Split Syntheses: Introducing Bottom-Up Control over Aluminum in SSZ-13 and ZSM‑5 Zeolites
Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite...
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| Published in: | JACS Au Vol. 5; no. 2; pp. 593 - 605 |
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| Main Authors: | , , , , , , , , , |
| Format: | Journal Article |
| Language: | English |
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American Chemical Society
24.02.2025
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| ISSN: | 2691-3704, 2691-3704 |
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| Abstract | Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite synthesis mixture can be impacted without heavily disrupting the delicate equilibria that are at play during crystallization. Recently, however, this view has started to change, with innovative techniques such as charge density mismatch or electro-assisted synthesis showing that the addition of new elements to the reactor midsynthesis might lead to new and surprising outcomes. In this manuscript, we show that by intermittent removal of certain fractions, notably Al-rich solids or Si-rich liquids, from the reaction medium during an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can control the Si/Al ratio of the final product, without heavily impacting the reaction time, particle size, or divalent cation capacity of the final product. This approach was named “split synthesis” and has led to several insights. By removing some Si-rich liquid phase after 40 min of synthesis, the Si/Al ratio of the daughter zeolite was lowered to a value of 20 (starting from 40), while the divalent cation capacity, a performance indicator for several acid and metal-catalyzed reactions, was kept maximized. On the other hand, when Al-rich solids were removed after 40 min (and in some cases colloidal silica was supplemented), we were able to rapidly synthesize small SSZ-13 zeolites with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle sizes in the range 100–150 nm and are traditionally difficult to crystallize in hydroxide medium. They showed a great olefin yield (6%) in the conversion of CO2 and H2 with ZnZrOx as cocatalyst. |
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| AbstractList | Zeolite synthesis is known as a difficult-to-control
process, with
many degrees of freedom that have a partially uncharted impact on
the final product. Due to this, many zeolite scientists have regarded
the initial mixing (aging) stage as the only time at which the chemical
composition of a zeolite synthesis mixture can be impacted without
heavily disrupting the delicate equilibria that are at play during
crystallization. Recently, however, this view has started to change,
with innovative techniques such as charge density mismatch or electro-assisted
synthesis showing that the addition of new elements to the reactor
midsynthesis might lead to new and surprising outcomes. In this manuscript,
we show that by intermittent removal of certain fractions, notably
Al-rich solids or Si-rich liquids, from the reaction medium during
an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can
control the Si/Al ratio of the final product, without heavily impacting
the reaction time, particle size, or divalent cation capacity of the
final product. This approach was named “split synthesis”
and has led to several insights. By removing some Si-rich liquid phase
after 40 min of synthesis, the Si/Al ratio of the daughter zeolite
was lowered to a value of 20 (starting from 40), while the divalent
cation capacity, a performance indicator for several acid and metal-catalyzed
reactions, was kept maximized. On the other hand, when Al-rich solids
were removed after 40 min (and in some cases colloidal silica was
supplemented), we were able to rapidly synthesize small SSZ-13 zeolites
with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle
sizes in the range 100–150 nm and are traditionally difficult
to crystallize in hydroxide medium. They showed a great olefin yield
(6%) in the conversion of CO2 and H2 with ZnZrOx
