A novel method for the assembly of nano-zeolite crystals on porous stainless steel microchannel and then zeolite film growth

A new method that is simple, efficient, and clean was developed for seeding surfaces with a monolayer of covalently bonded zeolite seeds. This method was used to seed the microchannels fabricated on porous stainless steel with NaA nano-zeolites enabling the deposition and growth of defect-free zeolite film. The NaA nano-zeolites were attached to the surface of the stainless steel via alkoxysilane linkers (e.g., 3-chloropropyltrimethoxysilane and 3-aminopropyltrimethoxysilane) grafted on the stainless steel. The NaA zeolite grown on the microchannel by hydrothermal synthesis consists of intergrown, (1 1 1)-oriented pyramidal NaA crystals that completely clad the stainless steel grains. The zeolite cladding the grains grew uniformly until the zeolite layers of neighboring grain impinges, then intergrew to fully bridge the gaps between the grains forming a defect-free film layer. A separation factor of 10,000 and a flux of 0.04 kg m−2 h−1 were obtained for water pervaporation from a 3 wt% water-benzaldehyde solution at room temperature.