Ultrafast synthesis of silicalite-1 using a tubular reactor with a feature of rapid heating

•The synthesis period of silicalite-1 in the tubular reactor was shortened to 10 min.•Extraordinarily high crystal growth rates of silicalite-1 were observed.•The apparent crystal growth rates were in the order of 103–104 nm/h.•The ultrafast synthesis would be very helpful to deepen the understanding of the crystallization of silicalite-1.

By combining the synthesis at a higher temperature with the addition of seed, ultrafast synthesis of silicalite-1, a pure-silica zeolite with MFI structure, has been achieved in a tubular reactor that can enable a rapid heating. The synthesis period of silicalite-1 has been shortened to 10 min, while it usually takes several hours or days using the conventional methods. Estimated from crystal size, the apparent crystal growth rate of silicalite-1 was on the order of 103 nm/h for the synthesis using TEOS as a silica source, while under another synthesis condition using colloidal silica as a silica source, the apparent crystal growth rate could be as high as 104 nm/h. High crystal growth rates demonstrated that the crystallization of silicalite-1 in the tubular reactor could be very fast.

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