Rapid synthesis of hierarchical ZSM-5 zeolites for the reactions involving larger reactant molecules

In this study, the ZSM-5 zeolites with a high hierarchy factor were synthesized rapidly and tested for the furfural hydroxymethylation (FH) to 5-hydroxymethylfurfural (HMF). The effect of seeding techniques (STs) and templates (both soft (Cetrimonium bromide, CTAB) and hard (bio-sourced secondary template, BSST)) on the final zeolite properties were studied. A significant variation in crystallinity and morphology with the ST and type of seed was observed. The CTAB addition increased the hierarchy factor (H factor) by 3 times, and the implicit seeds decreased the hydrothermal time by 2 times. The zeolite yield, crystallinity, and pore geometry were a strong function of [CTA⁺]/[Na⁺] ratio. Slit and ink bottle-shaped pore morphologies were observed with only seed or seed + BSST and with seed + CTAB, respectively, and both exhibited the bimodal pore size distribution. The zeolites with ink bottle-shaped pores outperformed those with slit pores in the FH and showed the highest selectivity to HMF of 65%, at 34% furfural conversion. The zeolites with high H factor showed catalytic and structural stability up to 5 successive recycle runs.