Synthesis of self-pillared zeolite nanosheets by repetitive branching

Influence of aluminum zoning toward external surfaces in MFI zeolites on propene oligomerization catalysis

Brønsted acid zeolites catalyze alkene oligomerization reactions, an important route to produce fuels and chemicals from light hydrocarbon feedstocks. Propene dimerization rates (per H+, 503 K) decrease monotonically with increasing crystallite size in MFI zeolites because heavy oligomer products remain occluded within microporous voids and restrict intrazeolite diffusion of reactants and products. Here, we show that the preferential zoning of framework Al centers and their associated H+ sites toward exterior surfaces of MFI crystallites in an "egg-shell" architecture minimizes the extent of diffusion-enhanced secondary reactions within a given crystallite, which increases both propene dimerization rates (per H+) and selectivity to true oligomer products. These results show that tailoring Al distributions to be spatially zoned toward external surfaces of medium-pore zeolite crystallites is efficacious at minimizing diffusion path lengths to increase alkene oligomerization rates and selectivity to true oligomer products.

Unraveling the Synergistic Mechanism of Ir Species with Various Electron Densities over an Ir/ZSM-5 Catalyst Enables High-Efficiency NO Reduction by CO

Selective catalytic reduction using CO as a reducing agent (CO-SCR) has exhibited its application potential in coal-fired, steel, and other industrial sectors. In comparison to NH3-SCR, CO-SCR can achieve synergistic control of CO and NO pollutants, making it a powerful denitrification technology that treats waste with waste. Unfortunately, the competitive adsorption of O2 and NO on CO-SCR catalysts inhibits efficient conversion of NOx under O2-containing conditions. In this work, we obtained two Ir sites with different electron densities, Ir1 single atoms in the oxidized Irδ+ state and Ir0 nanoparticles in the metallic state, by controlled pretreatment of the Ir/ZSM-5 catalyst with H2 at 200 °C. The coexistence of Ir1 single atoms and Ir0 nanoparticles on ZSM-5 creates a synergistic effect, which facilitates the reduction of NO through CO in the presence of O2, following the Langmuir-Hinshelwood mechanism. The ONNO dimer is formed on the Ir1 single atom sites and then spills over to the neighboring Ir0 nanoparticles for subsequent reduction to N2 by CO. Specifically, this tandem reaction enables 83% NO conversion and 100% CO conversion on an Ir-based catalyst at 250 °C under 3% O2.

Upcycling of polyethylene to gasoline through a self-supplied hydrogen strategy in a layered self-pillared zeolite

Conversion of plastic wastes to valuable carbon resources without using noble metal catalysts or external hydrogen remains a challenging task. Here we report a layered self-pillared zeolite that enables the conversion of polyethylene to gasoline with a remarkable selectivity of 99% and yields of >80% in 4 h at 240 °C. The liquid product is primarily composed of branched alkanes (selectivity of 72%), affording a high research octane number of 88.0 that is comparable to commercial gasoline (86.6). In situ inelastic neutron scattering, small-angle neutron scattering, solid-state nuclear magnetic resonance, X-ray absorption spectroscopy and isotope-labelling experiments reveal that the activation of polyethylene is promoted by the open framework tri-coordinated Al sites of the zeolite, followed by β-scission and isomerization on Brönsted acids sites, accompanied by hydride transfer over open framework tri-coordinated Al sites through a self-supplied hydrogen pathway to yield selectivity to branched alkanes. This study shows the potential of layered zeolite materials in enabling the upcycling of plastic wastes.

Synthesis of Two-Dimensional Zeolite Nanosheets Applied to the Catalytic Cracking of a Waste Cooking Oil Model Compound to Produce Light Olefins

Hierarchical zeolites can provide multidimensional spatial networks and, therefore, have significant potential as catalysts for the cracking of biomass to generate light olefins. The present work synthesized the diquaternary ammonium-type surfactant [C18H37-N+(CH3)2-(CH2)6-N+(CH3)2-C6H13]Br2, incorporating hydrophobic 18-carbon alkyl groups for usage as a structure-directing agent. This compound was subsequently used to prepare nanosheets of a hierarchical ZSM-5 two-dimensional zeolite (HNZSM-5) through a one-pot hydrothermal method. The crystal phase, morphology, and hierarchical structure of the HNZSM-5 were analyzed using various techniques, including X-ray diffraction, electron microscopy, and N2 adsorption/desorption. When applied to the catalytic cracking of a waste cooking oil model compound, the HNZSM-5 exhibited superior activity and stability compared with a conventional ZSM-5. This performance was attributed to the more accessible acid sites and unique lamellar structure of the former material. The HNZSM-5 also outlasted the conventional zeolite, showing deactivation after 45 h of reaction compared with 20 h, indicating exceptional stability and excellent resistance to coking.

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.

