Silanol-Engineered Nonclassical Growth of Zeolite Nanosheets from Oriented Attachment of Amorphous Protozeolite Nanoparticles

Zeolite nonclassical growth via particle attachment has been proposed for two decades, yet the attachment mechanism and kinetic regulation remain elusive. Here, nonclassical growth of an MFI-type zeolite has been achieved by using amorphous protozeolite (PZ) nanoparticles containing encapsulated TPA⁺ templates and abundant silanols (Si-OH) as sole precursors under hydrothermal conditions. The silanol characteristics of the precursor were studied by two-dimensional (2D) solid-state nuclear magnetic resonance (NMR) correlation spectroscopy, which were proven to play critical roles in determining precursor attachment behavior and crystal growth orientation. Under mechanical ball-milling or tablet-pressing process, pressure drove the fusion of spherical PZ into platelet-like integrated PZ (IPZ) coupled with transformations of external silanols from evenly distributed to curvature-dependent distributed and internal silanols from isolated to spatially proximate. Compared to isolated silanols, the spatially proximate silanols possessed a stronger correlation with TPA⁺, benefiting the formation of Si-O-Si bonds via silanol condensation. Subsequently, driven by minimization of surface energy, particle attachment of the platelet-like IPZ precursor preferentially occurred at high-curvature surfaces with high-density silanols, leading to anisotropic rates of nonclassical growth and thus the formation of high-aspect-ratio MFI-type zeolite nanosheets. Advanced electron microscopy provided direct evidence of attachment of amorphous IPZ precursors to crystalline intermediate surfaces along the c-axis direction with the formation of amorphous-crystalline interfaces, followed by interface elimination and structural evolution to a single-crystalline phase. Our findings not only unravel the zeolite nonclassical growth mechanism but also reveal the critical role of silanol chemistry in kinetic regulation, which is of great importance for pursuing a tailored zeolite synthesis.