High-throughput synthesis and catalytic properties of a molecular sieve with 18- and 10-member rings

Crystalline molecular sieves with large pores and high adsorption capacities have many potential applications. Of these materials, zeolites are of particular interest owing to their stability in a wide range of experimental conditions. An aluminophosphate with very large circular channels(5) containing 18 oxygen atoms (18-ring channels) has been synthesized, but in the search for large-pore zeolites, most of the materials which have been synthesized up to now contain only 14-ring channels; the synthesis of zeolites with larger ring structures has been believed to be hindered by the low Si-O-Si bond angles available. A silicogaloaluminate (ECR-34) with unidirectional 18-ring channels was recently reported, but exhibited low micropore volume, thus rendering the material less attractive for catalytic applications. Here we report the structure and catalytic activity of the silicogermanate zeolite ITQ-33; this material exhibits straight large pore channels with circular openings of 18-rings along the c axis interconnected by a bidirectional system of 10-ring channels, yielding a structure with very large micropore volume. The conditions for synthesis are easily accessible, but are not typical, and were identified using high-throughput techniques.     

Supramolecular self-assembled molecules as organic directing agent for synthesis of zeolites

Solid materials with uniform micropores, such as zeolites, can act as selective catalysts and adsorbents for molecular mixtures by separating those molecules small enough to enter their pores while leaving the larger molecules behind. Zeolite A is a microporous material with a high void volume. Despite its widespread industrial use in, for example, molecular separations and in detergency, its capability as a petroleum-refining material is limited owing to its poor acid-catalytic activity and hydrothermal stability, and its low hydrophobicity. These characteristics are ultimately a consequence of the low framework Si/Al ratio (normally around one) and the resulting high cationic fraction within the pores and cavities. Researchers have modified the properties of type-A zeolites by increasing the Si/Al compositions up to a ratio of three. Here we describe the synthesis of zeolite A structures exhibiting high Si/Al ratios up to infinity (pure silica). We synthesize these materials, named ITQ-29, using a supramolecular organic structure-directing agent obtained by the self-assembly, through pi-pi type interactions, of two identical organic cationic moieties. The highly hydrophobic pure-silica zeolite A can be used for hydrocarbon separations that avoid oligomerization reactions, whereas materials with high Si/Al ratios give excellent shape-selective cracking additives for increasing propylene yield in fluid catalytic cracking operations. We have also extended the use of our supramolecular structure-directing agents to the synthesis of a range of other zeolites.     

Sn-zeolite beta as a heterogeneous chemoselective catalyst for Baeyer-Villiger oxidations

The Baeyer-Villiger oxidation, first reported more than 100 years ago, has evolved into a versatile reaction widely used to convert ketones-readily available building blocks in organic chemistry-into more complex and valuable esters and lactones. Catalytic versions of the Baeyer-Villiger oxidation are particularly attractive for practical applications, because catalytic transformations simplify processing conditions while minimizing reactant use as well as waste production. Further benefits are expected from replacing peracids, the traditionally used oxidant, by cheaper and less polluting hydrogen peroxide. Dissolved platinum complexes and solid acids, such as zeolites or sulphonated resins, efficiently activate ketone oxidation by hydrogen peroxide. But these catalysts lack sufficient selectivity for the desired product if the starting material contains functional groups other than the ketone group; they perform especially poorly in the presence of carbon-carbon double bonds. Here we show that upon incorporation of 1.6 weight per cent tin into its framework, zeolite beta acts as an efficient and stable heterogeneous catalyst for the Baeyer-Villiger oxidation of saturated as well as unsaturated ketones by hydrogen peroxide, with the desired lactones forming more than 98% of the reaction products. We ascribe this high selectivity to direct activation of the ketone group, whereas other catalysts first activate hydrogen peroxide, which can then interact with the ketone group as well as other functional groups.     

A large-cavity zeolite with wide pore windows and potential as an oil refining catalyst

Crude oil is an important feedstock for the petrochemical industry and the dominant energy source driving the world economy, but known oil reserves will cover demand for no more than 50 years at the current rate of consumption. This situation calls for more efficient strategies for converting crude oil into fuel and petrochemical products. At present, more than 40% of oil conversion is achieved using catalysts based on faujasite; this zeolite requires extensive post-synthesis treatment to produce an ultrastable form, and has a large cavity accessible through four 0.74-nm-wide windows and thus limits the access of oil molecules to the catalytically active sites. The use of zeolites with better accessibility to their active sites should result in improved catalyst efficiency. To date, two zeolites with effective pore diameters exceeding that of faujasite have been reported, but their one-dimensional pore topology excludes use in oil refining. Similarly, zeolites with large pores and a three-dimensional pore topology have been reported, but in all these materials the pore openings are smaller than in faujasite. Here we report the synthesis of ITQ-21, a zeolite with a three-dimensional pore network containing 1.18-nm-wide cavities, each of which is accessible through six circular and 0.74-nm-wide windows. As expected for a zeolite with this structure, ITQ-21 exhibits high catalytic activity and selectivity for valuable products in preliminary oil refining tests.