Insight into Structural and Physicochemical Properties of ZrO2-SiO2 Monolithic Catalysts with Hierarchical Pore Structure: Effect of Zirconium Precursor

Zirconia–silica monolithic catalysts with hierarchical micro/macroporous structure were obtained in a sol-gel process combined with phase separation using inorganic salts, i.e., oxychloride, oxynitrate and sulphate, as a zirconium source. It was found that the use of zirconium oxychloride and prehydrolysis of tetraethoxysilane (TEOS) resulted in materials characterized by a well-developed continuous structure of macropores with a diameter of ca. 10 μm. For zirconium oxynitrate and sulfate modified materials, the prehydrolysis hardly affected the macropore size. The micropores with a diameter of 1.5 nm in the skeleton of all materials provided a large surface area of 550–590 m2/g. A high dispersion of zirconia in the silica skeleton in all studied materials was shown. However, the largest surface concentration of Lewis and Brönsted acid sites was found in the monolith synthesized with zirconium oxychloride. The monoliths were used as a core for continuous-flow microreactors and high catalytic activity was confirmed in the deacetalization of benzylaldehyde dimethyl acetal. The process was characterized by a high efficiency at low temperature, i.e., 35 °C.