Acceleration of Zeolite Crystallization: Current Status, Mechanisms, and Perspectives

Zeolites are important classes of crystalline materials and possess well-defined channels and cages with molecular dimensions. They have been extensively employed as heterogeneous catalysts and gas adsorbents due to their relatively large specific surface areas, high pore volumes, compositional flexibility, definite acidity, and hydrothermal stability. The zeolite synthesis normally undergoes high-temperature hydrothermal treatments with a relatively long crystallization time, which exhibits low synthesis efficiency and high energy consumption. Various strategies, e.g., modulation of the synthesis gel compositions, employment of special silica/aluminum sources, addition of seeds, fluoride, hydroxyl (·OH) free radical initiators, and organic additives, regulation of the crystallization conditions, development of new approaches, etc., have been developed to overcome these obstacles. And, these achievements make prominent contributions to the topic of acceleration of the zeolite crystallization and promote the fundamental understanding of the zeolite formation mechanism. However, there is a lack of the comprehensive summary and analysis on them. Herein, we provide an overview of the recent achievements, highlight the significant progress in the past decades on the developments of novel and remarkable strategies to accelerate the crystallization of zeolites, and basically divide them into three main types, i.e., chemical methods, physical methods, and the derived new approaches. The principles/acceleration mechanisms, effectiveness, versatility, and degree of reality for the corresponding approaches are thoroughly discussed and summarized. Finally, the rational design of the prospective strategies for the fast synthesis of zeolites is commented on and envisioned. The information gathered here is expected to provide solid guidance for developing a more effective route to improve the zeolite crystallization and obtain the functional zeolite-based materials with more shortened durations and lowered cost and further promote their applications.

Zeolite Synthesis in the Presence of Metallosiloxanes for the Quantitative Encapsulation of Metal Species for the Selective Catalytic Reduction (SCR) of NOx

Metal encapsulation in zeolitic materials through one-pot hydrothermal synthesis (HTS) is an attractive technique to prepare zeolites with a high metal dispersion. Due to its simplicity and the excellent catalytic performance observed for several catalytic systems, this method has gained a great deal of attention over the last few years. While most studies apply synthetic methods involving different organic ligands to stabilize the metal under synthesis conditions, here we report the use of metallosiloxanes as an alternative metal precursor. Metallosiloxanes can be synthesized from simple and cost-affordable chemicals and, when used in combination with zeolite building blocks under standard synthesis conditions, lead to quantitative metal loading and high dispersion. Thanks to the structural analogy of siloxane with TEOS, the synthesis gel stabilizes by forming siloxane bridges that prevent metal precipitation and clustering. When focusing on Fe-encapsulation, we demonstrate that Fe-MFI zeolites obtained by this method exhibit high catalytic activity in the NH3 -mediated selective catalytic reduction (SCR) of NOx along with a good H2 O/SO2 tolerance. This synthetic approach opens a new synthetic route for the encapsulation of transition metals within zeolite structures.

Fenton Reaction–Unique but Still Mysterious

This study is devoted to the Fenton reaction, which, despite hundreds of reports in a number of scientific journals, provides opportunities for further investigation of its use as a method of advanced oxidation of organic macro- and micropollutants in its diverse variations and hybrid systems. It transpires that, for example, the choice of the concentrations and ratios of basic chemical substances, i.e., hydrogen peroxide and catalysts based on the Fe2+ ion or other transition metals in homogeneous and heterogeneous arrangements for reactions with various pollutants, is for now the result of the experimental determination of rather randomly selected quantities, requiring further optimizations. The research to date also shows the indispensability of the Fenton reaction related to environmental issues, as it represents the pillar of all advanced oxidation processes, regarding the idea of oxidative hydroxide radicals. This study tries to summarize not only the current knowledge of the Fenton process and identify its advantages, but also the problems that need to be solved. Based on these findings, we identified the necessary steps affecting its further development that need to be resolved and should be the focus of further research related to the Fenton process.

