Fe/ZSM-5 nanosheet
zeolites of varying thickness were synthesized
with di- and tetraquaternary ammonium structure directing agents and
extensively characterized for their textural, structural, and catalytic
properties. Introduction of Fe3+ ions in the framework
of nanosheet zeolites was slightly less effective than in bulk ZSM-5
zeolite. Steaming was necessary to activate all catalysts for N2O decomposition and benzene oxidation. The higher the Fe content,
the higher the degree of Fe aggregation was after catalyst activation.
The degree of Fe aggregation was lower when the crystal domain size
of the zeolite or the Fe content was decreased. These two parameters
had a substantial influence on the catalytic performance. Decreasing
the number of Fe sites along the b-direction strongly
suppressed secondary reactions of phenol and, accordingly, catalyst
deactivation. This together with the absence of diffusional limitations
in nanosheet zeolites explains the much higher phenol productivity
obtainable with nanostructured Fe/ZSM-5. Steamed Fe/ZSM-5 zeolite
nanosheet synthesized using C22-6-3·Br2 (domain size in b-direction ∼3 nm)
and containing 0.24 wt % Fe exhibited the highest catalytic performance.
During the first 24 h on stream, this catalyst produced 185 mmolphenol g–1. Calcination to remove the coke
deposits completely restored the initial activity.