Light olefin production
from methanol
using various zeolite catalysts
has industrial and economic importance considering the growth of the
petrochemical market. Zeolites are generally synthesized using various
organic templates as structure-directing agents (SDAs). In this study,
synthesis of a series of ZSM-5 zeolites was performed systematically
using the microwave-assisted crystallization method, and these samples
were analyzed in detail to understand the effect of the SDA concentration.
Powder diffraction, N
2
adsorption, scanning electron microscopy,
ammonia adsorption desorption, and
27
Al and
29
Si NMR spectroscopies were used for the characterization. The organic
SDA tetrapropyl ammonium hydroxide (TPAOH/SiO
2
mole ratio
= 0.0500) is found to have an optimum concentration against the silica
precursor for achieving the highest crystallinity, suitable morphology,
ideal pore size, effective pore volume, and tuned microporous/mesoporous
area. For samples with a template concentration ratio of 0.050 or
higher,
29
Si and
27
Al NMR data revealed the
presence of an intact ZSM-5 structure. Using a fixed bed reactor at
500 °C and atmospheric pressure, the catalytic performance of
the selected catalysts from the series is investigated for the methanol-to-olefin
conversion reaction. The sample with the highest crystallinity showed
the best conversion, selectivity toward light olefins, and time on
stream stability. It is also worth noting that the highest crystallinity,
micropore area, and micropore volume are reached for the optimum value
rather than the highest template concentration. This allows for a
reduction in the template concentration and a move closer to a synthesis
pathway benign to environment and economics.