Synthesis of ZSM-5/porous mullite honeycomb composite from sintered Malaysia kaolin via hydrothermal processing

The synthesis and properties of ZSM-5 film on a porous mullite honeycomb have been investigated using Malaysia kaolin. Amorphous silica-glass in the kaolin honeycomb sintered at 1450 degreesC was used as a source for ZSM-5 formation. The honeycomb was hydrothermally treated in NaOH, tetrapropylammonium bromide, and water to prepare a novel ZSM-5/mullite honeycomb composite via in-situ crystallization at 160 to 180 degreesC. This paper describes the formation of mullite from Malaysia kaolin at 1400 to 1500 degreesC, the effects of hydrothermal conditions such as reaction temperature, time, and concentration of NaOH solution on the formation of ZSM-5 crystals on the honeycomb, and on the porous properties of the composite.