Design and synthesis of 3D ordered macroporous ZrO2/Zeolite nanocomposites

Zeolite NaY nanocrystals (20−50 nm) were hydrothermally grown on polyelectrolyte-coated three-dimensionally ordered macroporous (3DOM) activated zirconia. The zeolite nanocrystallites uniformly coated the macropore walls of 3DOM sulfated zirconia, but sulfate groups were lost during the hydrothermal reaction. 3DOM tungstated zirconia was found to be more stable in the strong basic environment of the zeolite precursor solution. Further, ion-exchange of zeolite NaY with ruthenium followed by hydrogen-reduction formed a composite of RuNaY and 3DOM activated zirconia. The presence of ruthenium was confirmed by X-ray photoelectron spectroscopy and the external shape of zeolite nanoparticles was maintained after ion-exchange, but the zeolite lattice fringes could not be observed by transmission electron microscopy after incorporation of reduced ruthenium. Although the catalytic activity of the materials has not yet been tested, these hierarchical nano- and microstructures bring multiple catalyst components (modified zeolite Y, a typical Fischer–Tropsch catalyst, and activated zirconia, an isomerization catalyst) together in intimate contact for potential multi-reaction processes.