Hierarchical Zeolite Single Crystal Reactor for Unprecedented Catalytic Efficiency

Abstract

As a size and shape selective catalyst, zeolites are widely used in petroleum and fine chemicals processing. However, their small micropores severely hinder molecular diffusion and are sensitive to coke formation. Hierarchically porous zeolite single crystals with fully interconnected, ordered and tunable multimodal porosity at macro-, meso- and micro-length scale like in leaves offer the ideal solution. However, their synthesis remains highly challenging. Here we report a versatile confined zeolite crystallization process to achieve these superior properties. Such bio-inspired zeolite single crystals lead to significantly improved mass transport properties by shortening the diffusion length while maintaining shape selective properties, endowing them with an unprecedentedly high efficiency of zeolite crystals, enhanced catalytic activities and cycle time, highly reduced coke formation and reduced deactivation rate in bulky-molecule reactions and methanol-to-olefins process. Their industrial utilization can lead to the design of innovative and intensified reactors and processes with highly enhanced efficiency and minimum energy consumption.