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Generation of ZSM-5 Nanocrystallites and Their Assembly into Hierarchical Architecture in a Phase-Transfer Synthesis

A method of phase-transfer water/toluene synthesis was developed to fabricate mesocrystals of Zeolite Socony Mobil-5 (ZSM-5) that contain both meso-/micropores and nanometer crystallites. The construction of a hierarchical architecture from nanozeolites via oriented attachment growth was achieved by a simple phase-transfer water/toluene synthesis by minimizing classical atom-by-atom crystallization. This opens the way to the cheap, highly efficient engineering of zeolitic morphologies. The physicochemical properties of the crystal were revealed by powder X-ray diffraction (XRD), N2 physical adsorption, inductively coupled plasma atomic emission spectroscopy (ICP-AES), scanning electron microscopy (SEM), transmission electron microscopy (TEM), ammonia temperature-programmed desorption (NH3-TPD) and pyridine infrared spectroscopy (Py-IR), indicating that the material has a high specific surface area, mesopore volume and Lewis acid content. The hierarchical ZSM-5 exhibits a prolonged catalytic lifetime in dimethyl ether–methyl ether (DTO) conversion and enhanced selectivity for propylene owing to the enhanced structural properties. The method can be extended to the synthesis of other graded zeolites controlled by the crystallization process and produce crystals comprising traversing mesoporosity and ultrasmall crystallites that are crucial for mass transfer enhancement.