Structured Catalysts and Catalytic Processes: Transport and Reaction Perspectives

The structure of catalysts determines the performance of catalytic processes. Intrinsically, the electronic and geometric structures influence the interaction between active species and the surface of the catalyst, which subsequently regulates the adsorption, reaction, and desorption behaviors. In recent decades, the development of catalysts with complex structures, including bulk, interfacial, encapsulated, and atomically dispersed structures, can potentially affect the electronic and geometric structures of catalysts and lead to further control of the transport and reaction of molecules. This review describes comprehensive understandings on the influence of electronic and geometric properties and complex catalyst structures on the performance of relevant heterogeneous catalytic processes, especially for the transport and reaction over structured catalysts for the conversions of light alkanes and small molecules. The recent research progress of the electronic and geometric properties over the active sites, specifically for theoretical descriptors developed in the recent decades, is discussed at the atomic level. The designs and properties of catalysts with specific structures are summarized. The transport phenomena and reactions over structured catalysts for the conversions of light alkanes and small molecules are analyzed. At the end of this review, we present our perspectives on the challenges for the further development of structured catalysts and heterogeneous catalytic processes.

Fabrication of a ZIF-on-lamella-zeolite architecture as a highly efficient catalyst for aldol condensation

Designing composite catalysts that harness the strengths of individual components while mitigating their limitations is a fascinating yet challenging task in catalyst engineering. In this study, we aimed to enhance the catalytic performance by anchoring ZIF-67 nanoparticles of precise sizes onto lamella Si-MWW zeolite surfaces through a stepwise regrowth process. Co ions were initially grafted onto the zeolite surface using ultrasonication, followed by a seed-assisted secondary growth method. Si-MWW proved to be the ideal zeolite support due to its thin layered structure, large external surface area and substantial lateral dimensions. The abundant Si-OH groups on its surface played a crucial role in securely binding Co ions, limiting size growth and preventing undesirable ZIF-67 aggregation. The resulting ZIF-67/MWW composite with finely dispersed nano-scale ZIF-67 particles exhibited a remarkable catalytic performance and stability in the aldol condensation reactions involving acetone and various aldehydes. This approach holds promise for designing MOF/zeolite composite catalysts.

Transformation of CO2 to Carbon Nanotubes by Catalytic Chemical Vapor Deposition using a Metal-Supported Hierarchical Zeolite Template

The conversion of CO2 into valuable substances is a topic of great interest in current research. Carbon nanotubes (CNT) have emerged as highly promising materials for CO2 conversion. In this study, we successfully developed a catalyst by loading active transition metals (Fe or Ni) onto hierarchical zeolite for CNT synthesis. Our catalyst demonstrated excellent performance under synthetic conditions. The most favorable CNT was obtained using the 25 wt.% FeHieFAU catalyst, which exhibited a diameter size of 23.1 nm, a CNT yield of 15.4 %, and an ID /IG ratio of 0.56, indicating high quality. Additionally, we investigated the beneficial effects of the synthesized CNT by testing their current response. Notably, the current response of the synthesized CNT surpassed that of commercial CNT when using a 0.5 M H2 SO4 supporting electrolyte and cyclic voltammetry (V vs. Ag/AgCl). These findings highlight the significant contributions of the small diameter and superior quality of our synthesized pure CNT, which offer potential improvements in current response compared to commercial CNT. This research opens new avenues for utilizing CNT in CO2 conversion and electrochemical applications.

Constructing Intrapenetrated Hierarchical Zeolites with Highly Complete Framework via Protozeolite Seeding

Creation of intrapenetrated mesopores with open highway from external surface into the interior of zeolite crystals are highly desirable that can significantly improve the molecular transport and active sites accessibility of microporous zeolites to afford enhanced catalytic properties. Here, different from traditional zeolite-seeded methods that generally produced isolated mesopores in zeolites, nanosized amorphous protozeolites with embryo structure of zeolites were used as seeds for the construction of single-crystalline hierarchical ZSM-5 zeolites with intrapenetrated mesopores (mesopore volume of 0.51 cm3  g-1 ) and highly complete framework. In this strategy, in contrast to the conventional synthesis, only a small amount of organic structure directing agents and a low crystallization temperature were adopted to promise the protozeolites as the dominant growth directing sites to induce crystallization. The protozeolite nanoseeds provided abundant nucleation sites for surrounding precursors to be crystallized, followed by oriented coalescence of crystallites resulting in the formation of intrapenetrated mesopores. The as-prepared hierarchical ZSM-5 zeolites exhibited ultra-long lifetime of 443.9 hours and a high propylene selectivity of 47.92 % at a WHSV of 2 h-1 in the methanol-to-propylene reaction. This work provides a facile protozeolite-seeded strategy for the synthesis of intrapenetrated hierarchical zeolites that are highly effective for catalytic applications.

