Direct synthesis of ultrathin FER zeolite nanosheets via a dual-template approach

Abstract

The synthesis of zeolites with nanosheet morphology has been attracting extensive attention. Despite the steady progress, the direct synthesis of ultrathin nanosheets of FER zeolite with thickness of less than 10 nm is still a great challenge. Herein we report a facile synthesis of FER zeolite nanosheets (named SCM-37) by using octyltrimethylammonium chloride (OTMAC) and 4-dimethylaminopyridine (4-DMAP) as dual organic templates. The effects of synthesis parameters, including initial molar ratio of SiO₂/Al₂O₃, crystallization temperature and time were investigated. It turned out that the crystallization field of SCM-37 was narrow. A two-step crystallization method was utilized to obtain pure and completely crystallized SCM-37 zeolite. SCM-37 was characterized by multiple techniques, including X-ray powder diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), nitrogen physisorption, Fourier transform infrared (FTIR), ammonia-temperature programmed desorption (NH₃-TPD) and nuclear magnetic resonance (NMR), and compared with the conventional FER zeolite (C-FER). The two most significant features of SCM-37 are the ultrathin crystal nanosheet and extremely high external surface area. The thickness of SCM-37 along the a-axis is 4∼7 nm, while that of C-FER is over 20 nm. The external surface area reaches 198 m² g⁻¹, which is over ten times larger than that of C-FER. The catalytic performances of the FER zeolites were evaluated by the cracking of 1,3,5-triisopropylbenzene (TiPB). Although possessing a lower amount of total acid sites, SCM-37 showed higher conversion of TiPB, as well as selectivity to the deep cracking products. The superior performance of SCM-37 was attributed to the higher external surface area arising from the ultrathin nanosheets.