Differences Between Individual ZSM-5 Crystals in Forming Hollow Single Crystals and Mesopores During Base Leaching

Surface-Protection-Induced Controllable Restructuring of Pores and Acid Sites of the Nano-ZSM-5 Catalyst and Its Influence on the Catalytic Conversion of Methanol to Hydrocarbons

Creating mesopores for the nano-ZSM-5 catalyst could further promote the diffusion of molecules in its micropores and improve the catalytic activity and stability. Inorganic alkali treatment of ZSM-5 usually removes internal silica for the existence of an aluminum distribution gradient and leads to a hollow structure. Herein, surface TPA⁺ adsorption-induced protective desilication and recrystallization successively occurred during hydrothermal treatment, and controllable mesopore fabrication was achieved. The evolution of mesopores and acid sites was characterized by N₂ physisorption, XRD, XRF, TEM, NH₃-TPD, Py-IR, ²⁷Al MAS NMR, ²⁹Si MAS NMR, and TG techniques. It was found that the TPAOH concentration influenced the formation of internal cavity and mesopores in the shell. Introducing TPABr into TPAOH solution increased the surface protection because of the increased TPA⁺ adsorption, and coated hollow ZSM-5 was obtained. The acidity was restructured during the above mesopore fabrication. High-concentration TPAOH solution promoted the insertion of destructive Al into the skeleton structure to form strong acid sites, and the catalytic lifetime was recovered and even obviously prolonged. This reflected the key role of strong acid sites on the catalytic performance. Applying hollow nano-ZSM-5 with a mesoporous shell and strong acidity increased the lifetime by 50% and the conversion capacity for liquid hydrocarbon by 20% compared to the parent sample.

Variation of Aluminium Distribution in Small-Sized ZSM-5 Crystals during Desilication

Hollow ZSM-5 zeolites of size below one micrometer can be produced by desilication of crystals with aluminium zoning. The parent crystals have a core-shell structure: the core part has nearly no aluminium, whereas the aluminium content in the shell increases when extending to exterior surface. Transmission electron microscopy confirmed the preservation of the crystalline shell after base leaching, but could not identify its subtle change. An increase of the Si/Al ratio of the surface was detected upon leaching the parent material to form the hollow zeolite by using ambient pressure X-ray photoelectron spectroscopy and infrared spectroscopy of substituted alkylpyridines. ²⁷ Al MAS NMR showed that base leaching results in a reduced percentage of distorted tetrahedrally coordinated aluminium. The reprecipitation of dissolved species occurs and tetrahedrally coordinated tin atoms can thus be introduced to the shell framework. Overall, the formation of hollow ZSM-5 zeolites by desilication involves not only the removal of silicon-rich core, but also a reduced percentage of exterior aluminium-related acid sites, which should be considered while using hollow zeolites in acid-catalyzed reactions.

Ultrasmall Metal Nanoparticles Confined within Crystalline Nanoporous Materials: A Fascinating Class of Nanocatalysts

Crystalline nanoporous materials with uniform porous structures, such as zeolites and metal-organic frameworks (MOFs), have proven to be ideal supports to encapsulate ultrasmall metal nanoparticles (MNPs) inside their void nanospaces to generate high-efficiency nanocatalysts. The nanopore-encaged metal catalysts exhibit superior catalytic performance as well as high stability and catalytic shape selectivity endowed by the nanoporous matrix. In addition, the synergistic effect of confined MNPs and nanoporous frameworks with active sites can further promote the catalytic activities of the composite catalysts. Herein, recent progress in nanopore-encaged metal nanocatalysts is reviewed, with a special focus on advances in synthetic strategies for ultrasmall MNPs (<5 nm), clusters, and even single atoms confined within zeolites and MOFs for various heterogeneous catalytic reactions. In addition, some advanced characterization methods to elucidate the atomic-scale structures of the nanocatalysts are presented, and the current limitations of and future opportunities for these fantastic nanocatalysts are also highlighted and discussed. The aim is to provide some guidance for the rational synthesis of nanopore-encaged metal catalysts and to inspire their further applications to meet the emerging demands in catalytic fields.

ZSM-5 decrystallization and dealumination in hot liquid water

ZSM-5 zeolite degrades the crystal surface framework and internal acid sites, dependent on the unique thermophysical nature of water solvent.

Conversion of methanol to propylene over hierarchical HZSM-5: the effect of Al spatial distribution

Different silicon sources caused diverse Al spatial distribution in HZSM-5, and this affected the hierarchical structures and catalytic performance of desilicated zeolites. After being treated with 0.1 M NaOH, HZSM-5 zeolites synthesized with silica sol exhibited relatively widely distributed mesopores and channels, and possessed highly improved propylene selectivity and activity stability.

