Morphology-Controlled Synthesis of H-type MFI Zeolites with Unique Stacked Structures through a One-Pot Solvent-Free Strategy

H-type aluminosilicate zeolites are extensively used as solid-acid catalysts and support materials in industrial catalysis. However, the conventional synthesis methods involving hydrothermal syntheses and ion-exchange processes suffer from severe water pollution and toxic gas emissions. Herein, H-type MFI zeolite catalysts with a unique stacked structure were directly synthesized in the presence of NH4F and with the help of zeolite confinement through a solvent-free route without further ion-exchange procedures. A range of ex situ and in situ characterization procedures were used to provide evidence of the simultaneous use of pre-made ZSM-5 and NH4F as a confined Al source and mineralizer, respectively. The confined zeolite framework of ZSM-5 prevented the formation of AlFx species between NH4F and Al atoms, ensuring that the prepared samples had desirable acidic properties. Moreover, the resulting morphology could be controlled by using different silica substrates. The obtained H-type MFI zeolites showed excellent catalytic performance in methanol-to-gasoline reactions owing to their unique structure and directly exposed acidic sites. The developed one-pot strategy provides an alternative method for the facile synthesis of H-type zeolites with defined morphology.