Controllable Synthesis of Silicalite-1 with Tailored c-Axis Length via KHSO4 and Seed Co-Additive Strategy

Zeolite morphology strongly determines its performance. Herein, Silicalite-1 was synthesized in a low-template system (TPA+/Si = 0.007) via a synergistic strategy using potassium bisulfate and seed suspension. The seeds supply abundant structural units to reduce nucleation barrier and accelerate crystallization, while KHSO4 facilitates silicate polycondensation and suppresses non-MFI impurities. Sulfate ions selectively adsorb on specific crystal facets via hydrogen bonding and induce preferential crystal growth along the c-axis. The c-axis size of Silicalite-1 can be precisely regulated by adjusting dosages of seeds and KHSO4. Well-defined plate-like crystals were obtained under the conditions of K+/Si = 0.25, a seed content of 2.42 wt%, and hydrothermal treatment at 180 °C for 8 h. Scale-up synthesis in a 2 L autoclave verifies its industrial potential. The product exhibits excellent adsorption capacity and cyclic stability toward methylene blue. This work provides a low-cost and green route for morphology-controlled synthesis of MFI-type zeolites.