Mild Hydrogenation of 2-Furoic Acid by Pt Nanoparticles Dispersed in a Hierarchical ZSM-5 Zeolite

Hydrogenation of biobased compounds can add value to platform molecules obtained from biomass refining. Herein, we explore the hydrogenation of 2-furoic acid (2-furancarboxylic acid, FCA), a derivative of furfural, with H2 generated in situ by NaBH4 hydrolysis at ambient conditions. Nearly complete conversion of FCA was obtained with tetrahydrofuroic acid (THFA) and 5-hydroxyvaleric acid (5-HVA) as the only two reaction products over Pt nanoparticles supported on hierarchical ZSM-5. Small Pt nanoparticles (2 to 3 nm) were stabilized by ZSM-5 nanosheets. At an optimized Pt loading, the Pt nanoparticles can catalyze the hydrolysis of NaBH4 and the subsequent hydrogenation of FCA with the assistance of Brønsted acid sites. Nanostructuring ZSM-5 into nanosheets and its acidity contributes to the stability of the dispersed Pt nanoparticles. Deactivation due to NaBO2 deposition on the Pt particles can be countered by a simple washing treatment. Overall, this approach shows the promise of mild hydrogenation of biobased feedstock coupled with NaBH4 hydrolysis.

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Unveiling the Structural Characteristics of Intergrowth Zeolites Synthesized in the Presence of Isopropylimidazolium-Based Cations and Fluoride Anions

Here, we present the synthesis of RTH/ITE and MEL/MFI intergrowth zeolites using 2-isopropylimidazolium-based cations as organic structure-directing agents (OSDAs) in concentrated fluoride media and their local structural properties. Phase selectivity in the synthesis of zeolite intergrowths was found to differ according to the concentration of OSDA cations and fluoride anions in the synthesis mixture as well as to the type of OSDA employed. Molecular modeling results suggest that the crystallization of intergrowth zeolites in fluoride media may be kinetically rather than thermodynamically controlled, as in ordered zeolites. Cs-corrected STEM analysis of MEL/MFI crystals synthesized at HF/OSDA = 2.0 in the presence of 2-isopropyl-1,3-dipropylimidazolium ions as an OSDA indicates the existence of previously unobserved MEL-MFI intergrowth along the [100] direction, leading to a partial blockage of MEL 10-ring channels.

Asymmetric nanoporous membranes for ethanol/water pervaporation separation and their design

To explore the design of pervaporation membranes for ethanol recovery, zeolite nanosheets with different surface characteristics on the feed and permeate sides are investigated via molecular dynamics simulations. The results demonstrate the significant role of the permeate-side surface in the separation performance. By adopting an asymmetric membrane design with a hydrophobic feed-side surface and a hydrophilic one on the permeate side, the separation factor can be enhanced by nearly three-fold as compared to that of both hydrophobic surfaces, with an improved permeation flux.

Epitaxial growth of metal-organic framework nanosheets into single-crystalline orthogonal arrays

Construction of two-dimensional nanosheets into three-dimensional regular structures facilitates the mass transfer and exploits the maximum potential of two-dimensional building blocks in applications such as catalysis. Here, we report the synthesis of metal-organic frameworks with an orthogonal nanosheet array. The assembly involves the epitaxial growth of single crystalline metal-organic framework nanosheets with a naturally non-preferred facet exposure as the shell on a cubic metal-organic framework as the core. The nanosheets, despite of two typical shapes and crystallographic orientations, also form a single crystalline orthogonally arrayed framework. The density and size of nanosheets in the core-shell-structured composite metal-organic frameworks can be well adjusted. Moreover, metal-organic frameworks with a single composition and hollow orthogonal nanosheet array morphology can be obtained. Benefiting from the unusual facet exposure and macroporous structure, the designed structure exhibits improved electrocatalytic oxygen evolution activity compared to conventional nanosheets.

Approaching High-Performance TS-1 Zeolites in the Presence of Alkali Metal Ions via Combination of Adjusting pH Value and Modulating Crystal Size

Lewis acid zeolites play an important role in industrially important green reactions closely related to fine chemical and biomass conversion. Titanium-doped TS-1 zeolite is a milestone Lewis acid zeolite widely used in industrially significant green oxidation processes with hydrogen peroxide as an oxidant under mild conditions. TS-1 zeolites are normally synthesized in basic conditions under hydrothermal treatment. Up to now, there has still been no success in synthesizing active TS-1 Lewis acid zeolites by using inorganic alkali, e.g., NaOH or KOH as base, which is cheaper and more stable compared to the quaternary ammonium hydroxide or organic amines used in traditional synthesis. Here, an inorganic base of NaOH was employed in synthesizing active TS-1 zeolites for the first time. The crucial factor was the control of adverse effects of sodium cations on the incorporation of active titanium cations. Higher catalytic activity was achieved by further reducing the size of the TS-1 crystal by using the seed-added strategy, which uses the catalytic activity of a commercial catalyst, the production cost being much lower than commercial TS-1 catalysts, indicating great commercial potential and the possibility of preparing other cheap Lewis acid catalysts by using inorganic alkali.

