Uniform hierarchical MFI nanosheets prepared via anisotropic etching for solution-based sub-100-nm-thick oriented MFI layer fabrication

Structurally Engineering Multi-Shell Hollow Zeolite Single Crystals via Defect-Directed Oriented-Kinetics Transformation and Their Heterostructures for Hydrodeoxygenation Reaction

Single-crystalline multi-shell hollow porous materials with high compartment capacity, large active surface area, and superior structural stability are expected to unlock tremendous potential across diverse critical applications. However, their synthetic methodology has not yet been well established. Here, we develop a defect-directed oriented-kinetics transformation approach to prepare multi-shell hollow aluminosilicate ZSM-5 zeolite (MFI) crystals with single-crystalline feature, hierarchical macro-/mesoporosity, controllable shell number, and high structural stability. The methodology lies in the creation of zeolite precursors consisting of multiple inhomogeneous layers with gradient-distributed defects along the [100] and [010] directions and irregularly discrete defects-rich regions along the [001] direction via continuous epitaxial growth. Subsequently, the locations with more defects could be preferentially etched to form voids or mesopores, meanwhile oriented recrystallization interconnects the nanoshells into a unified architecture along the [001] direction. Benefiting from the easily accessible bifunctional metal/acid sites and the capability for reactant accumulation, the resultant multi-shell hollow Ni-loaded zeolite catalysts show significantly enhanced catalytic activity in the hydrodeoxygenation of stearic acid into liquid fuels. The insight gained from this systematic study will facilitate the rational design and synthesis of diverse multi-shell hollow structured single-crystalline porous materials for a broad range of potential applications.

Oriented Titanium-MOF Membrane for Hydrogen Purification

Precise hydrogen sorting from purge gas (H2/N2) and coke gas (H2/CH4), commonly carried out by cryogenic distillation, still suffers from low separation efficiency, high energy consumption, and considerable capital cost. Though still in its infancy, membrane technology offers a potential to achieve more efficient hydrogen purification. In this study, an optimum separation of hydrogen towards both methane and nitrogen via a kinetically-driven mechanism is realized through preferred orientation control of a MOF membrane. Relying on the 0.3 nm-sized window aligned vertical to the substrate, b-oriented Ti-MOF membrane exhibits ultra-high hydrogen selectivity, surpassing the upper bound limit of separating H2/N2 and H2/CH4 gas pairs attained so far by inorganic membranes. This spectacular selectivity is combined with a high H2 permeability owing to the synergistic effect of the 1 nm-sized MOF channel.

Atmospheric Pressure Alkaline Etching of MFI Zeolite Under Mild Temperature Toward Hollow Microstructure and Ultralow k Film

Constructing a hollow structure inside zeolite is very helpful for improving its performance. Unlike the conventional alkaline etching technique usually operated at high temperature (typically 170 °C) and high pressure (autogenerated in autoclave), here, it is discovered that zeolite MFI nano-box can be achieved under mild etching conditions of atmospheric pressure and low temperature of 80 °C, making it very attractive for energy conservation and practical applications. A hollow-structure formation mechanism of protection-dissolution etching is demonstrated by characterizing MFI crystals obtained under different etching time, temperature, and etchant concentration. The utilization of template agent-free secondary growth leads to the successful fabrication of a continuous b-oriented hierarchical MFI zeolite film with desired microstructure of embedded cavities and opened pores. The advantage of the newly constructed film is highlighted by its ultralow k value accompanied with high mechanical strength.

Constructing Hierarchical Zeolites with Highly Complete Framework via Controlled Desilication

Desilication in alkaline medium has been widely used in construction of hierarchical zeolites for industrially relevant catalytic processes. The built of hierarchy in zeolites, especially with low aluminum stability or high Si/Al ratio, often suffers from uncontrolled destruction of zeolitic framework, accompanied by a significant loss of microporous domains and intrinsic acidity after desilication. Here, we report a novel and simple methodology for preparation of hierarchical zeolites with highly complete framework and minimum sacrifice of microporosity and acidity. The pre-impregnated amines in zeolite micropores act as inner pore-directing agents (iPDAs), largely protecting the zeolitic framework and moderating the silicon extraction during the alkaline treatment. The resulting hierarchical zeolites exhibit high crystallinity, tunable hierarchy, stable framework, and well-preserved acidity, endowing them with significantly improved mass transport properties and enhanced activities in catalytic conversion of methanol or furfural.

