The introduction of synthetic zeolites has led to a paradigm shift in catalysis, separations, and adsorption processes, due to their unique properties such as crystallinity, high-surface area, acidity, ion-exchange capacity, and shape-selective character. However, the sole presence of micropores in these materials often imposes intracrystalline diffusion limitations, rendering low utilisation of the zeolite active volume in catalysed reactions. This critical review examines recent advances in the rapidly evolving area of zeolites with improved accessibility and molecular transport. Strategies to enhance catalyst effectiveness essentially comprise the synthesis of zeolites with wide pores and/or with short diffusion length. Available approaches are reviewed according to the principle, versatility, effectiveness, and degree of reality for practical implementation, establishing a firm link between the properties of the resulting materials and the catalytic function. We particularly dwell on the exciting field of hierarchical zeolites, which couple in a single material the catalytic power of micropores and the facilitated access and improved transport consequence of a complementary mesopore network. The carbon templating and desilication routes as examples of bottom-up and top-down methods, respectively, are reviewed in more detail to illustrate the benefits of hierarchical zeolites. Despite encircling the zeolite field, this review stimulates intuition into the design of related porous solids (116 references).

Hierarchical zeolites: enhanced utilisation of microporous crystals in catalysis by advances in materials design.

The hydrothermal synthesis of zeolites: precursors, intermediates and reaction mechanism

Great interest has arisen in the past years in the development of hierarchical zeolites, having at least two levels of porosities. Hierarchical zeolites show an enhanced accessibility, leading to improved catalytic activity in reactions suffering from steric and/or diffusional limitations. Moreover, the secondary porosity offers an ideal space for the deposition of additional active phases and for functionalization with organic moieties. However, the secondary surface represents a discontinuity of the crystalline framework, with a low connectivity and a high concentration of silanols. Consequently, hierarchical zeolites exhibit a less “zeolitic behaviour” than conventional ones in terms of acidity, hydrophobic/hydrophilic character, confinement effects, shape-selectivity and hydrothermal stability. Nevertheless, this secondary surface is far from being amorphous, which provides hierarchical zeolites with a set of novel features. A wide variety of innovative strategies have been developed for generating a secondary porosity in zeolites. In the present review, the different synthetic routes leading to hierarchical zeolites have been classified into five categories: removal of framework atoms, surfactant-assisted procedures, hard-templating, zeolitization of preformed solids and organosilane-based methods. Significant advances have been achieved recently in several of these alternatives. These include desilication, due to its versatility, dual templating with polyquaternary ammonium surfactants and framework reorganization by treatment with surfactant-containing basic solutions. In the last two cases, the materials so prepared show both mesoscopic ordering and zeolitic lattice planes. Likewise, interesting results have been obtained with the incorporation of different types of organosilanes into the zeolite crystallization gels, taking advantage of their high affinity for silicate and aluminosilicate species. Crystallization of organofunctionalized species favours the formation of organic–inorganic composites that, upon calcination, are transformed into hierarchical zeolites. However, in spite of this impressive progress in novel strategies for the preparation of hierarchical zeolites, significant challenges are still ahead. The overall one is the development of methods that are versatile in terms of zeolite structures and compositions, capable of tuning the secondary porosity properties, and being scaled up in a cost-effective way. Recent works have demonstrated that it is possible to scale-up easily the synthesis of hierarchical zeolites by desilication. Economic aspects may become a significant bottleneck for the commercial application of hierarchical zeolites since most of the synthesis strategies so far developed imply the use of more expensive procedures and reagents compared to conventional zeolites. Nevertheless, the use of hierarchical zeolites as efficient catalysts for the production of high value-added compounds could greatly compensate these increased manufacturing costs.

Synthesis strategies in the search for hierarchical zeolites

Design of hierarchical zeolite catalysts by desilication

Recent studies have shown that desilication by treatment in alkaline medium is, with respect to other methods, a very suitable and reproducible methodology to obtain mesoporous ZSM-5 zeolites with preserved structural integrity. This feature article analyzes mechanistic and kinetic aspects associated with this post-synthesis treatment. Framework aluminium controls the process of framework silicon extraction and makes desilication selective towards intracrystalline mesopore formation. An optimal molar Si/Al ratio in the range of 25–50 has been identified. At higher Si/Al ratios non-selective and excessive extraction of framework silicon occurs, while minor extraction and limited mesopore formation occurs at lower ratios. The presence of non-framework aluminium species, for example obtained by steam treatment, inhibits mesopore formation by alkaline treatment due to reinsertion of these species into the zeolite framework. Additional kinetic optimization of the physicochemical properties of the hierarchical porous zeolite structures is achieved by variation of time and temperature of the alkaline treatment. A successive combination of post-treatments, in which desilication is followed by dealumination, enables a decoupled modification of the mesoporous and acidic properties, being interesting in catalyst design and optimization. Preliminary work on other zeolite framework types has shown a promising outlook of the alkaline treatment. Development of mesoporous zeolites via desilication should induce a more efficient usage of the zeolite crystal due to an improved accessibility and a facilitated transport to and from the active sites.

Ankica Čimek

Papers

Dissolution of high-silica zeolites in alkaline solutions II. Dissolution of ‘activated’ silicalite-1 and ZSM-5 with different aluminum content

Kinetics of zeolite dissolution: Part 1. Dissolution of zeolite A in hot sodium hydroxide