Design of an Organic Template for Synthesizing ITR Zeolites under Ge-Free Conditions

Germanosilicate zeolites with various structures have been extensively synthesized, but the syntheses of corresponding zeolite structures in the absence of germanium species remain a challenge. One such example is an ITR zeolite structure, which is a twin of the ITH zeolite structure. Through the modification of a classic organic template for synthesizing ITH zeolites and thus designing a new organic template with high compatibility to ITR zeolite assisted by theoretical simulation, we, for the first time, show the Ge-free synthesis of an ITR structure including pure silica, aluminosilicate, and borosilicate ITR zeolites. These materials have high crystallinity, corresponding to an ITR content of more than 95%. In the methanol-to-propylene (MTP) reaction, the obtained aluminosilicate ITR zeolite exhibits excellent propylene selectivity and a long lifetime compared with conventional aluminosilicate ZSM-5 zeolite. The strategy for the design of organic templates might offer a new opportunity for rational syntheses of novel zeolites and, thus, the development of highly efficient zeolite catalysts in the future.

Facile synthesis of aluminosilicate zeolites with STT, CHA and MWW topology structures

Efficient synthesis of zeolites with different topologies is of great significance for both fundamental research and industrial application. Herein, the SSZ-23 zeolite, an odd zeolite containing 7-membered ring (7-MR) and 9-MR channels, has been synthesized under fluorine-free conditions via the route of pre-aging and pH regulation. By this novel synthesis route, the crystallization time can be significantly shortened to 3 days, nearly half as that by the conventional route in fluoride media. The pH value of the aging gel, i.e., the basicity, is found to play a key role in the synthesis, as SSZ-13 and SSZ-25 zeolites can be synthesized simply by changing the basicity of the same aging gel. Characterization results indicate that decreasing the basicity can promote the condensation between Si and Si/Al species and thus increase the framework density of the resulting zeolites. Finally, the dimethyl ether (DME) carbonylation reaction is employed to evaluate the catalytic properties of the above three zeolites with an identical chemical composition, and to reveal the unique confinement effect in various zeolite topologies.

Machine learning-assisted crystal engineering of a zeolite

It is shown that Machine Learning (ML) algorithms can usefully capture the effect of crystallization composition and conditions (inputs) on key microstructural characteristics (outputs) of faujasite type zeolites (structure types FAU, EMT, and their intergrowths), which are widely used zeolite catalysts and adsorbents. The utility of ML (in particular, Geometric Harmonics) toward learning input-output relationships of interest is demonstrated, and a comparison with Neural Networks and Gaussian Process Regression, as alternative approaches, is provided. Through ML, synthesis conditions were identified to enhance the Si/Al ratio of high purity FAU zeolite to the hitherto highest level (i.e., Si/Al = 3.5) achieved via direct (not seeded), and organic structure-directing-agent-free synthesis from sodium aluminosilicate sols. The analysis of the ML algorithms' results offers the insight that reduced Na₂O content is key to formulating FAU materials with high Si/Al ratio. An acid catalyst prepared by partial ion exchange of the high-Si/Al-ratio FAU (Si/Al = 3.5) exhibits improved proton reactivity (as well as specific activity, per unit mass of catalyst) in propane cracking and dehydrogenation compared to the catalyst prepared from the previously reported highest Si/Al ratio (Si/Al = 2.8).

MFI Type Zeolite Aggregates with Nanosized Particles via a Combination of Spray Drying and Steam-Assisted Crystallization (SAC) Techniques

Hydrothermal synthesis is the state-of-the-art technique for the preparation of zeolites and related porous solids. However, when it comes to the preparation of nanosized zeolites, this technique is limited by low yields, separation problems and high amounts of waste. In this work, we utilized the strengths of a combination of spray drying and steam-assisted crystallization (SAC), also known as dry gel conversion, to reduce these problems. At spray drying temperatures between 300 and 400 °C, it was possible to convert all the amorphous material via SAC into zeolite particles without extra addition of template. Kinetic studies of SAC revealed that about 4 to 8 days are needed to achieve the formation of a 100% crystalline product. The newly formed crystalline phase was crystallized on the surface of the nanosized zeolites and led to a slight increase in the primary particle size while the macroscopic morphology of the spray-dried aggregates was preserved. This work demonstrates that the combination of spray drying and SAC are useful tools in supplementing the hydrothermal synthesis of nanosized zeolites.

A Six-Membered Ring Molecular Sieve Achieved by a Reconstruction Route

Zeolite molecular sieves with at least eight-membered rings are widely applied in industrial applications, while zeolite crystals with six-membered rings are normally regarded as useless products due to the occupancy of the organic templates and/or inorganic cation in the micropores that could not be removed. Herein, we showed that a novel six-membered ring molecular sieve (ZJM-9) with fully open micropores could be achieved by a reconstruction route. The mixed gas breakthrough experiments such as CH₃OH/H₂O, CH₄/H₂O, CO₂/H₂O, and CO/H₂O at 25 °C showed that this molecular sieve was efficient for selective dehydration. Particularly, a lower desorption temperature (95 °C) of ZJM-9 than that (250 °C) of the commercial 3A molecular sieve might offer an opportunity for saving more energy in dehydration processes.