Carbon-based zero valent iron catalyst for NOX removal at low temperatures: performance and kinetic study

In order to solve the problem of nitrous oxide (NO_X) removal at low temperatures, the carbon-based zero valent iron (C-ZFe) catalyst was prepared and studied. According to the kinetic study and the obtained kinetic parameters, the De-NO_X reactor was designed to provide information for industrial applications. The box-behnken experimental design (BBD) was used to study the performance of C-ZFe, and the optimized operating parameters were obtained as the temperature was 408.15 K, the catalyst bed height was 140 cm (the space velocity was 459 h^-1), the concentration of NO was 550 ppm, under which the NO_X conversion was 72.7%. A kinetic model based on Langmuir-Hinshelwood (L-H) and Mars Van Krevelen mechanism was used to describe the kinetics for the reduction of NO by C-ZFe at low temperatures. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), surface area and pore size distribution measurements, X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS) results supported the validity of the model proposed. The gas-solid catalytic kinetic process of NO removal by C-ZFe was a quasi-first-order kinetic reaction, the apparent activation energy was 41.57 kJ/mol, and the pre-exponential factor was 2980 min^-1.

A review on the characterization of metal active sites over Cu-based and Fe-based zeolites for NH3-SCR

Cu-based and Fe-based zeolites are promising catalysts for NH3-SCR due to their high catalytic activity, wide temperature window and good hydrothermal stability, while the detailed investigation of NH3-SCR mechanism should be based on the accurate determination of active metal sites. This review systematically summarizes the qualitative and quantitative determination of metal active sites in Cu-based or Fe-based zeolites for NH3-SCR reactions based on advanced characterization methods such as UV-vis absorption (UV-vis), temperature-programmed reduction with H2 (H2-TPR), X-ray photoelectron spectroscopy (XPS), X-ray absorption fine structure spectroscopy (XAFS), Infrared spectroscopy (IR), Electron paramagnetic resonance (EPR), Mössbauer spectroscopy and DFT calculations. The application and limitations of different characterization methods are also discussed to provide insights for further study of the NH3-SCR reaction mechanism over metal-based zeolites.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

Two-Dimensional Ultrathin Silica Films

Two-dimensional (2D) ultrathin silica films have the potential to reach technological importance in electronics and catalysis. Several well-defined 2D-silica structures have been synthesized so far. The silica bilayer represents a 2D material with SiO₂ stoichiometry. It consists of precisely two layers of tetrahedral [SiO₄] building blocks, corner connected via oxygen bridges, thus forming a self-saturated silicon dioxide sheet with a thickness of ∼0.5 nm. Inspired by recent successful preparations and characterizations of these 2D-silica model systems, scientists now can forge novel concepts for realistic systems, particularly by atomic-scale studies with the most powerful and advanced surface science techniques and density functional theory calculations. This Review provides a solid introduction to these recent developments, breakthroughs, and implications on ultrathin 2D-silica films, including their atomic/electronic structures, chemical modifications, atom/molecule adsorptions, and catalytic reactivity properties, which can help to stimulate further investigations and understandings of these fundamentally important 2D materials.

One-Pot Synthesis of Ultra-Small Pt Dispersed on Hierarchical Zeolite Nanosheet Surfaces for Mild Hydrodeoxygenation of 4-Propylphenol

The rational design of ultra-small metal clusters dispersed on a solid is of crucial importance in modern nanotechnology and catalysis. In this contribution, the concept of catalyst fabrication with a very ultra-small size of platinum nanoparticles supported on a hierarchical zeolite surface via a one-pot hydrothermal system was demonstrated. Combining the zeolite gel with ethylenediaminetetraacetic acid (EDTA) as a ligand precursor during the crystallization process, it allows significant improvement of the metal dispersion on a zeolite support. To illustrate the beneficial effect of ultra-small metal nanoparticles on a hierarchical zeolite surface as a bifunctional catalyst, a very high catalytic performance of almost 100% of cycloalkane product yield can be achieved in the consecutive mild hydrodeoxygenation of 4-propylphenol, which is a lignin-derived model molecule. This instance opens up perspectives to improve the efficiency of a catalyst for the sustainable conversion of biomass-derived compounds to fuels.

