Preparation of ZSM-5 zeolite honeycomb monoliths using microporous silica obtained from metakaolinite

Zeolite honeycomb monoliths were prepared from ZSM-5 powders synthesized under hydrothermal conditions using microporous silica obtained by selective leaching of metakaolinite. This honeycomb material was compared with those prepared using alkoxides (TEOS) as the silica source. The honeycomb monoliths were formed by extrusion of paste made from the synthesized powders through a multi-channel honeycomb die. The morphology and porous properties of these materials were studied using XRD, FTIR, SEM and N₂/Ar adsorption. ZSM-5 grains in the monoliths prepared from metakaolinite showed platy morphology with preferred orientation of the crystals in the extruded surface, and displayed an absence of secondary growth. The twinned morphology of ZSM-5 crystals was observed in the monoliths prepared using TEOS and this contributed to an increase in the external surface area even though the total surface area was identical to that of samples prepared from metakaolinite. The physical properties, thermal stability and mechanical strength of the monoliths was compared with zeolite-coated honeycombs. The results show that microporous silica prepared by acid leaching of metakaolinite is a cost-effective raw material for preparing ZSM-5 honeycomb monoliths with controlled morphology and tunable SiO₂/Al₂O₃ ratios.