Preparation of Hierarchical Porous Zeolite Particles with Multiscale Pore Architectures through a Template-Assisted Spray Process for Enhanced Toluene Adsorption Rate

Hierarchical porous zeolite particles featuring multiscale pore architectures have gained significant attention due to their enhanced mass transfer properties and superior adsorption capabilities. This study reports the first successful synthesis of hierarchical porous zeolites with integrated micropores, mesopores, and macropores using a template-assisted spray process, addressing the limitations of conventional zeolites in adsorbing large organic molecules such as toluene. By employing poly(methyl methacrylate) (PMMA) particles (about 350 nm in size) as a template, we achieved precise control over macropore formation, providing a new level of flexibility in tailoring zeolite pore architectures. The effect of the PMMA/zeolite mass ratio on the resulting macroporous structures and their toluene adsorption performance was systematically investigated. The results revealed that the hierarchical porous zeolite exhibited a significantly enhanced toluene adsorption rate compared to samples synthesized without the PMMA template. This improvement is attributed to the optimized macroporous structure, which facilitates efficient mass transfer. Importantly, this study addresses a critical gap in the literature by demonstrating the successful integration of macropores into zeolites through an environmentally friendly process, with significant implications for applications in volatile organic compound removal. This advancement in porous zeolite design could enable more efficient and practical solutions for industrial air purification and environmental remediation.