Modified reverse ADOR assembles Al-rich UTL zeolite from IPC-1P layers

Abstract

Extra-large pore zeolites clear the way for the synthesis of fine chemicals and bulky compounds unable to enter the channels of medium- and large-pore zeolites. However, such extra-large pore zeolites rarely contain catalytically active elements and often show limited stability. In this study, we modified the Reverse assembly–disassembly–organisation–reassembly (ADOR) process to prepare extra-large pore zeolite UTL from layered IPC-1P while simultaneously incorporating a high amount of aluminium (reaching Si/Al = 15) into the framework. Using this modified Reverse ADOR approach, we significantly reduced the synthesis time of alumino-germanosilicate UTL from the 28 days needed for direct synthesis to only 24 hours for reconstruction and 14 days in total. Furthermore, in the tetrahydropyranylation of 1-decanol over the reconstructed UTL zeolite, directly synthesised UTL and commercial Beta zeolite, used as a reference, reconstructed UTL provided conversion up to 61.4%, outperforming directly synthesised UTL and Beta with 14.8 and 0% conversion, respectively. The modified Reverse ADOR procedure enables us to introduce mesoporosity into zeolites, which further improves their catalytic performance by facilitating active site accessibility.