Towards the Rational Design of Efficient Organic Structure‐Directing Agents for Zeolite Synthesis

Zeolites are crystalline microporous materials with application in diverse fields, especially in catalysis. The ability to prepare zeolites with targeted physicochemical properties for a specific catalytic application is a matter of great interest, because it allows the efficiency of the entire chemical process to be increased (higher product yields, lower undesired by‐products, less energy consumption, and cost savings, etc). Nevertheless, directing the zeolite crystallization towards the material with the desired framework topology, crystal size, or chemical composition is not an easy task, since several variables influence the nucleation and crystallization processes. The combination of accumulated knowledge, rationalization, and innovation has allowed the synthesis of unique zeolitic structures in the last few years. This is especially true in terms of the design of organic and inorganic structure‐directing agents (SDAs). In this Minireview we will present the rationale we have followed in our studies to synthesize new zeolite structures, while putting this in perspective with the advances made by other researchers of the zeolite community.     

B‐MWW Zeolite: The Case Against Single‐Site Catalysis

Boron‐containing materials have recently been identified as highly selective catalysts for the oxidative dehydrogenation (ODH) of alkanes to olefins. It has previously been demonstrated by several spectroscopic characterization techniques that the surface of these boron‐containing ODH catalysts oxidize and hydrolyze under reaction conditions, forming an amorphous B₂(OH)_xO_(3?x/2) (x=0–6) layer. Yet, the precise nature of the active site(s) remains elusive. In this Communication, we provide a detailed characterization of zeolite MCM‐22 isomorphously substituted with boron (B‐MWW). Using ¹¹B solid‐state NMR spectroscopy, we show that the majority of boron species in B‐MWW exist as isolated BO₃ units, fully incorporated into the zeolite framework. However, this material shows no catalytic activity for ODH of propane to propene. The catalytic inactivity of B‐MWW for ODH of propane falsifies the hypothesis that site‐isolated BO₃ units are the active site in boron‐based catalysts. This observation is at odds with other traditionally studied catalysts like vanadium‐based catalysts and provides an important piece of the mechanistic puzzle.     

Critical Factors in the Seed‐Assisted Synthesis of Zeolite Beta and “Green Beta” from OSDA‐Free Na+–Aluminosilicate Gels

Organic structure‐directing agent (OSDA)‐free synthesis of zeolite beta is a subject of both scientific and industrial interest. Herein, we report a comprehensive investigation into the effects of various parameters on the seed‐assisted crystallization of zeolite beta in the absence of OSDA. The crystallization behavior of “OSDA‐free beta” is strongly governed by the chemical composition of the starting Na⁺‐aluminosilicate gel as well as by the Si/Al ratios of the calcined beta seed crystals, which are prepared using tetraethylammonium hydroxide (TEAOH). Furthermore, OSDA‐free beta seed crystals can be used to form zeolite beta, termed “green beta”. XRD, scanning electron microscopy, inductively coupled plasma atomic emission spectroscopy, and ²⁷Al magic angle spinning NMR analyses showed that the OSDA‐free beta and green beta were of high purity and crystallinity. The nitrogen adsorption–desorption of OSDA‐free beta and green beta revealed higher surface areas and larger volumes in the micropore region than those of the beta seeds synthesized with OSDA after calcination. These results provide a robust and reliable process for the environmentally friendly production of high‐quality zeolite beta in a completely OSDA‐free Na⁺‐aluminosilicate system.     

Synthesis of Silicate Zeolite Analogues Using Organic Sulfonium Compounds as Structure‐Directing Agents

A microporous crystalline silica zeolite of the MEL structure type and three other zeolite analogues composed of germanosilicate frameworks were synthesized using tributylsulfonium, triphenylsulfonium, or tri(para‐tolyl)sulfonium as the structure‐directing agent. The germanosilicates thus obtained had ISV, ITT, or a new zeolite structure depending on the synthesis conditions. The structure of the new germanosilicate was solved using X‐ray powder diffraction data with the aid of a charge‐flipping method. The solution indicated a crystal structure belonging to the P63/mmc space group with cell parameters of a=16.2003 Å and c=21.8579 Å. After calcination, the new germanosilicate material exhibited two types of accessible micropores with diameters of 0.61 and 0.78 nm.     

Direct Synthesis of Nano‐Ferrierite along the 10‐Ring‐Channel Direction Boosts Their Catalytic Behavior

Ferrierite zeolites with nanosized crystals and external surface areas higher than 250 m² g^?1 have been prepared at relatively low synthesis temperature (120 °C) by means of the collaborative effect of two organic structure directing agents (OSDA). In this way, hierarchical porosity is achieved without the use of post‐synthesis treatments that usually involve leaching of T atoms and solid loss. Adjusting the synthesis conditions it is possible to decrease the crystallite size in the directions of the 8‐ and 10‐ring channels, [010] and [001] respectively, reducing their average pore length to 10–30 nm and increasing the number of pores accessible. The small crystal size of the nano‐ferrierites results in an improved accessibility of reactants to the catalytic active centers and enhanced product diffusion, leading to higher conversion and selectivity with lower deactivation rates for the oligomerization of 1‐pentene into longer‐chain olefins.     