2D MOFs and Zeolites for Composite Membrane and Gas Separation Applications: A Brief Review

Commercial membranes have predominantly been fabricated from polymers due to their economic viability and processability. This choice offers significant advantages in energy efficiency, cost-effectiveness, and operational simplicity compared to conventional separation techniques like distillation. However, polymeric membranes inherently exhibit a trade-off between their permeability and selectivity, which is summarized in the Robeson upper bound. To potentially surpass these limitations, mixed-matrix membranes (MMMs) can be an alternative solution, which can be constructed by combining polymers with inorganic additives such as metal-organic frameworks (MOFs) and zeolites. Incorporating high-aspect-ratio fillers like MOF nanosheets and zeolite nanosheets is of significant importance. This incorporation not only enhances the efficiency of separation processes but also reinforces the mechanical robustness of the membranes. We outline synthesis techniques for producing two-dimensional (2D) crystals (including nanocrystals with high aspect ratio) and provide examples of their integration into membranes to customize separation performances. Moreover, we propose a potential trajectory for research in the area of high-aspect-ratio materials-based MMMs, supported by a mathematical-model-based performance prediction.

Room-Temperature Synthesis of Zeolite Membranes toward Optimized Microstructure and Enhanced Butane Isomer Separation Performance

Room temperature (RT) synthesis of high-performance zeolite membranes, which is profound from techno-economic and eco-friendly perspectives, remains a grand challenge. In this work, we pioneered the RT preparation of well-intergrown pure-silica MFI zeolite (Si-MFI) membranes, which was realized through adopting highly reactive NH₄F-mediated gel as nutrient during epitaxial growth. Benefiting from the introduction of fluoride anions as mineralizing agent as well as precisely tuned nucleation and growth kinetics at RT, both their grain boundary structure and thickness could be deliberately controlled, resulting in the formation of Si-MFI membranes showing unprecedented n-/i-butane separation factor (96.7) and n-butane permeance (5.16 × 10^-7 mol m^-2 s^-1 Pa^-1) in the case of a feed molar ratio of 10/90, which well transcended the state-of-the-art membranes reported in the literature. This RT synthetic protocol was also proven effective for preparing highly b-oriented Si-MFI film, thus showing great promise for the preparation of diverse zeolite membranes with optimized microstructure and superior performance.

Controllable Orientation Growth of ZSM-5 for Methanol to Hydrocarbon Conversion: Cooperative Effects of Seed Induction and Medium pH Control

The growth orientation of ZSM-5 zeolites strongly affects product selectivity in methanol conversion reaction. Here, we proposed a versatile synthetic strategy by introducing seeds and controlling medium pH to achieve controllable orientation growth of ZSM-5. The systematic analysis of the crystallization process indicated that the introduction of seeds ensured successful crystallization in a quasi-neutral solution and the dissolution rate of seeds and aluminosilicate determined the growth orientation of ZSM-5. In the quasi-neutral solution, the slow dissolution of seeds and aluminosilicate enhanced growth advantages along the c axis. The ratio between the length of the c axis and b axis (L_c/L_b) of the obtained ZSM-5 at pH of 7 could reach 8.1, much higher than 1.8 obtained at pH of 11. No obvious impact of seed added amount on growth orientation was found, while with increasing seed crystal size, the obtained ZSM-5 showed preferred growth along the c axis. The L_c/L_b of the sample adding seeds with a size of 355 nm reached 7.9, much higher than 2.1 of the sample adding seeds with a size of 70 nm. The obtained ZSM-5 with specific growth orientation exhibited potential shape selectivity in methanol to aromatics and olefin reaction. This work opens new possibilities to tailor the orientation growth of ZSM-5 based on the seed-induced strategy under mild conditions.

Interzeolite Conversion-Synthesized Sub-1 μm NaA Zeolite Membrane for C2H2/C2H4 Selective Separation

Zeolite membranes with reduced thickness and high continuity are of paramount importance for accelerating selective gas separation for resemblant molecules, and the synthesis of such membranes remains a grand challenge. Herein, we developed an interzeolite conversion synthesis approach to grow NaA zeolite membranes on NaX. The conversion of NaX into NaA proceeded via mild hydrothermal treatment of a dilute synthesis solution, preferentially forming a continuous polycrystalline NaA layer on the surface of NaX, which was precrystallized on a porous alumina support. The thickness of the NaA zeolite membrane was successfully controlled to the submicron scale (500 nm). The synthesized NaA membrane functioned as a selective separator for C₂H₂ and C₂H₄ gases. Taking the traditionally in situ grown membrane as a reference, the interzeolite-derived membrane exhibited a 3.5-fold separation factor and ∼4.0 times C₂H₂ permeance. This approach provides an alternative synthesis option for zeolite membranes with advanced properties, and high efficiency in terms of superior gas selectivity and permeability is promising in precise gas separation.

