Amine-free synthesis of high-silica MFI zeolite by the conventional hydrothermal route

Abstract

High-silica MFI zeolite can hardly be prepared by the conventional hydrothermal synthesis route in the absence of amines, which is ascribed to the competitive growth of quartz, magadiite, or kenyaite phase. In this work, these impurity phases were excluded from the synthetic gel through a low-temperature crystallization method, while the growth of zeolite phase was promoted by seed-directed and C2H5OH filling. Consequently, well-crystallized ZSM-5 samples with controllable Si/Al ratios (46–205) and uniform particle sizes were successfully prepared, and the crystallization process was tracked by multiple characterization techniques, pointing toward a nonclassical particle attachment crystallization process. Interestingly, we found that the optimal C2H5OH/SiO2 ratio can be proportionally reduced by decreasing the H2O/SiO2 ratio in the synthetic gel. More importantly, the obtained high-silica MFI zeolite exhibited a much higher catalytic stability than the conventional sample synthesized using tetrapropylammonium as the template during the methanol-to-propylene and n-butene cracking reactions, which may be attributed to its fewer defect sites determined by 1H magic angle spinning nuclear magnetic resonance techniques. Overall, this work provides an efficient route for the large-scale production of high-silica ZSM-5 samples.