Interchain-expanded extra-large-pore zeolites.

Stable aluminosilicate zeolites with extra-large pores that are open through rings of more than 12 tetrahedra could be used to process molecules larger than those currently manageable in zeolite materials. However, until very recently1-3, they proved elusive. In analogy to the interlayer expansion of layered zeolite precursors4,5, we report a strategy that yields thermally and hydrothermally stable silicates by expansion of a one-dimensional silicate chain with an intercalated silylating agent that separates and connects the chains. As a result, zeolites with extra-large pores delimited by 20, 16 and 16 Si tetrahedra along the three crystallographic directions are obtained. The as-made interchain-expanded zeolite contains dangling Si-CH3 groups that, by calcination, connect to each other, resulting in a true, fully connected (except possible defects) three-dimensional zeolite framework with a very low density. Additionally, it features triple four-ring units not seen before in any type of zeolite. The silicate expansion-condensation approach we report may be amenable to further extra-large-pore zeolite formation. Ti can be introduced in this zeolite, leading to a catalyst that is active in liquid-phase alkene oxidations involving bulky molecules, which shows promise in the industrially relevant clean production of propylene oxide using cumene hydroperoxide as an oxidant.

A 3D extra-large-pore zeolite enabled by 1D-to-3D topotactic condensation of a chain silicate.

Zeolites are microporous silicates with a large variety of applications as catalysts, adsorbents, and cation exchangers. Stable silica-based zeolites with increased porosity are in demand to allow adsorption and processing of large molecules but challenge our synthetic ability. We report a new, highly stable pure silica zeolite called ZEO-3, which has a multidimensional, interconnected system of extra-large pores open through windows made by 16 and 14 silicate tetrahedra, the least dense polymorph of silica known so far. This zeolite was formed by an unprecedented one-dimensional to three-dimensional (1D-to-3D) topotactic condensation of a chain silicate. With a specific surface area of more than 1000 square meters per gram, ZEO-3 showed a high performance for volatile organic compound abatement and recovery compared with other zeolites and metal-organic frameworks.

A stable aluminosilicate zeolite with intersecting three-dimensional extra-large pores.

Zeolites are crystalline porous materials with important industrial applications, including uses in catalytic and adsorption-separation processes. Access into and out of their inner confined space, where adsorption and reactions occur, is limited by their pore apertures. Stable multidimensional zeolites with larger pores able to process larger molecules are in demand in the fine chemical industry and for the oil processing on which the world still relies for fuels. Currently known extra-large-pore zeolites display poor stability and/or lack pore multidimensionality, limiting their usefulness. We report ZEO-1, a robust, fully connected aluminosilicate zeolite with mutually intersecting three-dimensional extra-large plus three-dimensional large pores. ZEO-1 is stable up to 1000°C, has an extraordinary specific surface area (1000 square meters per gram), and shows potential as a catalytic cracking catalyst.

Structure-direction towards the new large pore zeolite NUD-3.

The new zeolite NUD-3 possesses a three-dimensional system of large pore channels that is topologically identical to those of ITQ-21 and PKU-14. However, the three zeolites have distinctly different frameworks: a particular single 4-membered ring inside the denser portion of the zeolite is missing in PKU-14, disordered in ITQ-21 and fully ordered in NUD-3. We document these differences and use molecular simulations to unravel the mechanism by which a particular structure directing agent dication, 1,1'-(1,2-phenylenebis(methylene))bis(3-methylimidazolium), is able to orient this inner ring.

An Extra-Large-Pore Pure Silica Zeolite with 16×8×8-Membered Ring Pore Channels Synthesized using an Aromatic Organic Directing Agent.

Extra-large-pore zeolites for processing large molecules have long been sought after by both the academia and industry. However, the synthesis of these materials, particularly extra-large-pore pure silica zeolites, remains a big challenge. Herein we report the synthesis of a new extra-large-pore silica zeolite, designated NUD-6, by using an easily synthesized aromatic organic cation as structure-directing agent. NUD-6 possesses an intersecting 16×8×8-membered ring pore channel system constructed by four-connected (Q4 ) and unusual three-connected (Q3 ) silicon species. The organic cations in NUD-6 can be removed in nitric acid to yield a porous material with high surface area and pore volume. The synthesis of NUD-6 presents a feasible means to prepare extra-large pore silica zeolites by using assembled aromatic organic cations as structure-directing agents.

A Stable Extra-Large-Pore Zeolite with Intersecting 14- and 10-Membered-Ring Channels.

The development of inorganic frameworks with extra-large pores (larger than 12-membered rings) has attracted considerable attention because of their potential applications in catalysis, the separation of large molecules, and so forth. We herein report the synthesis of the new extra-large-pore zeolite NUD-2 by using the supramolecular self-assembly of simple aromatic organic cations as structure-directing agents (SDAs). NUD-2 is a high-silicon-content germanosilicate with interconnecting 14×10-membered-ring channels. The SDAs in NUD-2 can be removed by calcination in air at 550 °C to yield permanent pores with a BET surface area of 500 m(2) g(-1) . Both germanium and organic cations in NUD-2 can also be removed by treatment with acid at lower temperature, thus not only affording recycling of germanium and SDAs, but also providing a highly stable siliceous zeolite. In addition, aluminum ions can be incorporated into the framework of NUD-2. The NUD-2 structure is yet another extra-large-pore zeolite synthesized by using the supramolecular self-assembling templating approach, thus demonstrating that this approach is a general and applicable strategy for synthesis of new large- and extra-large-pore zeolites.

An extra-large-pore zeolite with intersecting 18-, 12-, and 10-membered ring channels.

Zeolites with extra-large pores have attracted great attention because of their important applications such as in hydrocracking, catalysis, and separation of large molecules. Despite much progress has been made during the past decades, the synthesis of these materials remains a big challenge. A new extra-large-pore zeolite NUD-1 (Nanjing University Du's group zeolite no. 1) is synthesized by using an approach based on supramolecular self-assemblies of small aromatic organic cations as structure-directing agents. NUD-1 possesses interconnecting 18-, 12-, and 10-membered ring channels, built from the same building units as those of ITQ-33 and ITQ-44. There coexist single 3-membered ring, double-3-membered ring and double-4-membered ring secondary building units in NUD-1, which have not been seen in any other zeolites.