ZSM‐5 Zeolite Nanosheets with Improved Catalytic Activity Synthesized Using a New Class of Structure‐Directing Agents

A new series of multiquaternary ammonium structure‐directing agents, based on 1,4‐diazabicyclo[2.2.2]octane, was prepared. ZSM‐5 zeolites with nanosheet morphology (10 nm crystal thickness) were synthesized under hydrothermal conditions using multiquaternary ammonium surfactants as the zeolite structure‐generating agents. Both wide‐angle and small‐angle diffraction patterns were obtained using only a suitable structure‐directing agent under a specific zeolite synthesis composition. A mechanism of zeolite formation is proposed based on the results obtained from various physicochemical characterizations. ZSM‐5 materials were investigated in catalytic reactions requiring medium to strong acidity, which are important for the synthesis of a wide range of industrially important fine and specialty chemicals. The catalytic activity of ZSM‐5 materials was compared with that of the conventional ZSM‐5 and amorphous mesoporous aluminosilicate Al‐MCM‐41. The synthesis strategy of the present investigation using the new series of structure‐directing agents could be extended for the synthesis of other related zeolites or other porous materials in the future. Zeolite with a structural feature as small as the size of a unit cell (5–10 nm) with hierarchically ordered porous structure would be very promising for catalysis.     

Synthesis of Pure Silica MWW Zeolite in Fluoride Medium by Using an Imidazolium-Based Long Dication

As the spacer length in 1,2-dimethylimidazolium-based dications increases beyond a specific point (six methylene units), they fail in structure-directing towards STW zeolites in any synthetic conditions. These dications can instead produce, under fluoride concentrated conditions, either *BEA [in the case of the eight-methylene-unit structure-directing agent (SDA)] or MWW (ten methylene units) zeolites. For any length of the dication, the default zeolite (MTW) is a relatively dense zeolite containing a unidimensional channel, whereas the zeolite demanding most specificity (STW, *BEA or MWW) is more porous, affording a larger concentration of the dication to be occluded. This work provides the first reported fluoride synthesis of pure silica MWW zeolites. Charge balance of the organic dications in this zeolite was achieved by combining “structural” silanolates, regular “connectivity defects” and occluded fluoride. Molecular mechanics calculations showed a perfect fit of the decamethylenebis(dimethylimidazolium) dication in the sinusoidal intralayer pore system of MWW. The calculations showed also that the dication is able to stabilize the interlayer space without disturbing the hydrogen-bonding system that holds the layers together in the as-made material. The ¹⁹F magic-angle spinning (MAS) NMR presented two distinct resonances at −71 and −83 ppm, which, on the basis of DFT calculations, we tentatively assigned to fluoride occluded in [4⁶6²] and [4¹5²6²] cages of the MWW structure, respectively. The same DFT study determines a different chemical shift of one methyl ¹³C nuclear magnetic resonance according to the imidazolium ring residing in the sinusoidal channels or in the large cup cavities, thus explaining an experimentally observed splitting of that resonance.     

Dual‐Mesoporous ZSM‐5 Zeolite with Highly b‐Axis‐Oriented Large Mesopore Channels for the Production of Benzoin Ethyl Ether

Dual‐mesoporous ZSM‐5 zeolite with highly b axis oriented large mesopores was synthesized by using nonionic copolymer F127 and cationic surfactant CTAB as co‐templates. The product contains two types of mesopores—smaller wormlike ones of 3.3 nm in size and highly oriented larger ones of 30–50 nm in diameter along the b axis—and both of them interpenetrate throughout the zeolite crystals and interconnect with zeolite microporosity. The dual‐mesoporous zeolite exhibits excellent catalytic performance in the condensation of benzaldehyde with ethanol and greater than 99 % selectivity for benzoin ethyl ether at room temperature, which can be ascribed to the zeolite lattice structure offering catalytically active sites and the hierarchical and oriented mesoporous structure providing fast access of reactants to these sites in the catalytic reaction. The excellent recyclability and high catalytic stability of the catalyst suggest prospective applications of such unique mesoporous zeolites in the chemical industry.     

Widening Synthesis Bottlenecks: Realization of Ultrafast and Continuous‐Flow Synthesis of High‐Silica Zeolite SSZ‐13 for NOx Removal

Characteristics of zeolite formation, such as being kinetically slow and thermodynamically metastable, are the main bottlenecks that obstruct a fast zeolite synthesis. We present an ultrafast route, the first of its kind, to synthesize high‐silica zeolite SSZ‐13 in 10 min, instead of the several days usually required. Fast heating in a tubular reactor helps avoid thermal lag, and the synergistic effect of addition of a SSZ‐13 seed, choice of the proper aluminum source, and employment of high temperature prompted the crystallization. Thanks to the ultra‐short period of synthesis, we established a continuous‐flow preparation of SSZ‐13. The fast‐synthesized SSZ‐13, after copper‐ion exchange, exhibits outstanding performance in the ammonia selective catalytic reduction (NH₃‐SCR) of nitrogen oxides (NO_x), showing it to be a superior catalyst for NO_x removal. Our results indicate that the formation of high‐silica zeolites can be extremely fast if bottlenecks are effectively widened.     

