One-step microwave synthesis of micron-sized ZSM-5/MCM-41 hierarchical porous materials for phenol hydroxyl alkylation

The application of micron-sized zeolites ZSM-5 in industrial complex reaction system, despite of its high crystallization and stability and low price, is limited due to their single microporous structures. This study explores the one-step microwave synthesis of ZSM-5/MCM-41 hierarchical porous materials under low alkaline conditions and with the assistance of microwave, and examines their catalytic performance by the synthesis of anisole with phenol and methanol as probe reaction. The results show that the prepared ZSM-5/MCM-41 layered porous materials exhibit typical characteristics of micro-mesoporous composites. They have higher surface area and pore capacity, and good connectivity between micropores and mesopores, compared with the original ZSM-5. The above-mentioned advantages enable prepared ZSM-5/MCM-41 materials to produce higher phenol conversion, selectivity and catalyst stability of anisole. Through systematic investigations, this study develops a low-cost synthesis method for micron-sized ZSM-5/MCM-41 hierarchical porous materials, which facilitates their industrial application in complex reaction systems.