Exceptionally stable and hierarchically porous self-standing zeolite monolith based on a solution-mediated and solid-state transformation synergistic mechanism

Although many strategies exist for fabricating hierarchical zeolite monolith, it is still challenging to synthesize pure hierarchical zeolite monolith with intracrystalline meso-/macropores and stability suitable for industrial application in a general and efficient process. Here we describe a simple quasi-solid gel crystallization route to prepare hierarchical self-standing ZSM-5 zeolite monolith via the use of Na+ and OH− as counterions to modify the breaking and remaking of T-O-T (T = Si or Al) bonds. X-ray diffraction (XRD), scanning electron microcopy (SEM), transmission electron microscopy (TEM), laser scan confocal microscopy (LSCM), N2 adsorption-desorption, mercury porosimetry, solid-state nuclear magnetic resonance (NMR), and compression mechanical testing were applied to elucidate the structure and mechanical stability of the obtained monolith. The self-standing monolith is composed of self-interconnected meso-/macroporous MFI crystals with tunable intracrystalline meso-/macropores and possesses an unusually mechanical stability with a crushing strength of 5.01 MPa. Combined with controllable structure of the defect-free membrane layer on the monolith top, the self-standing zeolite monolith should widen their potential applications.