Directly Synthesis of ZSM-22 Particles by Adding Polyurethane Foam in Ionic Liquid-directed Dry-gel-conversion

Pure-silica ZSM-22 particles with millimeter size were directly synthesized by adding polyurethane foam (PU foam) in ionic liquid-directed dry-gel-conversion process, where the dry gel was prepared under the unusual acidic condition for hydrolyzing the silica precursor with 1,3-alkylimidazolium ionic liquid as the structure directing agent (SDA). Both the PU foam and the ionic liquid-directed dry-gel-conversion process played essential roles in the formation of macroscopic morphology, because only powder-like sample could be obtained in the absence of foam, and moreover, no such special morphology could be achieved on ZSM-22 zeolite prepared by the PU foam-added traditional hydrothermal synthetic route. Various synthetic parameters were systematically studied, including the influence of PU foam, adding time and adding amount of PU foam, as well as the crystallization time.