Synthesis of MFI-type zeolites under atmospheric pressure

Silicalite and highly silicious ZSM-5 were synthesized using two reaction mixtures with different crystal growth environments, a dispersed low density mixture and a separated high density mixture, at 93+/-3 degreesC under the atmospheric pressure. Nucleation behavior and the transformation process of two mixtures were investigated utilizing various analytical techniques such as XRD, FT-IR, TGA, SEM, and pH measurement. During the induction period, the same intermediate phase was observed in both mixtures. The presence of this phase was found to be dependent on the degree of dilution of the reaction mixture. After the induction period, a sharp increase in both the degree of crystallization and the pH of the reaction mixture was detected. This indicates that the pH change in the reaction mixture is closely related to the crystallization process. From these observations, a crystallization mechanism is proposed on the basis of the appearance of stable silicate species and the role of OH- ions during the induction period. According to this mechanism, MFI-type zeolite grows by condensation reaction among the stable silicate species formed during the induction period.