Recent Advances in Tetra- (Ti, Sn, Zr, Hf) and Pentavalent (Nb, V, Ta) Metal-Substituted Molecular Sieve Catalysis

Metal substitution of molecular sieve systems is a major driving force in developing novel catalytic processes to meet current demands of green chemistry concepts and to achieve sustainability in the chemical industry and in other aspects of our everyday life. The advantages of metal-substituted molecular sieves include high surface areas, molecular sieving effects, confinement effects, and active site and morphology variability and stability. The present review aims to comprehensively and critically assess recent advances in the area of tetra- (Ti, Sn, Zr, Hf) and pentavalent (V, Nb, Ta) metal-substituted molecular sieves, which are mainly characterized for their Lewis acidic active sites. Metal oxide molecular sieve materials with properties similar to those of zeolites and siliceous molecular sieve systems are also discussed, in addition to relevant studies on metal-organic frameworks (MOFs) and some composite MOF systems. In particular, this review focuses on (i) synthesis aspects determining active site accessibility and local environment; (ii) advances in active site characterization and, importantly, quantification; (iii) selective redox and isomerization reaction applications; and (iv) photoelectrocatalytic applications.

Steering interface effect of H-ZSM-5 zeolites with tailored surface barriers to improve their catalytic performances

An efficient zeolite interface with optimized surface barriers was tailored by passivating the hydroxyl-group defects at surfaces or near pore mouths. The surface permeability of the modified zeolite was almost 90% greater than that of the pristine one, leading to remarkable improvements in C=2-3 selectivity and an anti-inactivation rate of 75% for the catalytic cracking reaction.

Unique Role of GeO2 as a Noninvasive Promoter of Nano-Sized Zeolite Crystals

The synthesis of zeolites with nano-sized dimensions is often limited to a narrow design space that conventionally relies upon the design of organics to direct hierarchical materials. Here, it is demonstrated that the addition of an inorganic modifier, germanium oxide (GeO₂ ), to a zeolite growth mixture directs the formation of crystals with ultrasmall dimensions. This effect is observed for zeolites ZSM-11 and ZSM-5 over a range of synthesis conditions wherein the role of GeO₂  in zeolite crystallization deviates from its typical function as a heteroatom. Notably, the final products contain trace amounts of Ge, which indicates the inorganic modifier does not compete for sites in the zeolite framework based on its formation of a discrete phase that enables GeO₂  recovery. Catalytic tests using the methanol-to-hydrocarbons reaction reveal significant enhancement in the performance of zeolite catalysts prepared with GeO₂  compared to reported examples of nano-sized zeolites. These findings highlight a potentially generalizable and commercially viable synthesis method to reduce mass-transport limitations in zeolites for diverse applications.

Low-Cost and Environmental-Friendly Route for Synthesizing Nano-Rod Aluminosilicate MAZ Zeolite

Preparation of nano-rod aluminosilicate Mazzit (MAZ) zeolite under low-cost and environmental-friendly route is attractive, but still challenging. Herein, we report a green route for synthesizing nano-rod MAZ zeolite (MAZ-N) using low-cost and environmental-friendly choline chloride as template. Various characterizations including powder X-ray diffraction (XRD), scanning electron microscope (SEM), N₂ sorption, and thermogravimetry-differential thermal analysis (TG-DTA) show that MAZ-N samples have good crystallinity and uniform porous structures. Furthermore, the crystallization process and impact of synthesis conditions of MAZ-N samples have been investigated in detail. These results suggest the potential applications of MAZ-N zeolites as supporting catalyst compounds in industrial processes.

Molecular transport in zeolite catalysts: depicting an integrated picture from macroscopic to microscopic scales

Increasing social sustainability triggers the persistent progress of industrial catalysis in energy transformation and chemical production. Zeolites have been demonstrated to be pivotal catalysts in chemical industries due to their moderate acidity and versatile well-defined pore structures. However, in the context of enhancing the performances of zeolite catalysts, the perspectives on the diffusion regulations within the pores and channels in the bulk phases or external surfaces of the zeolites are often overlooked. Establishing the structure-transport-reactivity relationships in heterogeneous catalysis can provide rational guidelines to design high-performance catalysts. Herein, this tutorial review attempts to systematically depict an integrated picture of molecular transport behaviors in zeolite catalysts from macroscopic to microscopic perspectives. The advances in the accurate diffusion measurements employing both macroscopic and microscopic techniques are briefly introduced. The diffusion characteristics in zeolite catalysts under working conditions (e.g., high temperature, multi-components, and reaction coupling) are then addressed. The macroscopic internal diffusion and the microscopic diffusion occurring in the micro-zones of zeolite crystals (e.g., surface diffusion, diffusion anisotropy, and confined diffusion) are reviewed and discussed in more detail. These diffusion behaviors highly impact the underlying reaction mechanism, catalytic performances, and catalyst optimization strategies. Finally, the multi-type pore systems of practical zeolite catalysts in industrial reactors and their transport behaviors are analyzed. The fully-crystalline monolithic zeolites in the absence of binders are highlighted as rising-star catalytic materials for industrial applications. The research challenges in this field and the potential future development directions are summarized.

