Effect of H2O Activity on Zeolite Formation

In an effort to understand the effects of H₂O activity on zeolite formation, we have synthesized LTA zeolite using a combination of freezing processes and varying drying temperatures. Sodium aluminate and sodium silicate were used to form LTA zeolite, according to the IZA (International Zeolite Association) protocol. The synthesis steps were modified by adding the precursor frozen process by a rapid liquid nitrogen (-196 °C) treatment or slow conventional freezer treatment (-20 °C). The samples were subsequently sonicated and then dried at 80 °C or 40 °C. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were performed on the samples immediately after the drying process as well as after 2 weeks and 1 month of aging the solid products. The results indicated that LTA zeolite does not form. The silica-alumina precursor after both freezing processes and after being dried at 80 °C showed the presence of sodalite displaying stable behavior over time. Both sets of samples dried at 40 °C and did not show the presence of zeolite immediately after the drying process. However, after 2 weeks, the liquid nitrogen-frozen precursor was characterized by the presence of EMT whereas zeolites never formed in the -20 °C samples. These results suggest that freezing processes differently control the H₂O activity during the drying and aging processes in the solid state. Thus, although the precursor chemical composition is the same, the type of zeolite formed is different.

Hierarchical Nanomanufacturing: From Shaped Zeolite Nanoparticles to High-Performance Separation Membranes

Despite more than a decade of intense research on the high-resolution selectivity of thin zeolite films as alternatives to energy-intensive industrial separations, membranes consisting of intergrown, oriented zeolite crystals have fallen short of gaining wide commercial application. Factors including poor performance, high cost, and difficulties in scale up have contributed to this, and have also stunted their application in other niche markets. Until recently, rational design of these materials was limited because of the elusive mechanism of zeolite growth, and forced more empirical approaches. New understanding of zeolite growth along with recent advances in the molecular engineering of crystal microstructure and morphology, assembly of crystal monolayers, and synthesis of ordered films constitute a strong foundation for meeting stringent industrial demands in the future. Together with new processing capabilities, such a foundation should make it possible to synthesize commercially viable zeolite membranes through hierarchical approaches. Such advances open exciting prospects beyond the realm of separations for assembly of novel and complex functional materials including molecular sensors, mechanically stable dielectrics, and novel reaction-diffusion devices.