One-Step Scalable Fabrication of Highly Selective Monolithic Zeolite MFI Membranes for Efficient Butane Isomer Separation

The reproducible fabrication of large-area zeolite membranes for gas separation is still a great challenge. We report the scalable fabrication of high-performance zeolite MFI membranes by single-step secondary growth on the 19-channel alumina monoliths for the first time. The packing density and mechanical strength of the monolithic membranes are much higher for these than for tubular ones. Separation performance of the monolithic membranes toward the butane isomer mixture was comparably evaluated using the vacuum and Wicke-Kallenbach modes. The n-butane permeances and n-butane/i-butane separation factors for the three membranes with an effective area of ∼84 cm² were >1.0 × 10^-7 mol (m² s Pa)^-1 and >50 at 343 K for an equimolar n-butane/i-butane mixture, respectively. We succeeded in scaling up the membrane synthesis with the largest area of 270 cm² to date which has 1.3 times the area of an industrial 1 m long tubular membrane. Monolith supported zeolite MFI membranes show great potential for industrial n-butane/i-butane separation.

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).

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.

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.

Watching Microwave-Induced Microscopic Hot Spots via the Thermosensitive Fluorescence of Europium/Terbium Mixed-Metal Organic Complexes

The hypothesis of microscopic hot spots is widely used to explain the unique microwave (MW) effect in materials science and chemical engineering, but it has not yet been directly measured. Herein we use Eu/Tb mixed-metal organic complexes as nano thermometers to probe the intrinsic temperature of MW-absorbing particles in MW fields based on the thermosensitive fluorescent spectra. According to the measurements of the temperature gradient at the solid/liquid interphase, we derive an MW-irradiated energy transfer model to predict the extent of microscopic hot spots. The fluorescence results agree with the model predictions that the MW-induced temperature gradient can be enlarged by increasing MW intensity, as well as the dielectric loss and size of particles. Conversely, the increase in the thermal conductivity and the dielectric loss of the liquid lowers the temperature gradient. This study enables control of MW-assisted synthesis and MW-responsive techniques.

Seed-sol-assisted construction of a coffin-shaped multilamellar ZSM-5 single crystal using CTAB

A coffin-shaped multilamellar ZSM-5 single crystal (CMZS) composed of orderly stacked 2D nanosheets (70-100 nm) was synthesized via the use of cetyltrimethylammonium bromide (CTAB) in the presence of silicalite-1 seed sol. This crystallization strategy opens a facile approach for industrial applications using CMZS in the catalytic conversion of bulky molecules.

Two-Dimensional MFI Zeolite Nanosheets Exfoliated by Surfactant Assisted Solution Process

Two-dimensional (2D) zeolite nanosheets are important for the synthesis of high flux zeolite membranes due to their lateral size in a preferred orientation. A way to obtain 2D zeolite nanosheets is to exfoliate interlocked structures generated during the hydrothermal synthesis. The mechanical and polymer assisted exfoliation process leads to mechanical damage in nanosheets and short lateral size. In the present study, polyvinylpyrrolidone (PVP) was introduced as an exfoliation agent and dispersant, so that multilamellar interlocked silicalite-1 zeolite nanosheets successfully exfoliated into a large lateral size (individual nanosheets 500~1200 nm). The good exfoliation behavior was due to the strong penetration of PVP into multilamellar nanosheets. Sonication assisted by mild milling helps PVP molecules to penetrate through the lamellar structure, contributing to the expansion of the distance between adjacent layers and thus decreasing the interactions between each layer. In addition, the stability of exfoliated nanosheets was evaluated with a series of organic solvents. The exfoliated nanosheets were well dispersed in n-butanol and stable for 30 days. Therefore, the PVP-assisted solution-based exfoliation process provides high aspect ratio MFI zeolite nanosheets in organic solvents for a long period.

