystallization. It is frequently debated whether kinetics or thermodynamics plays a more prominent role in the ability of molecular modifiers to impact crystal nucleation and growth processes. In the case of nanoporous zeolites, approaches in rational design often capitalize on the ability of organics, used as either modifiers or structure-directing agents, to markedly impact the physicochemical properties of zeolites. It has been demonstrated for multiple topologies that modifier-zeolite interactions can alter crystal size and morphology, yet few studies have distinguished the roles of thermodynamics and kinetics. We use a combination of calorimetry and molecular modeling to estimate the binding energies of organics on zeolite surfaces and correlate these results with synthetic trends in crystal morphology. Our findings reveal unexpectedly small energies of interaction for a range of modifiers with two zeolite structures, indicating the effect of organics on zeolite crystal surface free energy is minor and kinetic factors most likely govern growth modification.

Fabrication of a core–shell MFI@TON material and its enhanced catalytic performance for toluene alkylation

Core–shell MFI@TON composites were designed and synthesized as a highly shape-selective catalyst for toluene alkylation by passivating the nonselective acid sites and tuning the diffusion behavior.

CO2 hydrogenation using bifunctional catalysts based on K-promoted iron oxide and zeolite: influence of the zeolite structure and crystal size

The influence of the zeolite structure and crystal size on bifunctional tandem catalysts combining K-promoted iron oxide (K/Fe₃O₄) with different zeolites has been studied for the CO₂ hydrogenation reaction at 320 °C and 25 bar.

Microfluidics and catalyst particles

In this review article, we discuss the latest advances and future perspectives of microfluidics for micro/nanoscale catalyst particle synthesis and analysis. In the first section, we present an overview of the different methods to synthesize catalysts making use of microfluidics and in the second section, we critically review catalyst particle characterization using microfluidics. The strengths and challenges of these approaches are highlighted with various showcases selected from the recent literature. In the third section, we give our opinion on the future perspectives of the combination of catalytic nanostructures and microfluidics. We anticipate that in the synthesis and analysis of individual catalyst particles, generation of higher throughput and better understanding of transport inside individual porous catalyst particles are some of the most important benefits of microfluidics for catalyst research.

Identifying the Factors Governing the Early-Stage Degradation of Cu-Chabazite Zeolite for NH3-SCR

To understand the degradation mechanism of the copper-ion-exchanged SSZ-13 (Cu-SSZ-13) is of high significance for rationally designing a zeolitic catalyst for ammonia-selective catalytic reduction of NO _x (NH₃-SCR). In this work, we focused on an Al-rich Cu-SSZ-13 and studied its structural degradation under hydrothermal conditions through a set of characterization techniques, including in situ X-ray diffraction (XRD), pair distribution function analysis and transmission electron microscopy-energy dispersive X-ray analysis (TEM-EDX). The results indicated that the chabazite structure tends to contract in the c direction upon hydrothermal treatment and consequently leads to the collapse of the four-membered ring. Such a structure change then results in the movement of isolated Cu²⁺ species from the face of the double six-membered ring to its center, which damages the structure further. However, the larger rings (6MRs and 8MRs) partially remain during the structure degradation, which possibly explains that some of the isolated Cu²⁺ species are alive even when the XRD-detectable crystallinity completely loses. The particle-by-particle observations through TEM-EDX analysis suggested that the occurrence of structural degradation differs remarkably from one individual particle to another. In general, particles with smaller size, having a lower Si/Al ratio and a higher Cu/Al ratio, tend to degrade easily. These results offer a thorough understanding of the structural degradation of Cu-SSZ-13 from the microscopic point of view and point out that the uniformity in composition and particle size of the zeolites plays a critical role in the early-stage degradation.

Additive-free synthesis of house-of-card faujasite zeolite by utilizing aluminosilicate gel memory

The gel “memory” effect of aluminosilicate sols was used to tune the mesopore size of hierarchical house-of-card faujasite in the absence of additives, following earlier findings by Khaleel et al. demonstrating the use of pre- and post-nucleation trajectories for the synthesis of high FAU content faujasite nanocrystals.

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.

Crystal Engineering for Catalysis

Crystal engineering relies upon the ability to predictively control intermolecular interactions during the assembly of crystalline materials in a manner that leads to a desired (and predetermined) set of properties. Economics, scalability, and ease of design must be leveraged with techniques that manipulate the thermodynamics and kinetics of crystal nucleation and growth. It is often challenging to exact simultaneous control over multiple physicochemical properties, such as crystal size, habit, chirality, polymorph, and composition. Engineered materials often rely upon postsynthesis (top-down) processes to introduce properties that would otherwise be challenging to attain through direct (bottom-up) approaches. We discuss the application of crystal engineering to heterogeneous catalysts with a focus on four general themes: ( a) tailored nanocrystal size, ( b) controlled environments surrounding active sites, ( c) tuned morphology with well-defined facets, and ( d) hierarchical materials with disparate pore size and active site distributions. We focus on nonporous materials, including metals and metal oxides, and two classes of porous materials: zeolites and metal organic frameworks. We review novel synthesis methods involving synergistic experimental and computational design approaches, the challenges facing catalyst development, and opportunities for future advancement in crystal engineering.