Recent Advances in the Seed-Directed Synthesis of Zeolites without Addition of Organic Templates

Zeolites have been widely employed in fields of petroleum refining, fine chemicals and environmental protection, but their syntheses are always performed in the presence of organic templates, which have many drawbacks such as high cost and polluted wastes. In recent years, the seed-directed synthesis of zeolites has been paid much attention due to its low-cost and environmentally friendly features. In this review, the seed-directed synthesis of Al-rich zeolites with homonuclear and heteronuclear features, the seed-directed synthesis of Si-rich zeolites assisted with ethanol and the utility of seed-directed synthesis have been summarized. This review could help zeolite researchers understand the recent progress of seed-directed synthesis.

Coking-Resistant Polyethylene Upcycling Modulated by Zeolite Micropore Diffusion

Although the mass production of synthetic plastics has transformed human lives, it has resulted in waste accumulation on the earth. Here, we report a low-temperature conversion of polyethylene into olefins. By mixing the polyethylene feed with rationally designed ZSM-5 zeolite nanosheets at 280 °C in flowing hydrogen as a carrier gas, light hydrocarbons (C₁-C₇) were produced with a yield of up to 74.6%, where 83.9% of these products were C₃-C₆ olefins with almost undetectable coke formation. The reaction proceeds in multiple steps, including polyethylene melting, flowing to access the zeolite surface, cracking on the zeolite surface, formation of intermediates to diffuse into the zeolite micropores, and cracking into small molecules in the zeolite micropores. The ZSM-5 zeolite nanosheets kinetically matched the cascade cracking steps on the zeolite external surface and within micropores by boosting the intermediate diffusion. This feature efficiently suppressed the intermediate accumulation on the zeolite surface to minimize coke formation. In addition, we found that hydrogen participation in the cracking process could hinder the formation of polycyclic species within zeolite micropores, which also contributes to the rapid molecule diffusion. The coking-resistant polyethylene upcycling process at a low temperature not only overturns the general viewpoint for facile coke formation in the catalytic cracking over the zeolites but also demonstrates how the polyethylene-based plastics can be upcycled to valuable chemicals. In addition to the model polyethylene, the reaction system worked efficiently for the depolymerization of multiple practically used polyethylene-rich plastics, enabling an industrially and economically viable path for dealing with plastic wastes.

Defect-Guided Synthesis of Hierarchical Sn-B-Beta Zeolite with Highly Exposed Sn Sites

Selectively anchoring active centers on the external surface for forming highly exposed acid sites is a highly desirable but challenging task in zeolite catalyst synthesis. Herein, a defect-guided etching-regrowth strategy is rationally designed for facilely positioning Sn Lewis acid sites on the outer surface of the Sn-B-Beta while fabricating a bifunctional hierarchical structure. The synthesis was conducted by hydrothermal treatment of the as-made B-Beta (uncalcined), which has intrinsic defects of the BEA structure, with Sn source and basic organic structure directing agent (SDA). Under a moderate SDA concentration, with blocked micropore channels, such SDA-triggered etching-regrowth will proceed along the defect defined pathway, which ensures Sn selectively anchored on the external surface. Moreover, this methodology has exclusively introduced tetrahedrally coordinated framework Sn with open Sn sites as the predominated species. Mono- and disaccharide isomerizations in ethanol over different Sn-Beta catalysts proved the prominent advantages of the hierarchical structure with highly exposed and synergetic acid sites.

Electron Diffraction Enables the Mapping of Coke in ZSM-5 Micropores Formed during Methanol-to-Hydrocarbons Conversion

Unveiling the coke formation in zeolites is an essential prerequisite for tackling the deactivation of these catalysts in the transformations of hydrocarbons. Herein, we present the direct mapping of coke in the micropores of ZSM‐5 catalysts used in methanol‐to‐hydrocarbons conversion by single‐crystal electron diffraction analysis. The latter technique revealed a polycyclic aromatic structure along the straight channel, wherein the high‐quality data permit refinement of its occupancy to about 40 %. These findings were exploited to analyze the evolution of micropore coke during the reaction. Herein, coke‐associated signals, which correlate with the activity loss, indicate that the nucleation of coke commences in the intersections of sinusoidal and straight channels, while the formation of coke in the straight pores occurs in the late stages of deactivation. The findings uncover an attractive method for analyzing coke deposition in the micropore domain.

Stacking-faulted CDO zeolite nanosheets efficient for bulky molecular reactions

The synthesis of thin zeolite nanosheets beneficial for catalytic reactions, adsorption and diffusion involving bulky molecules remains a great challenge. Herein, we report a unique layered zeolitic nanosheet ECNU-57 with a CDO-type structure that was synthesized by employing small-molecular 1,4-bis(N-methylpyrrolidinium) cations as the organic structure-directing agent (OSDA). The ECNU-57 nanosheets are 50 nm thick along the b-axis and have an open hierarchical porosity with 486 m² g^-1 surface area. HRTEM investigation indicates that the nanosheets exhibit a stacking fault structure along the b-axis with the inclusion of the FER structure since the CDO and FER topologies possess very similar building layers. As a solid-acid catalyst, ECNU-57 exhibits promising performances in the reactions of 1,3,5-triisopropylbenzene cracking and Friedel-Crafts acylation, due to its enhanced mass transfer and more accessible active sites to bulky organic molecules.

