Although ZSM-11 zeolite is an encouraging catalyst for converting methanol to propene (MTP), its inadequate catalytic durability hinders realistic application. Herein, three high-silica ZSM-11 zeolites, designated ZSM-11-DAO, ZSM-11-TBAOH and ZSM-11-TBABr, were synthesized hydrothermally using 1,8-octanediamine (DAO), tetrabutylammonium hydroxide (TBAOH) and tetrabutylammonium bromide (TBABr) as the organic template agents, respectively. The effect of organic template agents on the crystal size and acidic properties of ZSM-11 zeolite as well as its catalytic performance and reaction mechanism in MTP was systematically studied through comprehensive characterization techniques such as X-ray diffraction (XRD), Fourier transform infrared spectra (FT-IR), scanning electron microscopy (SEM), isothermal adsorption of methanol vapor, inductively coupled plasma optical emission spectrometry (ICP-OES), temperature-programmed desorption of ammonia (NH3-TPD), FT-IR spectra of pyridine adsorption (Py-IR), FT-IR spectra of 2,6-ditert-butylpyridine adsorption (dTBPy-IR), X-ray photoelectron spectroscopy (XPS), thermogravimetric analysis (TGA), ultraviolet-visible diffuse reflectance spectroscopy (DR UV-vis), gas chromatography-mass spectrometry (GC-MS) and 13C/27Al/29Si MAS NMR. The results indicate that although ZSM-11-DAO zeolite possesses a higher concentration of framework aluminum atoms (AlF) situated within the straight channels, it features substantially larger crystal size. In contrast, both ZSM-11-TBAOH and ZSM-11-TBABr exhibit comparably smaller crystal size, but the latter contains a greater proportion of AlF preferentially enriched in the straight channels relative to the former. The synergistic effect of reduced crystal size and preferential enrichment of AlF within the straight channels effectively suppresses the formation of reactive aromatic intermediates and impedes their further condensation into coke precursors during MTP reaction; consequently, the propagation of the aromatic-based mechanism is significantly inhibited, and the relative contribution of alkene-based mechanism is improved. Compared to both ZSM-11-DAO and ZSM-11-TBAOH, ZSM-11-TBABr zeolite demonstrates higher selectivity to propene and better catalytic stability in MTP. This study not only presents an effective strategy for improving the catalytic performance of high-silica ZSM-11 zeolite in MTP but also unravels the effect of the crystal size and distribution of acid sites on the formation and evolution of active aromatic intermediates.
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