Simple and sustainable synthesis of loosely stacked nano-H-ZSM-5 aggregates from kaolin and catalytic studies

The conversion of natural clay to crystalline zeolites has been the subject of considerable interest from both academic and industrial circles. We present an effective strategy for converting kaolin to ZSM-5 zeolite, addressing the issue of reduced mesopore formation in conventional nano-ZSM-5 aggregates due to close-packing. This strategy utilizes kaolin as the sole source of silicon and aluminum, and by decoupling the nucleation and growth of ZSM-5 crystals, loosely stacked nano-H-ZSM-5 aggregates with high crystallinity crystals can be synthesized in a solid-like system by employing a tiny amount of TPAOH (TPAOH/SiO₂ = 0.064). The resulting nano-H-ZSM-5 aggregates exhibited high specific surface area (405.66 m²/g), high mesopore volume (0.64 cm³/g), and superior catalytic activity. This strategy offers a novel approach to the cost-effective synthesis of nano-H-ZSM-5 aggregates suitable for industrial applications.