A fast route for synthesizing nano-sized ZSM-5 aggregates

Nano-sized ZSM-5 aggregates have been rapidly synthesized from leached metakaolin by solid-like state conversion. The influence of synthesis conditions such as TPA(+)/SiO2, NaOH/SiO2 and SiO2/Al2O3 molar ratios on the final products was investigated. The properties of nano-sized ZSM-5 aggregates were characterized by XRD, SEM, HRTEM, Si-29 and Al-27 MAS NMR, NH3-TPD, TG, N-2 adsorption-desorption and particle size analysis. The results clearly showed that nano-sized ZSM-5 aggregates could be obtained within 2 h via solid-like state conversion. SEM revealed that the obtained ZSM-5 aggregates were irregular spheres that consisted of nano-sized crystallites with 30-50 nm. The crystallization process indicated that the size of flaky raw materials gradually decreased and formed nano-sized particles as time prolonged. Therefore, the transformation mechanism followed the solution mediated mechanism, though only a little water was contained in the system. Compared with the conventional hydrothermal route, the solid-like state conversion not only significantly shortened the crystallization time, but also totally avoided the emission of waste liquids. In addition, for the methanol dehydration reaction, the nano-sized ZSM-5 aggregates obtained by this method showed much better catalytic performance, C2-C4 olefin selectivity and longer lifetime to endure coke deposition than the sample obtained by the hydrothermal route.