Polyelectrolyte-surfactant complex as a template for the synthesis of zeolites with intracrystalline mesopores.

Mesoporous zeolite silicalite-1 and Al-ZSM-5 with intracrystalline mesopores were synthesized with polyelectrolyte-surfactant complex as the template. Complex colloids were first formed by self-assembly of the anionic polymer poly(acrylic acid) (PAA) and the cationic surfactant cetyltrimethylammonium bromide (CTAB) in basic solution. During the synthesis procedure, upon the addition of the silica source, microporous template (tetrapropylammonium hydroxide), and NaCl, these PAA/CTA complex colloids underwent dissociation and gave rise to the formation of hollow silica spheres with mesoporous shells templated by CTAB micelles and PAA domains as the core. Under hydrothermal treatment, the hollow silica spheres gradually merged together to form larger particles with the PAA domains embedded as the space occupant, which acted as a template for intracrystalline mesopores during the crystallization of the zeolite framework. Amphiphilic organosilane was used to enhance the connection between the PAA domain and the silica phase during the synthesis. After calcination, single crystal-like zeolite particles with intracrystalline mesopores of about 5-20 nm were obtained, as characterized by X-ray diffraction, scanning electron microscopy, transmission electron microscopy, and N(2) adsorption measurements. With the addition of an aluminum source in the synthesis, mesoporous zeolite Al-ZSM-5 with intracrystalline mesopores was also synthesized, and enhanced catalytic property was observed with mesoporous Al-ZSM-5 in acetalization of cyclohexanone with methanol.