MFI-Type Zeolite Membranes for Pervaporation Separation of Dichlorobenzene Isomers

MFI-type zeolitic membranes were prepared on the porous α-A₂O₃ support to investigate the separation properties of dichlorobenzene isomers. The pervaporation tests were performed with unary and binary isomer mixtures at 333 K. The results indicate that the silicalite membranes, irrespective of being synthesized by the templated or template-free method, are permeable for all dichlorobenzene isomers. The pervaporation fluxes of the pure dichlorobenzene isomers decrease in the order p-DCB > o-DCB > m-DCB. For the binary pervaporation system, the dichlorobenzene fluxes are all less than those with a single component due to the binary interactions between DCB isomers and between the DCB isomer and the zeolite membrane. Comparatively, the template-free MFI-type zeolite exhibits higher selectivity for dichlorobenzene isomers due to less inter-crystalline gaps. The separation factors for p-/o-DCB and p-/m-DCB can reach 16.7 and 22.0, respectively.

Hierarchy Control of MFI Zeolite Membrane towards Superior Butane Isomer Separation Performance

Microstructural optimization (such as thickness and preferred orientation) is a major concern for performance enhancement of zeolite membranes. In this study, we demonstrated that the introduction of hierarchy easily enabled concurrent thickness reduction and orientation control of zeolite membranes. Specifically, hierarchical MFI zeolite membranes comprising higher degree of (h0h) preferentially oriented ultrathin (ca. 390 nm) selective top layers and porous intermediate layers on porous α-Al₂ O₃ substrates were fabricated. The use of hollow-structured MFI nanoseeds and the employment of single-mode microwave heating during membrane processing were found indispensable for the preparation of MFI zeolite membranes with superior butane isomer separation performance, thereby surpassing the current n-/i-butane selectivity versus n-butane permeance trade-off limits of MFI zeolite membranes prepared via solution-based synthetic protocols.

Platelike MFI Crystals with Controlled Crystal Faces Aspect Ratio

Zeolite crystals offering a short diffusion pathway through the pore network are highly desired for a number of catalytic and molecule separation applications. Herein, we develop a simple synthetic strategy toward reducing the thickness along the b-axis of MFI-type crystals, thus providing a short diffusion path along the straight channel. Our approach combines preliminary aging and a fluoride-assisted low-temperature crystallization. The synthesized MFI crystals are in the micrometer-size range along the a- and c-axis, while the thickness along the b-axis is a few tens of nanometers. The synthesis parameters controlling the formation of platelike zeolite are studied, and the factors controlling the zeolite growth are identified. The synthesis strategy works equally well with all-silica MFI (silicalite-1) and its Al- and Ga-containing derivatives. The catalytic activity of platelike ZSM-5 in the methanol-to-hydrocarbons (MTH) reaction is compared with a commercial nanosized ZSM-5 sample, as the platelike ZSM-5 exhibits a substantially extended lifetime. The synthesis of platelike MFI crystals is successfully scaled up to a kilogram scale.

In situ constructed zeolite membranes on rough supports with the assistance of reticulated hydrotalcite interlayer

Zeolite membranes with unique physical and chemical properties are emerging as attractive candidates for membrane separation. However, defects in the zeolite layer seriously affect their molecular sieving performance. In this study, a novel strategy for preparing compact zeolite membranes on rough supports with the assistance of a reticulated hydrotalcite layer was developed. The reticulated hydrotalcite layer was grown on the inner surface of a 170 mm length ceramic tube by an in situ hydrothermal method, and a NaA zeolite membrane was prepared on this reticulated layer by the microwave-heating method. The hydrotalcite interlayer could not only improve the smoothness and regularity of the surface of the support but also fix the Si/Al active ingredients using its reticulate structure, finally effectively improving the quality and stability of the zeolite layer. The optimal molar ratio of the synthesis solution for the synthesis of the zeolite membrane was 3Na₂O : 2SiO₂ : Al₂O₃ : 200H₂O. The permeance flux of H₂ through the zeolite membrane synthesized under the optimal conditions was high as 0.47 × 10⁻⁶ mol m⁻² s⁻¹ Pa⁻¹, and its permselectivity for H₂ over N₂ was 4.7, which was higher than the corresponding Knudsen diffusion coefficient. This study provides a new idea for the preparation of defect-free membranes on rough supports.

Reticulated hydrotalcite interlayer controls infiltration of active ingredients into the support, improving the quality and stability of the zeolite membrane.