Synthesis of high-quality nano-H-ZSM-5 single crystals zeolite from montmorillonite and MTO catalytic studies

Clay is a rich aluminosilicate resource with unique advantages as a raw material for zeolites production. However, synthesizing nanosized single-crystalline zeolites through a simple approach using clay remains a significant challenge. In this paper, acid-washed montmorillonite (MSR) was used to prepare nano-H-ZSM-5 single crystals with high crystallinity, uniform grain size and permeable straight pores under the induction of a small amount of organic template tetrapropylammonium hydroxide (TPAOH). Through temperature-staged treatment, the nucleation and growth process of zeolite were decoupled, ultimately achieving precise control over the size of the nano-single crystals. Mechanistic study showed that the low-temperature aging process produces smaller structural units which probably derived from the geopolymer topology of the clay, providing more active sites for zeolite nucleation, leading to the rapid crystallization during the high-temperature process. The porous structure promotes material diffusion, inhibits aromatic cycling and reduces carbon formation in the pores. The large specific surface area and nanoscale multilayer pore structure delay carbon accumulation and increase carbon holding capacity. These properties make nano-ZSM-5 single crystals an excellent choice for high olefin selectivity and long catalytic life in the methanol-to-olefin reaction. This synthetic route provides a general strategy for preparing nanosized zeolite single crystals from clay.