From amorphous to crystalline: Transformation of silica membranes into silicalite-1 (MFI) zeolite layers

The transformation of microporous, amorphous silica membranes into b-oriented silicalite-1 (MFI) zeolite layers via in-situ crystallisation was investigated. The effect of synthesis parameters, such as the type and concentration of the silica precursor, crystallisation time and temperature, on the morphology of silicalite-1 (MFI) zeolite layers was studied. By optimizing these parameters, silicalite-1 zeolite layers were formed from the already-deposited silica layers, which promotes the crystallisation from the surface in the preferred b-orientation. The use of a monomeric silica precursor, which has slower hydrolysis kinetics than a colloidal one, resulted in the formation of zeolite crystals via heterogeneous nucleation on the surface and suppressed the formation of crystal nuclei in the liquid media via homogeneous nucleation, which then would further deposit onto the surface in a random orientation. Lastly, by optimizing the crystallisation time and temperature of the synthesis, thickness, coverage and orientation of silicalite-1 zeolite layers were controlled.