as cocatalyst. Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite synthesis mixture can be impacted without heavily disrupting the delicate equilibria that are at play during crystallization. Recently, however, this view has started to change, with innovative techniques such as charge density mismatch or electro-assisted synthesis showing that the addition of new elements to the reactor midsynthesis might lead to new and surprising outcomes. In this manuscript, we show that by intermittent removal of certain fractions, notably Al-rich solids or Si-rich liquids, from the reaction medium during an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can control the Si/Al ratio of the final product, without heavily impacting the reaction time, particle size, or divalent cation capacity of the final product. This approach was named “split synthesis” and has led to several insights. By removing some Si-rich liquid phase after 40 min of synthesis, the Si/Al ratio of the daughter zeolite was lowered to a value of 20 (starting from 40), while the divalent cation capacity, a performance indicator for several acid and metal-catalyzed reactions, was kept maximized. On the other hand, when Al-rich solids were removed after 40 min (and in some cases colloidal silica was supplemented), we were able to rapidly synthesize small SSZ-13 zeolites with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle sizes in the range 100–150 nm and are traditionally difficult to crystallize in hydroxide medium. They showed a great olefin yield (6%) in the conversion of CO2 and H2 with ZnZrOx as cocatalyst. Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite synthesis mixture can be impacted without heavily disrupting the delicate equilibria that are at play during crystallization. Recently, however, this view has started to change, with innovative techniques such as charge density mismatch or electro-assisted synthesis showing that the addition of new elements to the reactor midsynthesis might lead to new and surprising outcomes. In this manuscript, we show that by intermittent removal of certain fractions, notably Al-rich solids or Si-rich liquids, from the reaction medium during an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can control the Si/Al ratio of the final product, without heavily impacting the reaction time, particle size, or divalent cation capacity of the final product. This approach was named "split synthesis" and has led to several insights. By removing some Si-rich liquid phase after 40 min of synthesis, the Si/Al ratio of the daughter zeolite was lowered to a value of 20 (starting from 40), while the divalent cation capacity, a performance indicator for several acid and metal-catalyzed reactions, was kept maximized. On the other hand, when Al-rich solids were removed after 40 min (and in some cases colloidal silica was supplemented), we were able to rapidly synthesize small SSZ-13 zeolites with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle sizes in the range 100-150 nm and are traditionally difficult to crystallize in hydroxide medium. They showed a great olefin yield (6%) in the conversion of CO and H with ZnZrOx as cocatalyst. Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite synthesis mixture can be impacted without heavily disrupting the delicate equilibria that are at play during crystallization. Recently, however, this view has started to change, with innovative techniques such as charge density mismatch or electro-assisted synthesis showing that the addition of new elements to the reactor midsynthesis might lead to new and surprising outcomes. In this manuscript, we show that by intermittent removal of certain fractions, notably Al-rich solids or Si-rich liquids, from the reaction medium during an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can control the Si/Al ratio of the final product, without heavily impacting the reaction time, particle size, or divalent cation capacity of the final product. This approach was named "split synthesis" and has led to several insights. By removing some Si-rich liquid phase after 40 min of synthesis, the Si/Al ratio of the daughter zeolite was lowered to a value of 20 (starting from 40), while the divalent cation capacity, a performance indicator for several acid and metal-catalyzed reactions, was kept maximized. On the other hand, when Al-rich solids were removed after 40 min (and in some cases colloidal silica was supplemented), we were able to rapidly synthesize small SSZ-13 zeolites with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle sizes in the range 100-150 nm and are traditionally difficult to crystallize in hydroxide medium. They showed a great olefin yield (6%) in the conversion of CO2 and H2 with ZnZrOx as cocatalyst.Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to this, many zeolite scientists have regarded the initial mixing (aging) stage as the only time at which the chemical composition of a zeolite synthesis mixture can be impacted without heavily disrupting the delicate equilibria that are at play during crystallization. Recently, however, this view has started to change, with innovative techniques such as charge density mismatch or electro-assisted synthesis showing that the addition of new elements to the reactor midsynthesis might lead to new and surprising outcomes. In this manuscript, we show that by intermittent removal of certain fractions, notably Al-rich solids or Si-rich liquids, from the reaction medium during an interzeolite conversion from FAU-to-CHA (and FAU-to-MFI), one can control the Si/Al ratio of the final product, without heavily impacting the reaction time, particle size, or divalent cation capacity of the final product. This approach was named "split synthesis" and has led to several insights. By removing some Si-rich liquid phase after 40 min of synthesis, the Si/Al ratio of the daughter zeolite was lowered to a value of 20 (starting from 40), while the divalent cation capacity, a performance indicator for several acid and metal-catalyzed reactions, was kept maximized. On the other hand, when Al-rich solids were removed after 40 min (and in some cases colloidal silica was supplemented), we were able to rapidly synthesize small SSZ-13 zeolites with Si/Al ratios up to 180. These high-Si SSZ-13 zeolites had particle sizes in the range 100-150 nm and are traditionally difficult to crystallize in hydroxide medium. They showed a great olefin yield (6%) in the conversion of CO2 and H2 with ZnZrOx as cocatalyst. |
| Author | Sakellariou, Dimitrios Baeckelmans, Beatrice Robijns, Sven Van Assche, Tom R. C. Devos, Julien Torka Beydokhti, Mostafa de Oliveira-Silva, Rodrigo De Witte, Niels Dusselier, Michiel De Frene, Tom |
| AuthorAffiliation | Department of Chemical Engineering Center for Sustainable Catalysis and Engineering (CSCE) Centre for Membrane Separations, Adsorption, Catalysis and Spectroscopy for Sustainable Solutions (cMACS) KU Leuven |
| AuthorAffiliation_xml | – name: Department of Chemical Engineering – name: Center for Sustainable Catalysis and Engineering (CSCE) – name: KU Leuven – name: Centre for Membrane Separations, Adsorption, Catalysis and Spectroscopy for Sustainable Solutions (cMACS) |
| Author_xml | – sequence: 1 givenname: Sven orcidid: 0000-0001-9229-1578 surname: Robijns fullname: Robijns, Sven organization: Center for Sustainable Catalysis and Engineering (CSCE) – sequence: 2 givenname: Julien orcidid: 0000-0002-2254-9016 surname: Devos fullname: Devos, Julien organization: Center for Sustainable Catalysis and Engineering (CSCE) – sequence: 3 givenname: Beatrice surname: Baeckelmans fullname: Baeckelmans, Beatrice organization: Center for Sustainable Catalysis and Engineering (CSCE) – sequence: 4 givenname: Tom orcidid: 0000-0001-6768-4732 surname: De Frene fullname: De Frene, Tom organization: Center for Sustainable Catalysis and Engineering (CSCE) – sequence: 5 givenname: Mostafa surname: Torka Beydokhti fullname: Torka Beydokhti, Mostafa organization: Center for Sustainable Catalysis and Engineering (CSCE) – sequence: 6 givenname: Rodrigo orcidid: 0000-0003-3903-2678 surname: de Oliveira-Silva fullname: de Oliveira-Silva, Rodrigo organization: KU Leuven – sequence: 7 givenname: Niels orcidid: 0000-0002-3541-1382 surname: De Witte fullname: De Witte, Niels organization: Department of Chemical Engineering – sequence: 8 givenname: Dimitrios orcidid: 0000-0001-7424-5543 surname: Sakellariou fullname: Sakellariou, Dimitrios organization: KU Leuven – sequence: 9 givenname: Tom R. C. orcidid: 0000-0002-0739-5688 surname: Van Assche fullname: Van Assche, Tom R. C. organization: Department of Chemical Engineering – sequence: 10 givenname: Michiel orcidid: 0000-0002-3074-2318 surname: Dusselier fullname: Dusselier, Michiel email: michiel.dusselier@kuleuven.be organization: Center for Sustainable Catalysis and Engineering (CSCE) |
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| Keywords | zeolite synthesis CO2-to-olefins hydrothermal synthesis CO2 conversion nanosized zeolites high-silica zeolites |
| Language | English |
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| Snippet | Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to... Zeolite synthesis is known as a difficult-to-control process, with many degrees of freedom that have a partially uncharted impact on the final product. Due to... |
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| Title | Split Syntheses: Introducing Bottom-Up Control over Aluminum in SSZ-13 and ZSM‑5 Zeolites |
| URI | http://dx.doi.org/10.1021/jacsau.4c00551 https://www.ncbi.nlm.nih.gov/pubmed/40017743 https://www.proquest.com/docview/3172270308 https://pubmed.ncbi.nlm.nih.gov/PMC11862926 https://doaj.org/article/ed20d82ca6eb4c2b83776530e2ba6ac7 |
| Volume | 5 |
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