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°C 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°C. This paper describes the formation of mullite from Malaysia kaolin at 1400 to 1500°C, 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.