Synthesis of Engineered Zeolitic Materials: From Classical Zeolites to Hierarchical Core-Shell Materials

The term "engineered zeolitic materials" refers to a class of materials with a rationally designed pore system and active-sites distribution. They are primarily made of crystalline microporous zeolites as the main building blocks, which can be accompanied by other secondary components to form composite materials. These materials are of potential importance in many industrial fields like catalysis or selective adsorption. Herein, critical aspects related to the synthesis and modification of such materials are discussed. The first section provides a short introduction on classical zeolite structures and properties, and their conventional synthesis methods. Then, the motivating rationale behind the growing demand for structural alteration of these zeolitic materials is discussed, with an emphasis on the ongoing struggles regarding mass-transfer issues. The state-of-the-art techniques that are currently available for overcoming these hurdles are reviewed. Following this, the focus is set on core-shell composites as one of the promising pathways toward the creation of a new generation of highly versatile and efficient engineered zeolitic substances. The synthesis approaches developed thus far to make zeolitic core-shell materials and their analogues, yolk-shell, and hollow materials, are also examined and summarized. Finally, the last section concisely reviews the performance of novel core-shell, yolk-shell, and hollow zeolitic materials for some important industrial applications.

Nanoscale tomography reveals the deactivation of automotive copper-exchanged zeolite catalysts

Copper-exchanged zeolite chabazite (Cu-SSZ-13) was recently commercialized for the selective catalytic reduction of NO _X with ammonia in vehicle emissions as it exhibits superior reaction performance and stability compared to all other catalysts, notably Cu-ZSM-5. Herein, the 3D distributions of Cu as well as framework elements (Al, O, Si) in both fresh and aged Cu-SSZ-13 and Cu-ZSM-5 are determined with nanometer resolution using atom probe tomography (APT), and correlated with catalytic activity and other characterizations. Both fresh catalysts contain a heterogeneous Cu distribution, which is only identified due to the single atom sensitivity of APT. After the industry standard 135,000 mile simulation, Cu-SSZ-13 shows Cu and Al clustering, whereas Cu-ZSM-5 is characterized by severe Cu and Al aggregation into a copper aluminate phase (CuAl₂O₄ spinel). The application of APT as a sensitive and local characterization method provides identification of nanometer scale heterogeneities that lead to catalytic activity and material deactivation.

Interconnected Hierarchical ZSM-5 with Tunable Acidity Prepared by a Dealumination-Realumination Process: A Superior MTP Catalyst

ZSM-5 that uses TPAOH as a template has an Al-rich exterior and defective Si-rich interior; thus, a simple base leaching selectively removed the Si-rich interior while the Al-rich exterior was protected. This catalyst showed no change in stability comparing with parent ZSM-5 during the MTP reaction that was attributed to the enclosed hollow structure and richly acidic outer shell. A preliminary fluorination, however, both removed defective Si-sites and caused distortion in tetrahedral aluminum that made the outer shell susceptible to alkaline treatment. These distorted tetrahedral Al were mostly leached out by NaOH in 1 min. Furthermore, aluminum in the filtrate was slowly redeposited onto the zeolite, serving as external pore-directing agents to control silicon dissolution from the Si-rich interior. This dealumination-realumination alkaline treatment process led to a higher solid yield and a uniform opened-mesopore structure with mesopores around 13 nm in diameter. This material was characterized by SEM, TEM, N₂ adsorption, and mercury porosimetry. In addition, NH₃-TPD, OH-IR, ²⁷Al MAS NMR, and ¹H MAS NMR results demonstrated that the reinserted Al were unlike the framework Al, contributing less to acidity. The dealumination-realumination process, therefore, was also capable of tuning the acidity of the mesoporous ZSM-5. This mesoporous catalyst exhibited a longer lifetime and a higher propylene selectivity than other catalysts with an enclosed mesopore structure.