Construction of Single-Crystalline Hierarchical ZSM-5 with Open Nanoarchitectures via Anisotropic-Kinetics Transformation for the Methanol-to-Hydrocarbons Reaction

We report an anisotropic-kinetics transformation strategy to prepare single-crystalline aluminosilicate MFI zeolites (ZSM-5) with highly open nanoarchitectures and hierarchical porosities. The methodology relies on the cooperative effect of in situ etching and recrystallization on the evolution of pure-silica MFI zeolite (silicalite-1) nanotemplates under hydrothermal conditions. The strategy enables a controllable preparation of ZSM-5 nanostructures with diverse open geometries by tuning the relative rate difference between etching and recrystallization processes. Meanwhile, it can also be extended to synthesize other heteroatom-substituted MFI zeolite nanocages. Compared with conventional ZSM-5 microcrystals, nanocrystals, and nanoboxes, the ZSM-5 nanocages with single-crystalline nature, highly open nanoarchitectures, and hierarchical porosities exhibit remarkably enhanced catalytic lifetime and low coking rate in the methanol-to-hydrocarbons (MTH) reaction.

Twin-free, directly synthesized MFI nanosheets with improved thickness uniformity and their use in membrane fabrication

Zeolite nanosheets can be used for the fabrication of low-defect-density, thin, and oriented zeolite separation membranes. However, methods for manipulating their morphology are limited, hindering progress toward improved performance. We report the direct synthesis (i.e., without using exfoliation, etching, or other top-down processing) of thin, flat MFI nanosheets and demonstrate their use as high-performance membranes for xylene isomer separations. Our MFI nanosheets were synthesized using nanosheet fragments as seeds instead of the previously used MFI nanoparticles. The obtained MFI nanosheets exhibit improved thickness uniformity and are free of rotational and MEL intergrowths as shown by transmission electron microscopy (TEM) imaging. The nanosheets can form well-packed nanosheet coatings. Upon gel-free secondary growth, the obtained zeolite MFI membranes show high separation performance for xylene isomers at elevated temperature (e.g., p-xylene flux up to 1.5 × 10^-3 mol m^-2 s^-1 and p-/o-xylene separation factor of ~600 at 250°C).

Ethanol and Water Adsorption in Conventional and Hierarchical All-Silica MFI Zeolites

Hierarchical zeolites containing both micro- (<2 nm) and mesopores (2-50 nm) have gained increasing attention in recent years because they combine the intrinsic properties of conventional zeolites with enhanced mass transport rates due to the presence of mesopores. The structure of the hierarchical self-pillared pentasil (SPP) zeolite is of interest because all-silica SPP consists of orthogonally intergrown single-unit-cell MFI nanosheets and contains hydrophilic surface silanol groups on the mesopore surface while its micropores are nominally hydrophobic. Therefore, the distribution of adsorbed polar molecules, like water and ethanol, in the meso- and micropores is of fundamental interest. Here, molecular simulation and experiment are used to investigate the adsorption of water and ethanol on SPP. Vapor-phase single-component adsorption shows that water occupies preferentially the mesopore corner and surface regions of the SPP material at lower pressures (P/P ₀ < 0.5) while loading in the mesopore interior dominates adsorption at higher pressures. In contrast, ethanol does not exhibit a marked preference for micro- or mesopores at low pressures. Liquid-phase adsorption from binary water-ethanol mixtures demonstrates a 2 orders of magnitude lower ethanol/water selectivity for the SPP material compared to bulk MFI. For very dilute aqueous solutions of ethanol, the ethanol molecules are mostly adsorbed inside the SPP micropore region due to stronger dispersion interactions and the competition from water for the surface silanols. At high ethanol concentrations (C _EtOH > 700 g L^-1), the SPP material becomes selective for water over ethanol.

Facile Synthesis of Nanosheet-Stacked Hierarchical ZSM-5 Zeolite for Efficient Catalytic Cracking of n-Octane to Produce Light Olefins

The development of an effective strategy for synthesizing two-dimensional MFI zeolites has attracted more and more attention. Herein, nanosheet-stacked hierarchical ZSM-5 zeolite was obtained by a seed-assisted hydrothermal synthesis route using a small amount of [C18H37-N+(CH3)2-C6H12-N+(CH3)2-C6H12]Br2 (C18-6-6Br2) as a zeolite structure-directing agent and triethylamine (TEA) as a zeolite growth modifier. By varying the molar ratio of C18-6-6Br2/TEA from 2.5/0 to 2.5/40, the morphologies and textural properties of the resultant HZ5-2.5/x catalysts were finely modulated. By increasing x from 5 to 40, the morphology of the HZ5-2.5/x changed from unilamellar assembly with narrow a–c plane to intertwined nanosheets with wide a–c plane and multilamellar nanosheets with house-of-cards morphology. The thickness of these nanosheets was almost 8–10 nm. In addition, selectivity to light olefins reached 70.7% for the HZ5-2.5/10 catalyst, which was 6.6% higher than that for CZSM-5 (64.1%). Furthermore, the MFI zeolite nanosheets exhibited better anticoking stability within the 60 h reaction time compared to conventional ZSM-5 zeolite, which could be attributed to the short diffusion path and hierarchical porosity. This work will provide valuable insights into the rational design of novel zeolite catalysts for the efficient cracking of hydrocarbons.

