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Synthesis of Uniform Mesoporous Zeolite ZSM-5 Catalyst

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Synthesis of Uniform Mesoporous Zeolite ZSM-5 Catalyst ( synthesis-uniform-mesoporous-zeolite-zsm-5-catalyst )

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ChemEngineering 2019, 3, 35 2 of 11 acetate, phenyl acetyl chloride, phenyl propionic, phenylpropionyl chloride [3], acetyl chloride [4] and acetic anhydride [5–7] has been widely reported. The catalyst activity and selectivity of zeolite H-Beta, H-ZSM-5, H-Y, and NH4-Y catalysts in the acylation reaction of anisole with acetic anhydride were compared by Freese et al. [5]. They reported a lower catalytic activity of H-ZSM-5 compared to H-Y and H-Beta catalysts with only 14% of conversion; this is due to smaller intersection channels in ZSM-5 [8]. Zeolites are microporous crystalline aluminosilicates that have a similar composition to the clay minerals. However, they are different in their well-defined three-dimensional microporous structures. Silicon, aluminum, and oxygen are arranged in a regular structure of tetrahedral units of [SiO4]− and [AlO4]−, forming a framework with regular pores. The pores are in the form of channels, tunnels, or cavities with a diameter of around 0.1–2 nm running through the material [9]. Mesoporous zeolites, consisting of microporous structure and intra-crystalline mesoporosity, show improved catalytic activities in many organic reactions because of their enhanced reactants and products diffusion from/to active sites in microporous via the mesoporous frameworks [10]. Such materials help to overcome the limitation of microporous zeolites pore size and therefore allow large molecules to diffuse through [11]. The synthesis of mesoporous ZSM-5 via a dissolution process include the re-assembling of amorphous silica directed by surfactant molecules simultaneously; the re-assembling of the total dissolved structure of zeolite around surfactant molecules has also been reported [12]. In the presence of long-chain alkyl ammonium surfactants, the dissolved silicates accumulate within surfactant molecules to make micelles and re-precipitate onto the surface of parent spheres surface to convert amorphous silica into mesoporous silica during the hydrothermal reaction [13]. The synthesis of mesoporous ZSM-5 zeolites has been extensively studied using a silylated polyethylenimine as a mesoporous-directing agent and polymers are the most widely used templates, including long-chain organosilicates, amphiphilic surfactants [14], polyvinyl butyral [15], CTAB, F127, and P123 [16]. The lesser reactive Al sites support the maintenance of the zeolite framework in an alkaline medium, while the Si atoms dissolve, rendering more open structures. Desilication in comparison to dealumination provides more controllable mesoporosity and also preserves the Brønsted acidity [17]. The study of ZSM-5 and silicalite-treated alkali with sodium hydroxide aqueous solutions at high concentrations showed that Si atoms could be removed with no change in the crystallinity of the zeolites. Therefore, the present work is focused on the synthesis of ZSM-5 and the treatment of synthesized zeolite with an alkali solution as well as several different surfactant templates to form a uniform-sized mesoporous material without deterioration of crystallinity of the parent zeolite structure. The catalytic activity of untreated and treated zeolite catalysts was also studied in a batch reactor at different temperatures. 2. Material and Methods 2.1. Materials Cetyl trimethyl ammonium bromide (CTAB) was purchased from Fisher Scientific whilst tetra propyl ammonium hydroxide (TPAOH), sodium hydroxide (NaOH), ammonium nitrate (NH4NO3), anisole and propionic anhydride were obtained from Merck. NH4-ZSM-5 (Si/Al = 23) was purchased from Zeolyst International. 2.2. Synthesis of Mesoporous ZSM-5 Catalyst NH4-ZSM-5 zeolite (0.176 g) was dispersed in deionized water (20 g) using an ultrasonic bath. TPAOH (0.2 g) was separately dissolved in a solution consisting of NaOH (0.312 g) and deionized water (20 g). The prepared solution was appropriately mixed using an ultrasonic bath for 5 min and then put in a Teflon-lined autoclave. The hydrothermal treatment of the obtained solution was performed at 100 ◦C for 24 h. Further, the treated product was washed a few times using deionized

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