Single Molecule Nanospectroscopy Visualizes Proton-Transfer Processes within a Zeolite Crystal

Visualizing proton-transfer processes at the nanoscale is essential for understanding the reactivity of zeolite-based catalyst materials. In this work, the Brønsted-acid-catalyzed oligomerization of styrene derivatives was used for the first time as a single molecule probe reaction to study the reactivity of individual zeolite H-ZSM-5 crystals in different zeolite framework, reactant and solvent environments. This was accomplished via the formation of distinct dimeric and trimeric fluorescent carbocations, characterized by their different photostability, as detected by single molecule fluorescence microscopy. The oligomerization kinetics turned out to be very sensitive to the reaction conditions and the presence of the local structural defects in zeolite H-ZSM-5 crystals. The remarkably photostable trimeric carbocations were found to be formed predominantly near defect-rich crystalline regions. This spectroscopic marker offers clear prospects for nanoscale quality control of zeolite-based materials. Interestingly, replacing n-heptane with 1-butanol as a solvent led to a reactivity decrease of several orders and shorter survival times of fluorescent products due to the strong chemisorption of 1-butanol onto the Brønsted acid sites. A similar effect was achieved by changing the electrophilic character of the para-substituent of the styrene moiety. Based on the measured turnover rates we have established a quantitative, single turnover approach to evaluate substituent and solvent effects on the reactivity of individual zeolite H-ZSM-5 crystals.

Hollow Alveolus-Like Nanovesicle Assembly with Metal-Encapsulated Hollow Zeolite Nanocrystals

Inspired by the vesicular structure of alveolus which has a porous nanovesicle structure facilitating the transport of oxygen and carbon dioxide, we designed a hollow nanovesicle assembly with metal-encapsulated hollow zeolite that would enhance diffusion of reactants/products and inhibit sintering and leaching of active metals. This zeolitic nanovesicle has been successfully synthesized by a strategy which involves a one-pot hydrothermal synthesis of hollow assembly of metal-containing solid zeolite crystals without a structural template and a selective desilication-recrystallization accompanied by leaching-hydrolysis to convert the metal-containing solid crystals into metal-encapsulated hollow crystals. We demonstrate the strategy in synthesizing a hollow nanovesicle assembly of Fe2O3-encapsulated hollow crystals of ZSM-5 zeolite. This material possesses a microporous (0.4-0.6 nm) wall of hollow crystals and a mesoporous (5-17 nm) shell of nanovesicle with macropores (about 350 nm) in the core. This hierarchical structure enables excellent Fe2O3 dispersion (3-4 nm) and resistance to sintering even at 800 °C; facilitates the transport of reactant/products; and exhibits superior activity and resistance to leaching in phenol degradation. Hollow nanovesicle assembly of Fe-Pt bimetal-encapsulated hollow ZSM-5 crystals was also prepared.

X-ray Excited Optical Fluorescence and Diffraction Imaging of Reactivity and Crystallinity in a Zeolite Crystal: Crystallography and Molecular Spectroscopy in One

Structure-activity relationships in heterogeneous catalysis are challenging to be measured on a single-particle level. For the first time, one X-ray beam is used to determine the crystallographic structure and reactivity of a single zeolite crystal. The method generates μm-resolved X-ray diffraction (μ-XRD) and X-ray excited optical fluorescence (μ-XEOF) maps of the crystallinity and Brønsted reactivity of a zeolite crystal previously reacted with a styrene probe molecule. The local gradients in chemical reactivity (derived from μ-XEOF) were correlated with local crystallinity and framework Al content, determined by μ-XRD. Two distinctly different types of fluorescent species formed selectively, depending on the local zeolite crystallinity. The results illustrate the potential of this approach to resolve the crystallographic structure of a porous material and its reactivity in one experiment via X-ray induced fluorescence of organic molecules formed at the reactive centers.

X-ray Excited Optical Fluorescence and Diffraction Imaging of Reactivity and Crystallinity in a Zeolite Crystal: Crystallography and Molecular Spectroscopy in One

Structure-activity relationships in heterogeneous catalysis are challenging to be measured on a single-particle level. For the first time, one X-ray beam is used to determine the crystallographic structure and reactivity of a single zeolite crystal. The method generates μm-resolved X-ray diffraction (μ-XRD) and X-ray excited optical fluorescence (μ-XEOF) maps of the crystallinity and Brønsted reactivity of a zeolite crystal previously reacted with a styrene probe molecule. The local gradients in chemical reactivity (derived from μ-XEOF) were correlated with local crystallinity and framework Al content, determined by μ-XRD. Two distinctly different types of fluorescent species formed selectively, depending on the local zeolite crystallinity. The results illustrate the potential of this approach to resolve the crystallographic structure of a porous material and its reactivity in one experiment via X-ray induced fluorescence of organic molecules formed at the reactive centers.

Creation of mesostructured hollow Y zeolite by selective demetallation of an artificial heterogeneous Al distributed zeolite crystal

A hollow mesoporous Y zeolite has been fabricated via a selective demetallation method based on an artificial heterogeneous Al distribution strategy.