Formation domain of SDA-free Y faujasite small crystals

The ternary phase diagram shows that the domain for obtaining Y faujasite small crystals is very narrow.

Facile synthesis of ECNU-20 (IWR) hollow sphere zeolite composed of aggregated nanosheets

A germanosilicate ECNU-20 (IWR) zeolite, with a nanosheets aggregated hollow structure, was synthesized using a commercially available amine as structure-directing agent.

Topotactic conversion of layered silicate RUB-15 to silica sodalite through interlayer condensation in N-methylformamide

Layered silicate RUB-15 was topotactically converted to silica sodalite through interlayer condensation by refluxing in N-methylformamide.

The effect of the zeolite pore size on the Lewis acid strength of extra-framework cations

The catalytic activity and the adsorption properties of zeolites depend on their topology and composition. For a better understanding of the structure-activity relationship it is advantageous to focus just on one of these parameters. Zeolites synthesized recently by the ADOR protocol offer a new possibility to investigate the effect of the channel diameter on the adsorption and catalytic properties of zeolites: UTL, OKO, and PCR zeolites consist of the same dense 2D layers (IPC-1P) that are connected with different linkers (D4R, S4R, O-atom, respectively) resulting in the channel systems of different sizes (14R × 12R, 12R × 10R, 10R × 8R, respectively). Consequently, extra-framework cation sites compensating charge of framework Al located in these dense 2D layers (channel-wall sites) are the same in all three zeolites. Therefore, the effect of the zeolite channel size on the Lewis properties of the cationic sites can be investigated independent of other factors determining the quality of Lewis sites. UTL, OKO, and PCR and pillared 2D IPC-1PI materials were prepared in Li-form and their properties were studied by a combination of experimental and theoretical methods. Qualitatively different conclusions are drawn for Li(+) located at the channel-wall sites and at the intersection sites (Li(+) located at the intersection of two zeolite channels): the Lewis acid strength of Li(+) at intersection sites is larger than that at channel-wall sites. The Lewis acid strength of Li(+) at channel-wall sites increases with decreasing channel size. When intersecting channels are small (10R × 8R in PCR) the intersection Li(+) sites are no longer stable and Li(+) is preferentially located at the channel-wall sites. Last but not least, the increase in adsorption heats with the decreasing channel size (due to enlarged dispersion contribution) is clearly demonstrated.

Determination of the Preassembled Nucleating Units That Are Critical for the Crystal Growth of the Metal-Organic Framework CdIF-4

Identifying the form and role of the chemical species that traverse the stages of crystallization is critical to understanding the formation process of coordination polymers. Herein, we report the combined use of in situ atomic force microscopy and mass spectrometry to identify preformed, complex, cadmium 2-ethylimidazole containing solution species in the growth solution of the cadmium 2-ethylimidazolate metal-organic framework CdIF-4, and show that they are critical in the surface nucleation for the crystal growth of this material. Surface nucleation appears to be instigated by these [Cdx (CH3 CO2 )y (C5 H7 N2 /C5 H8 N2 )z ]-containing solution species and not by sole addition of the ligand molecules. The CH3 CO2 (-) or Cd(CH3 CO2 )2 groups of the former are substituted subsequently as the framework growth proceeds. Our greater understanding of such solution species and their role in crystallization will guide future syntheses of designed functional coordination polymers.

Organic template-free synthesis of zeolite mordenite nanocrystals through exotic seed-assisted conversion

A facile and organic-template-free route of exotic seed-assisted conversion is proposed to synthesize nano-crystallite assembled MOR zeolite with rich mesopores, high crystallinity, perfect framework, and high activity for large molecule cracking.

Zeolite synthesis in hydrated silicate ionic liquids

Hydrated alkali silicate ionic liquids (HSIL) were prepared by hydrolysis of tetraethoxysilane (TEOS) in alkali hydroxide–water mixtures, inducing coacervation and phase separation. The resulting optically clear, homogenous silicate ionic liquid offers exceptional potential for monitoring zeolite crystallisation. This enhanced synthesis route provides access to analysis of speciation, mechanistic details of zeolite formation, and brings organic-template-free zeolite synthesis by design within reach.