Seed-Assisted Synthesis and Catalytic Performance of Nano-sized ZSM-5 Aggregates in a One-Step Crystallization Process

Hierarchical nano-sized ZSM-5 aggregates were successfully synthesized via a seed-assisted method in the presence of cetyltrimethylammonium bromide (CTAB) through a facile one-step crystallization process. Commercial ZSM-5 zeolites with a SiO2/Al2O3 ratio comparable to that of ZSM-5 products were treated with alkali and used as the seed particles. The influences of crystallization conditions were investigated, and the possible synthesis mechanism was proposed. ZSM-5 zeolites with different amounts of CTAB added were characterized using many techniques and evaluated in toluene alkylation with methanol. The results showed that a trace amount of CTAB significantly promoted the crystallization of ZSM-5 zeolite, with the morphology changing from hexagonal-shape crystals to uniform spherical aggregates. CTAB may act as the structure-directing agent and assemble the primary crystallites to generate hierarchical ZSM-5 aggregates. The ZSM-5 zeolite with the smallest primary particles of 50–80 nm exhibited large specific surface area, abundant mesopores, and the greatest microporosity. The hierarchical nano-sized ZSM-5 aggregate showed higher toluene conversion and a longer lifetime without compromising the selectivity to xylene and p-xylene in toluene alkylation with methanol.