Short-channeled mesoporous Zr–Al-SBA-15 as a highly efficient catalyst for hydroxyalkylation of phenol with formaldehyde to bisphenol F

• Short-channeled Zr–Al-SBA-15 is prepared by a one-pot hydrothermal synthesis method.
• The catalysts were characterized by using various techniques.
• The catalytic activities of catalysts were tested by synthesis of bisphenol F.
• Short-channeled Zr–Al-SBA-15 exhibited higher catalytic activity and reusability than conventional Al-SBA-15.
• A high bisphenol F yield of 96.1% was obtained at the optimum reaction conditions.

Short-channeled Zr–Al-SBA-15 catalysts with well-ordered mesostructures were prepared by a one-pot hydrothermal synthesis method under mild acidic condition, and their catalytic activities were tested in the hydroxyalkylation of phenol with formaldehyde. The physicochemical characteristics of the catalysts were characterized by XRD, SEM, TEM, pyridine FTIR, and N2 adsorption–desorption isotherm techniques. By using this catalyst, an efficient and environmentally benign process for the synthesis of bisphenol F in a heterogeneous manner was developed. Compared with the conventional Al-SBA-15 catalysts, the short-channeled Zr–Al-SBA-15 exhibited higher catalytic activity and reusability in hydroxyalkylation of phenol because its short channels can effectively reduce the molecular diffusion resistance and avoid pore block. Under the optimum hydroxyalkylation conditions (phenol/formaldehyde molar ratio 30:1, catalyst concentration 0.004 g/cm3, reaction temperature 90 °C and reaction time 60 min), a high bisphenol F yield of 96.1% could be achieved over the short-channeled Zr–Al-SBA-15 catalyst. A kinetic model for hydroxyalkylation of phenol with formaldehyde to bisphenol F has been developed.