Synthesis of Zeolites Using the ADOR (Assembly-Disassembly-Organization-Reassembly) Route

The overall goal of this video is to demonstrate the assembly-disassembly-organization-reassembly method to prepare new zeolite materials by dissaembling a preassembled zeolite into its components before organizing and reassembling them in different ways to form new materials. Zeolites are extremely important solids that are used in a variety of industries from oil refinery catalysts to antibacterial coatings on medical devices. The ADOR method for preparing zeolites is very different to traditional methods of zeolite synthesis.

And as a consequence the types of materials we can prepare also differ. This opens up many opportunities for new applications. In this video we will show you how to make two new zeolites that have different pore sizes, IPC-4, which has the smallest pore size, and the larger, IPC-2.

To assemble the parent germanium-UTL zeolite, first dissolve 1.08 grams of germanium dioxide into 15 milliliters of a solution of the structure-directing agent. Add 1.246 grams of fumed silicon dioxide, portionwise, to the solution, and stir for a further 30 minutes until a homogeneous solution is formed. Transfer the resulting gel to a Polytetrafluoroethylene-lined autoclave.

Then place it in an oven and heat to 175 degrees Celcius for 10 days. After 10 days, remove the autoclave from the oven and allow it to cool naturally to room temperature. Recover the white zeolite product by filtration.

Wash with copious amounts of water before drying the zeolite at 70 degrees Celsius overnight. Remove the structure-directing agent from the pores of the zeolite by heating the zeolite to 550 degrees Celsius at a rate of 1 degree Celsius per minute, then hold the temperature at 550 degrees Celsius for six hours before cooling to room temperature at a rate of 2 degrees Celsius per minute. Acquire a powder x-ray diffraction pattern to confirm the structure using the manufacturer's protocol.

Store the calcined zeolite in a dry, inert atmosphere to prevent hydrolysis of the material. To disassemble the parent zeolite, hydrolyze the germanosilicate UTL to form IPC-1P by adding 1 gram of calcined zeolite to 160 milliliters of a 0.1 molar hydrochloric acid solution. After heating this mixture at 95 degrees Celsius for 18 hours, cool to room temperature and recover the solid by filtration using filter paper.

Wash the solid with copious amounts of water, and dry at 70 degrees Celsius overnight. The final steps are to organize and reassemble the IPC-1P into the new zeolites. To prepare the IPC-4 zeolite, place 0.5 grams of IPC-1P in a ceramic crucible.

Heat the sample to 575 degrees Celsius at a heating rate of 1 degree Celsius per minute. Then, hold the temperature at 575 degrees Celsius for six hours, before cooling to room temperature at a rate of 2 degrees Celsius per minute. Acquire a powder x-ray diffraction spectrum to confirm the structure using the manufacturer's protocol.

To prepare the IPC-2 zeolite, add 0.5 grams of IPC-1P to 10 milliliters of 1.0 molar nitric acid solution. Then, add 0.1 grams of Diethoxymethylsilane to the solution. Transfer the solution to a Polytetrafluoroethylene-lined autoclave.

And heat in an oven at 175 degrees Celsius for 18 hours. Remove the autoclave from the oven and allow it to cool naturally to room temperature. Recover the white product by filtration, wash with copious amounts of water, and dry at 70 degrees Celsius overnight.

Place the product in a ceramic crucible and heat with a heating-cooling protocol. Finally, acquire a powder x-ray diffraction spectrum to confirm the structure using the manufacturer's protocol. Preparation of IPC-4 starts with the preassembled germanium UTL.

Exposure to a 0.1 molar acidic solution leads to disassembly, which forms IPC-1P. The IPC-1P layers are then organized into a favorable orientation. At this point, the layers are reassembled into a zeolite via condensation to form IPC-4.

Shown here is the overall process for the preparation of IPC-2. Exposure to a 0.1 molar acidic solution leads to the formation of IPC-1P, as before. Extra silicon species are then introduced between the layers of the resulting IPC-1P to organize the system.

The layers are then reassembled into a zeolite via condensation to form IPC-2. The difference between the final IPC-2 and IPC-4 materials is their pore size, caused by the introduction of extra silicon between the layers. The difference between the two structures can be seen in the x-ray diffraction patterns.

The most intense peak for IPC-2 is at a lower 2-theta angle than that for IPC-4, showing that it has a larger unit cell. Other techniques, such as nitrogen adsorption experiments, can also be used to visualize the difference in pore size between the materials. IPC-4 has a lower capacity for nitrogen than IPC-2, whereas the parent UTL zeolite has the highest capacity for nitrogen.

Once mastered, this process is a reliable and general method of making zeolites. Variations in the procedure, which can be found in the literature, can lead to other zeolites such as IPC-6, IPC-7, IPC-9 and IPC-10. After its development, this technique paved the way for researchers in the field of zeolites to explore the synthesis of materials that were previously thought to have been unfeasible.

Such work opens up great possibilities to prepare zeolites with new types of structure that we hope will subsequently open up new applications. After watching this video, you should have a good understanding of how to perform the ADOR process, and with a little practice, you should be able to make the modifications that are listed in the published literature to make all other possible zeolites as well. The major advantages of this technique are that the final materials are truly predictable and that the porosity of the final solid is controllable in a way not possible in traditional zeolite synthesis.

Generally, individuals new to this method will struggle because it goes against what is normally thought. Rather than build up the material from the bottom up, you first take a material and disassemble it, before rebuilding it back up into material with a new structure.