Synthesis of a Specified,Silica Molecular Sieve by Using Computationally Predicted Organic Structure‐Directing Agents

Crystalline molecular sieves are used in numerous applications, where the properties exploited for each technology are the direct consequence of structural features. New materials are typically discovered by trial and error, and in many cases, organic structure‐directing agents (OSDAs) are used to direct their formation. Here, we report the first successful synthesis of a specified molecular sieve through the use of an OSDA that was predicted from a recently developed computational method that constructs chemically synthesizable OSDAs. Pentamethylimidazolium is computationally predicted to have the largest stabilization energy in the STW framework, and is experimentally shown to strongly direct the synthesis of pure‐silica STW. Other OSDAs with lower stabilization energies did not form STW. The general method demonstrated here to create STW may lead to new, simpler OSDAs for existing frameworks and provide a way to predict OSDAs for desired, theoretical frameworks.     

Organic‐Free Synthesis of Zeolite Y with High Si/Al Ratios: Combined Strategy of In Situ Hydroxyl Radical Assistance and Post‐Synthesis Treatment

Zeolite Y, with a high SiO₂/Al₂O₃ ratio (SAR), plays an important role in fluidized catalytic cracking processes. However, in situ synthesis of zeolite Y with high SARs remains a challenge because of kinetic limitations. Here, zeolite Y with an SAR of 6.35 is synthesized by a hydroxyl radical assisted route. Density‐functional theory (DFT) calculations suggest that hydroxyl radicals preferentially enhanced the formation of Si‐O‐Si bonds, thus leading to an increased SAR. To further increase the SAR, a dealumination process was carried out using citric acid, with a subsequent second‐step hydrothermal crystallization, giving an SAR of up to 7.5 while maintaining good crystallinity and high product yield. The resultant zeolite Y shows good performance in cumene cracking. Introduced here is a new strategy for synthesizing high SAR zeolite Y, which is widely used in commercial applications.     

Large Zeolite H‐ZSM‐5 Crystals as Models for the Methanol‐to‐Hydrocarbons Process: Bridging the Gap between Single‐Particle Examination and Bulk Catalyst Analysis

The catalytic, deactivation, and regeneration characteristics of large coffin‐shaped H‐ZSM‐5 crystals were investigated during the methanol‐to‐hydrocarbons (MTH) reaction at 350 and 500 °C. Online gas‐phase effluent analysis and examination of retained material thereof were used to explore the bulk properties of large coffin‐shaped zeolite H‐ZSM‐5 crystals in a fixed‐bed reactor to introduce them as model catalysts for the MTH reaction. These findings were related to observations made at the individual particle level by using polarization‐dependent UV‐visible microspectroscopy and mass spectrometric techniques after reaction in an in situ microspectroscopy reaction cell. Excellent agreement between the spectroscopic measurements and the analysis of hydrocarbon deposits by means of retained hydrocarbon analysis and time‐of‐flight secondary‐ion mass spectrometry of spent catalyst materials was observed. The obtained data reveal a shift towards more condensed coke deposits on the outer zeolite surface at higher reaction temperatures. Zeolites in the fixed‐bed reactor setup underwent more coke deposition than those reacted in the in situ microspectroscopy reaction cell. Regeneration studies of the large zeolite crystals were performed by oxidation in O₂/inert gas mixtures at 550 °C. UV‐visible microspectroscopic measurements using the oligomerization of styrene derivatives as probe reaction indicated that the fraction of strong acid sites decreased during regeneration. This change was accompanied by a slight decrease in the initial conversion obtained after regeneration. H‐ZSM‐5 deactivated more rapidly at higher reaction temperature.     

Facile Synthesis,Characterization, and Catalytic Behavior of a Large‐Pore Zeolite with the IWV Framework

Large‐pore microporous materials are of great interest to process bulky hydrocarbon and biomass‐derived molecules. ITQ‐27 (IWV) has a two‐dimensional pore system bounded by 12‐membered rings (MRs) that lead to internal cross‐sections containing 14 MRs. Investigations into the catalytic behavior of aluminosilicate (zeolite) materials with this framework structure have been limited until now due to barriers in synthesis. The facile synthesis of aluminosilicate IWV in both hydroxide and fluoride media is reported herein using simple, diquaternary organic structure‐directing agents (OSDAs) that are based on tetramethylimidazole. In hydroxide media, a zeolite product with Si/Al=14.8–23.2 is obtained, while in fluoride media an aluminosilicate product with Si/Al up to 82 is synthesized. The material produced in hydroxide media is tested for the hydroisomerization of n‐hexane, and results from this test reaction suggest that the effective pore size of zeolites with the IWV framework structure is similar to but slightly larger than that of ZSM‐12 (MTW), in fairly good agreement with crystallographic data.