Supercritical fluid-mediated alumination of mesoporous silica and its beneficial effect on hydrothermal stability

We have investigated the use of supercritical fluids (SCFs) as carriers/solvents during the postsynthesis alumination of mesoporous silica. SCFs were found to be ideally suited for transport of Al into mesoporous silica and to lead to Al-grafted aluminosilicate materials that exhibit exceptional hydrothermal (steam) stability even for highly aluminated materials. The improvements in steam stability arising from the use of SCFs as grafting media (as compared to aqueous or organic solvents) are remarkable, especially for Al-grafted MCM-41 materials with high (Si/Al < or = 10) Al contents. It is proposed that under supercritical fluid conditions Al is sorbed on the surface of the pore walls of the host Si-MCM-41 with little penetration into the pore wall region, that is, the low solvating power of SCFs ensures the deposition of Al onto rather than into the silica framework. This is because the host silica framework cannot undergo any significant hydrolysis (to allow penetration of Al into the pore wall region) during the SCF-mediated alumination. Removal of the Al (i.e., dealumination) which occurs during steaming is therefore less detrimental to the structural integrity of SCF-grafted Al-MCM-41 materials since any dealumination that occurs will not involve removal of Al from deep within the pore walls.