Nonionic polymer and amino acid-assisted synthesis of ZSM-5 nanocrystals and their catalytic application in the alkylation of 2-methylnaphthalene.

The synthesis of nanosized ZSM-5 zeolites with high crystallinity and suitable acidity is very significant for their great potential in various catalytic applications. Herein, a series of zeolite ZSM-5 crystals with different particle sizes and SiO2 /Al2 O3 ratios (10-30) were synthesized by a temperature-varying two-step crystallization method in a concentrated gel system containing L-lysine and/or polyvinylpyrrolidone (PVP) additives. By optimizing the addition amounts of the two additives, the crystal size of the ZSM-5 zeolite could be reduced to less than 100 nm. Meanwhile, relatively high crystallinity and framework Al incorporation rates could be achieved, resulting in the generation of high-quality ZSM-5 nanocrystals. The nanosized H-form ZSM-5 zeolite with a SiO2 /Al2 O3 ratio of 20 showed enhanced catalytic efficiency and stability for the alkylation of 2-methylnaphthalene (2-MN) with methanol to produce an important intermediate, 2,6-dimethylnaphthalene (2,6-DMN). A relatively high and steady yield of 2,6-DMN (above 7.2%) could be achieved during 20 h time-on-stream at 400 °C. The smaller crystal size, higher crystallinity and framework Al content could provide more accessible Brønsted acid sites in the 10-membered ring channel of the ZSM-5 nanocrystals, which are the main active sites responsible for the shape-selectivity of the targeted product of 2,6-DMN. As a result, the formation of other side products like 1-MN and poly-MN could be effectively inhibited, thus leading to an improved 2,6-DMN yield and coke resistance over the nanosized ZSM-5 catalyst.