Synthesis of Cost-Effective Hierarchical MFI-Type Mesoporous Zeolite: Introducing Diatomite as Silica Source

Zeolite, as an intricate microporous material with redox sites, has been widely examined in many chemical industries. However, zeolite is not available everywhere, and it is expensive considering the price of raw materials from which it can be synthesized. In this study, ZSM-5 zeolite, as a local silica source with the high crystallinity, was synthesized, based on diatomite exploited from a mine in the north-west of Iran. The diatomite was employed as the only source of silica, and underwent hydrothermal transformation in a Teflon-lined autoclave operating at 170 °C without any alkaline post-treatment. The effects of the reaction pH and the reaction time on the properties of the synthesized MFI-type zeolite were monitored. The hydrothermal reaction time was optimized and hierarchical ZSM-5 hexagonal crystals were obtained. Furthermore, the effect of Si/Al ratio on the crystallinity of the resulting zeolite was investigated. The XRD, SEM, TEM, BET, FTIR, TPD, TGA, and DSC analyses were carried out to characterize the synthesized zeolites. The results confirmed the creation of MFI-type zeolites from diatomite applying hydrothermal process at an optimized pH and reaction time. In addition, the synthesized ZSM-5 zeolites exhibited a narrow pore size distribution resembling the mesoporous structure of standard ZSM-5 zeolites. Plenty of regularly arranged pores with diameters of 300–500 nm were observed inside the round circle-like sections of diatomite. For zeolites in which Si/Al ratio was higher (55 compared to 37), a relatively narrower pore size distribution similar to that of the standard ZSM-5 zeolite was detected. Comparably, the synthesized zeolites also contained stronger acid sites, rendering it as an excellent catalyst for the conversion of methanol to gasoline.