Ultrafast synthesis of silicalite-1 using sodium silicate and ultrafast encapsulation of metal nanoclusters for propane dehydrogenation

The demand for zeolites is expected to grow rapidly due to their expanding applications in catalysis and separation, which drives the need for efficient synthesis routes based on economical raw materials. To overcome the limitations of time-consuming conventional zeolite synthesis, an ultrafast and low-cost route has been developed using industrial-grade sodium silicate as the silica source. This approach enables minute-level synthesis of silicalite-1 zeolite through a combination of acid neutralization and seeding strategies. Notably, carbon dioxide was also demonstrated as an effective neutralizing agent, offering a sustainable alternative. This ultrafast route further enabled the in-situ encapsulation of metal nanoclusters during zeolite crystallization, which resulted in well-defined metal-zeolite catalysts. Using Pt–Zn as a model system, the catalysts exhibited high activity and long-term stability in propane dehydrogenation. This work presents a scalable and economical route for producing high-performance zeolite catalysts and highlights the potential for broader application in commercial dehydrogenation processes and beyond.