Microstructures formed by secondary growth of fired ZSM-5 seed crystals

Oriented ZSM-5 seed crystals on an α-Al2O3 porous substrate were hydrothermally treated in a raw sol. The ZSM-5 membranes were fabricated via secondary growth of the seed crystals. For some samples, the seed-applied substrate was fired at 300 or 600 °C before the secondary growth in order to enhance adhesion between the substrate and the seed crystals. The influence of the firing on the subsequent secondary growth of the seed crystals was examined by XRD, SEM, and TEM. The TEM images of the sample fired at 300 °C showed that the resulting membrane was continuous, and in the membrane, large ZSM-5 particles were distributed in a porous matrix. The ZSM-5 particles were slightly smaller than the used seed crystals. HR-TEM observations showed that the porous matrix is comprised of ZSM-5 micro-crystals, and the part adjacent to the large ZSM-5 crystals has the same crystallographic orientation as the large crystals. The TEM images of the sample fired at 600 °C showed that the resulting layer is comprised of particles with a core-shell structure. The core consisted of ZSM-5 micro-crystals, whereas the shell was composed of large ZSM-5 rod-like crystals. It is inferred that the formation of these interesting microstructures is related to the degradation of the template agent, NPr4OH, in the seed crystals by firing at 300 and 600 °C. The part including no template is dissolved by a hydrothermal treatment, and the dissolved species is re-crystallized via reaction with a template agent in the used raw sol, resulting in the formation of interesting microstructures.