Influence of different preparation methods on the activity of Ce and Mo co-doped ZSM-5 catalysts for the selective catalytic reduction of NOx by NH3

The Ce-doped different MoO₃ [conventional molybdenum oxide (con-MoO₃) or nano molybdenum oxide (nano-MoO₃) and synthetic molybdenum oxide (syn-MoO₃)] modification of ZSM-5 catalyst synthesized by different preparation methods (the combination of grinding and ion-exchange method and the combination of impregnation and ion-exchange method) was studied on selective catalytic reduction (SCR) of NO_x with NH₃. The results demonstrated that the SCR performance of the prepared Ce-doped syn-MoO₃ modification of ZSM-5 catalyst [Ce(0.9%)-syn-MoO₃(6%)/ZSM-5] by the combination of impregnation and ion-exchange method was better than Ce-doped con-MoO₃ modification of ZSM-5 [Ce(0.9%)-con-MoO₃(6%)/ZSM-5] and Ce-doped nano-MoO₃ modification of ZSM-5 [Ce(0.9%)-nano-MoO₃(6%)/ZSM-5] via the combination of grinding and ion-exchange method, especially when the temperature window is 200-350 °C. That is because it is easy to form Mo-O-Al by the smaller sized MoO₃ more easily interacting well with Brønsted acid under calcining temperature, which results in the decrease of Brønsted acid sites in the catalyst. Combing with the binding energy of Mo for all the catalysts, the combination of Mo and Al (Mo-O-Al) altered the chemical environment around the Mo species. Furthermore, Ce(0.9%)-syn-MoO₃(6%)/ZSM-5 exhibited excellent sulfur resistance.

Copper-Iron Bimetal Ion-Exchanged SAPO-34 for NH3-SCR of NOx

SAPO-34 was prepared with a mixture of three templates containing triethylamine, tetraethylammonium hydroxide, and morpholine, which leads to unique properties for support and production cost reduction. Meanwhile, Cu/SAPO-34, Fe/SAPO-34, and Cu-Fe/SAPO-34 were prepared through the ion-exchanged method in aqueous solution and used for selective catalytic reduction (SCR) of NOx with NH3. The physical structure and original crystal of SAPO-34 are maintained in the catalysts. Cu-Fe/SAPO-34 catalysts exhibit high NOx conversion in a broad temperature window, even in the presence of H2O. The physicochemical properties of synthesized samples were further characterized by various methods, including XRD, FE-SEM, EDS, N2 adsorption-desorption isotherms, UV-Vis-DRS spectroscopy, NH3-TPD, H2-TPR, and EPR. The best catalyst, 3Cu-1Fe/SAPO-34 exhibited high NOx conversion (> 90%) in a wide temperature window of 250–600 °C, even in the presence of H2O. In comparison with mono-metallic samples, the 3Cu-1Fe/SAPO-34 catalyst had more isolated Cu2+ ions and additional oligomeric Fe3+ active sites, which mainly contributed to the higher capacity of NH3 and NOx adsorption by the enhancement of the number of acid sites as well as its greater reducibility. Therefore, this synergistic effect between iron and copper in the 3Cu-1Fe/SAPO-34 catalyst prompted higher catalytic performance in more extensive temperature as well as hydrothermal stability after iron incorporation.

Ethylene glycol assisted synthesis of hierarchical Fe-ZSM-5 nanorods assembled microsphere for adsorption Fenton degradation of chlorobenzene

A unique zeolite catalyst, Fe doped ZSM-5 microsphere assembled by uniform nanorod-like crystals with hierarchical pore structure, was successfully synthesized and applied for the adsorption and degradation of trace chlorobenzene (CB) in the presence of H₂O₂. The organic ferric salts as the precursors, ethylene glycol as a chelating/reducing agent and the dynamic two-stage temperature-varied hydrothermal technique, together made the synthesized hierarchical Fe-ZSM-5 nanorods assembled microspheres (FZ-CA-5EG) to be characterized by abundant highly dispersed and valency-controlled framework Fe^3+/2+ species. As a result of these features, the FZ-CA-5EG showed excellent ability of adsorption and degradation efficiency of CB, and enhanced durability due to negligible leaching of framework Fe species. Moreover, the hydroxyl radicals were determined as the main the reactive oxygen species of CB oxidation degradation, and a possible adsorption-oxidation degradation pathway was proposed.