Zeolite nanosheets for catalysis

Zeolites with well-defined micropores have been widely used as heterogeneous catalysts in the fields of petroleum refining, fine chemicals, and environment protection. However, the sole micropores in the zeolite structures usually impose diffusion constraints, which would greatly influence their catalytic performances. Therefore, it is highly desirable to shorten the diffusion pathway of zeolites and thus eliminate the diffusion constraints. One of the efficient methods is to synthesize zeolite nanosheets, which has become a hot topic in the past decades. In this tutorial review, the recent progresses in the synthesis of zeolite nanosheets and their relevant catalysis are briefly discussed. Various strategies for the synthesis of zeolite nanosheets are summarized including delamination, templated crystallization, additive-assisted synthesis, seed-directed synthesis, and gaseous expansion synthesis. In addition, the catalytic reactions of zeolite nanosheets with acidic and metal sites are also outlined. This tutorial review should be significant for the design and preparation of highly efficient zeolite catalysts.

Design of a Small Organic Template for the Synthesis of Self-Pillared Pentasil Zeolite Nanosheets

Zeolite nanosheets with excellent mass transfer are attractive, but their successful syntheses are normally resulted from a huge number of experiments. Here, we show the design of a small organic template for the synthesis of self-pillared pentasil (SPP) zeolite nanosheets from theoretical calculations in interaction energies between organic templates and pentasil zeolite skeletons. As expected, the SPP zeolite nanosheets with the thickness at 10-20 nm have been synthesized successfully. Characterizations show that the SPP zeolite nanosheets with about 90% MFI and 10% MEL structures have good crystallinity, the house-of-card morphology, large surface area, and fully four-coordinated aluminum species. More importantly, methanol-to-propylene tests show that the SPP zeolite nanosheets exhibit much higher propylene selectivity and longer reaction lifetime than conventional ZSM-5 zeolite. These results offer a good opportunity to develop highly efficient zeolite catalysts in the future.

Improvement of adsorption and catalytic properties of zeolites by precisely controlling their particle morphology

An aluminosilicate zeolite has a porous structure with openings comparable to the molecular size, which endows it with unique adsorptive and catalytic properties that are highly dependent on its chemical composition and crystal morphology. Thus, the precise control or rational design of zeolite's particle morphology has attracted much attention as it can greatly improve the adsorptive separation and catalytic properties by effectively adjusting the diffusion path of adsorbates, reactants and products. This paper reviews the recent progress made in the synthesis and application of zeolites with a specific crystal/particle morphology with emphasis on the control of the crystal size and facet exposure degree, oriented assembly of crystals, creation of hierarchical porous structures and synthesis of core-shell structures. It is shown that an appropriate decrease of the crystal size and/or an increase of the exposure degree of certain facets by adding seeds and optimizing the synthesis conditions enhances the catalytic stability and product selectivity in some reactions. This can also be achieved by introducing plenty of mesopores and/or macropores in zeolites as a result of significant alleviation of diffusion limitation. Assembly of zeolite crystals into membranes on porous substrates improves the adsorptive separation performance of zeolites, for e.g. alcohol/water mixture and xylene and butane isomers. Core-shell-structured composites with metal nanoparticles or subnanoparticles as the core and the zeolite, including its modified counterpart, as the shell show excellent catalytic performance in some hydrogenation, dehydrogenation and oxidation reactions. In addition, attempts to illustrate the relationship between zeolite's particle morphology and its catalytic performance are discussed and strategies for the rational design of zeolite's particle size and behavior are envisioned.

Single-walled zeolitic nanotubes

We report the synthesis and structure of single-walled aluminosilicate nanotubes with microporous zeolitic walls. This quasi-one-dimensional zeolite is assembled by a bolaform structure-directing agent (SDA) containing a central biphenyl group connected by C₁₀ alkyl chains to quinuclidinium end groups. High-resolution electron microscopy and diffraction, along with other supporting methods, revealed a unique wall structure that is a hybrid of characteristic building layers from two zeolite structure types, beta and MFI. This hybrid structure arises from minimization of strain energy during the formation of a curved nanotube wall. Nanotube formation involves the early appearance of a mesostructure due to self-assembly of the SDA molecules. The biphenyl core groups of the SDA molecules show evidence of π stacking, whereas the peripheral quinuclidinium groups direct the microporous wall structure.