The prediction and synthesis of new crystal structures enable the targeted preparation of materials with desired properties. Among porous solids, this has been achieved for metal-organic frameworks, but not for the more widely applicable zeolites, where new materials are usually discovered using exploratory synthesis. Although millions of hypothetical zeolite structures have been proposed, not enough is known about their synthesis mechanism to allow any given structure to be prepared. Here we present an approach that combines structure solution with structure prediction, and inspires the targeted synthesis of new super-complex zeolites. We used electron diffraction to identify a family of related structures and to discover the structural 'coding' within them. This allowed us to determine the complex, and previously unknown, structure of zeolite ZSM-25 (ref. 8), which has the largest unit-cell volume of all known zeolites (91,554 cubic ångströms) and demonstrates selective CO2 adsorption. By extending our method, we were able to predict other members of a family of increasingly complex, but structurally related, zeolites and to synthesize two more-complex zeolites in the family, PST-20 and PST-25, with much larger cell volumes (166,988 and 275,178 cubic ångströms, respectively) and similar selective adsorption properties. Members of this family have the same symmetry, but an expanding unit cell, and are related by hitherto unrecognized structural principles; we call these family members embedded isoreticular zeolite structures.
Many industrially important materials, ranging from ceramics to catalysts to pharmaceuticals, are polycrystalline and cannot be grown as single crystals. This means that non-conventional methods of structure analysis must be applied to obtain the structural information that is fundamental to the understanding of the properties of these materials. Electron microscopy might appear to be a natural approach, but only relatively simple structures have been solved by this route. Powder diffraction is another obvious option, but the overlap of reflections with similar diffraction angles causes an ambiguity in the relative intensities of those reflections. Various ways of overcoming or circumventing this problem have been developed, and several of these involve incorporating chemical information into the structure determination process. For complex zeolite structures, the FOCUS algorithm has proved to be effective. Because it operates in both real and reciprocal space, phase information obtained from high-resolution transmission electron microscopy images can be incorporated directly into this algorithm in a simple way. Here we show that by doing so, the complexity limit can be extended much further. The power of this approach has been demonstrated with the solution of the structure of the zeolite TNU-9 (|H9.3|[Al9.3Si182.7O384]; ref. 10) with 24 topologically distinct (Si,Al) atoms and 52 such O atoms. For comparison, ITQ-22 (ref. 11), the most complex zeolite known to date, has 16 topologically distinct (Si,Ge) atoms.
A solid understanding of the molecular-level mechanisms responsible for zeolite crystallization remains one of the most challenging issues in modern zeolite science. Here we investigated the formation pathway for high-silica LTA zeolite crystals in the simultaneous presence of tetraethylammonium (TEA(+)), tetramethylammonium (TMA(+)), and Na(+) ions as structure-directing agents (SDAs) with the goal of better understanding the charge density mismatch synthesis approach, which was designed to foster cooperation between two or more different SDAs. Nucleation was found to begin with the formation of lta-cages rather than the notably smaller sod and d4r-cages, with concomitant incorporation of TMA(+) and Na(+) into a very small amount of the solid phase with a low Si/Al ratio (ca. 2.5). The overall characterization results of our work demonstrate that sod-cages are first built around the preorganized lta-cages and that d4r-cages are in turn constructed by the progressive addition of low-molecular-weight (alumino)silicate species, which promotes the formation and growth of embryonic LTA zeolite crystals. We also show that the crystal growth may take place by a similar process in which TEA(+) is also incorporated, forming a single LTA zeolite phase with a higher Si/Al ratio (ca. 3.3).
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