ZSM-5-based mesostructures by combined alkali dissolution and re-assembly: Process controlling and scale-up

•ZSM-5-based mesostructures were synthesized via two-step integrated strategy.•Two-step integrated strategy was scaled-up to 50 L scale.•Mesoporosity and textural properties during the strategy could be varied.•Feasible method of transforming alkali dissolution to re-assembly was proposed.

In this work, ZSM-5-based mesostructures were synthesized via two-step integrated synthesis strategy. Mesoporosity and textural properties of ZSM-5-based mesostructures were controlled by varying several parameters, which can affect either alkali dissolution or mesostructure re-assembly. The effects of these synthesis parameters on mesopore regularity and textural properties of ZSM-5-based mesostructures were also identified and optimized initially at 0.25 L scale. Based on the results at 0.25 L scale, the process was scaled up to 5 and 50 L scale. A new strategy for transformation of alkali dissolution to mesostructure re-assembly during two-step integrated synthesis for scale-up is proposed. The results of the samples prepared at 5 and 50 L scale revealed that the present strategy is stable and reproducible for industrial scale manufacturing and applications.

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