Effect of Ethanol on the Morphology and Textual Properties of ZSM-5 Zeolite

The morphology of ZSM-5 zeolite impacts the adsorption, separation and diffusion of molecules. The morphology and textural properties of ZSM-5 zeolites were adjusted by regulating the content of ethanol in the synthesis gel. When the ratio of ethanol/SiO2 was lower than 2, the obtained crystals were isolated particles. With higher ethanol concentration, the chainlike zeolite was generated due to the condensation of terminal Si-OH groups. The crystals stacked more and more compactly with the increase in ethanol concentration, resulting in decreased specific surface area, total volume and mesoporous volume. The crystal size increased gradually with the increase in the ethanol concentration. Moreover, some other small molecular alcohols could also induce the formation of chainlike morphology of ZSM-5.

Excellent performance of one-pot synthesized Fe-containing MCM-22 zeolites for the selective catalytic reduction of NOx with NH3

One-pot synthesized OP-Fe/M22 zeolites exhibit excellent performances in NH₃-SCR reactions.

Selective Catalytic Reduction of Nitric Oxide with Propylene over Fe/Beta Catalysts Under Lean-Burn Conditions

Fe/Beta catalysts were used for the selective catalytic reduction of nitric oxide with propylene (C3H6-SCR) under lean-burn conditions, which were prepared by liquid ion-exchange (LIE), solid-state ion-exchange (SIE), and incipient wet-impregnation (IWI) methods. The iron species on Fe/Beta were characterized and identified by a combination of several characterization techniques. The results showed preparation methods had a significant influence on the composition and distribution of iron species, LIE method inclined to produce more isolated Fe3+ ions at ion-exchanged sites than IWI and SIE method. C3H6-SCR activity tests demonstrated Fe/Beta(LIE) possessed remarkable catalytic activity and N2 selectivity at temperature 300–450 °C. Kinetic studies of C3H6-SCR reaction suggested that isolated Fe3+ species were more active for NO reduction, whereas Fe2O3 nanoparticles enhanced the hydrocarbon combustion in excess of oxygen. According to the results of in situ DRIFTS, more isolated Fe3+ sites on Fe/Beta(LIE) would promote the formation of the key intermediates, i.e., NO2 adspecies and formate species, then led to the superior C3H6-SCR activity. The slight decrease of SCR activity after hydrothermal aging of Fe/Beta(LIE) catalyst might be due to the migration of isolated Fe3+ ions into oligomeric clusters and/or Fe2O3 nanoparticles.

Experimental Evidence of the Mechanism of Selective Catalytic Reduction of NO with NH3 over Fe-Containing BEA Zeolites

Various temperature-programmed techniques were used as tools in mechanistic studies of selective catalytic reduction (SCR) of NO with ammonia in the presence of Fe-containing BEA zeolites. Moreover, FTIR studies of adsorbed NH₃ and NO were conducted to determine the interactions of reactants with the catalyst surface. Iron was introduced into BEA zeolite by three different methods: i) two-step post-synthesis; ii) conventional wet impregnation; iii) ion exchange. The catalytic activity was dependent on the method used for iron introduction. The reactivities of NH₃ and NO adsorbed on iron-modified zeolites obtained by impregnation and ion-exchange methods were higher than those measured for the catalyst obtained by a two-step post-synthesis method. The activity of Fe-containing zeolites in SCR was related to the form of deposited iron species, as well as to the nature, strength, and concentration of acid sites. Possible reaction pathways of NO reduction over the FeBEA zeolite catalysts were presented and discussed.

Zeolite acidity strongly influences hydrogen peroxide activation and oxygenate selectivity in the partial oxidation of methane over M,Fe-MFI (M: Ga, Al, B) zeolites

Brönsted acidity plays a crucial role in the partial oxidation of methane to oxygenated products.

Comprehensive study of the promotional mechanism of F on Ce–Mo/TiO2 catalysts for wide temperature NH3-SCR performance: the activation of surface Ti–F bonds

The CeFMoTiO_x catalyst was prepared via a solvothermal method. It confirmed that O_α was not only generated during the transformation between Ce⁴⁺ and Ce³⁺ but was also released from F⁻ species of the surface Ti–F bonds.

Iron nanostructured catalysts: design and applications

This review is focused on the recent advances in the design of iron nanostructures and their catalytic applications.