ABSTRACT
Hierarchical zeolites are a class of microporous catalysts and adsorbents that also contain mesopores, which allow for fast transport of bulky molecules and thereby enable improved performance in petrochemical and biomass processing. We used repetitive branching during one-step hydrothermal crystal growth to synthesize a new hierarchical zeolite made of orthogonally connected microporous nanosheets. The nanosheets are 2 nanometers thick and contain a network of 0.5-nanometer micropores. The house-of-cards arrangement of the nanosheets creates a permanent network of 2- to 7-nanometer mesopores, which, along with the high external surface area and reduced micropore diffusion length, account for higher reaction rates for bulky molecules relative to those of other mesoporous and conventional MFI zeolites.
ABSTRACT
Zeolite nanocrystals were prepared from three-dimensionally ordered mesoporous-imprinted (3DOm-i) silicalite-1 by a fragmentation method involving sonication and dissolution within a certain pH range. 3DOm-i silicalite-1 with spherical elements with diameters ranging from 10 to 40 nm and a wide range of crystal sizes (100-200 nm, 500-600 nm, and 1-2 µm) was used as the starting material. The highest yield (57%) of isolated nanocrystals was obtained for 3DOm-i silicalite-1 with a crystal size of 100-200 nm and a spherical element diameter of 40 nm. The smallest nanocrystals obtained, albeit in very low yields, had a 10 nm diameter. Preparation of stable silicalite-1 nanocrystal suspensions fragmented from 20 and 40 nm 3DOm-i silicalite-1 was demonstrated. Cryogenic transmission electron microscopy showed that the isolated zeolite nanocrystals can be used as seeds for the epitaxial growth of silicalite-1. An application of these findings was demonstrated: silicalite-1 nanocrystal suspensions were used to deposit seed layers on porous α-alumina disks, which were converted to continuous thin (300-400 nm) films by secondary growth that exhibited both high permeances and separation factors (3.5 × 10(-7) mol m(-2) s(-1) Pa(-1) and 94-120, respectively, at 150 °C) for p- and o-xylene.
