Optimized Synthesis of ZSM-11 Catalysts using 1,8-Diaminooctane as a Structure-Directing Agent

Developing new zeolite catalysts for (petro)chemical applications is nontrivial owing to challenges that include the identification of commercially-viable syntheses. The vast majority of syntheses require the use of an organic structure-directing agent (OSDA), which has economic and environmental shortcomings. In the search for alternative zeolites to common industrial catalysts, such as ZSM-5 (MFI), a promising candidate is ZSM-11 (MEL), a close structural analogue of MFI. ZSM-11 is comprised of 3-dimensional straight channels that have less diffusion limitations than MFI. Side-by-side comparisons of ZSM-11 and ZSM-5 catalysts reveal the former exhibits significantly longer time-on-stream lifetime in many reactions; however, there are several difficulties associated with the preparation of ZSM-11, which include the ability to identify inexpensive OSDAs that produce small crystals in high yield. Here, we examine ZSM-11 synthesis using 1,8-diaminooctane (DAO), which produces ZSM-11 crystals with sizes of ca. 300 nm. We demonstrate that the use of MEL seeds allows for an order of magnitude reduction in the quantity of DAO without sacrificing crystal purity or yield (>80 %). Catalytic tests using methanol to hydrocarbons as a representative reaction show that H-ZSM-11 lifetime and selectivity are similar for samples prepared with and without seeds. Collectively our findings highlight an efficient method to produce ZSM-11 as a potential alternative to ZSM-5 for catalytic applications.