Application of artificial neural networks to high-throughput synthesis of zeolites
Transcript of Application of artificial neural networks to high-throughput synthesis of zeolites
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Microporous and Mesoporous Materials 78 (2005) 73–81
Application of artificial neural networks to high-throughputsynthesis of zeolites
M. Moliner a, J.M. Serra a, A. Corma a,*, E. Argente b, S. Valero b, V. Botti b
a Instituto de Tecnologıa Quımica, UPV-CSIC, Universidad Politecnica de Valencia, Avda. de los Naranjos s/n, E-46022 Valencia, Spainb Dep. Sistemas Informaticos y Computacion, Universidad Politecnica de Valencia, Camino Vera s/n, E-46022 Valencia, Spain
Received 5 July 2004; received in revised form 21 September 2004; accepted 21 September 2004
Available online 24 November 2004
Abstract
It is shown that multi-phase crystalline systems in zeolite synthesis can be modelled by using artificial neural networks (ANNs)
and considering as input variables the molar compositions of the starting synthesis gel. Experimental data were obtained using high-
throughput tools for synthesis of solid materials under hydrothermal conditions and following a multi-level factorial experimental
design of the system TEA:SiO2:Na2O:Al2O3:H2O. The study of several neural networks resulted in a non-linear model able to pre-
dict the occurrence and crystallinity of zeolite beta and competing phases, being the predictions much better than those obtained by
classical quadratic models.
� 2004 Elsevier Inc. All rights reserved.
Keywords: Neural networks; Zeolites; Beta; High-throughput synthesis; Data mining; Factorial design
1. Introduction
There are a large number of variables that can influ-
ence the crystallisation kinetics and the final crystalline
phase or phases produced during the hydrothermal syn-thesis of microporous materials. These factors include,
among others, gel composition, type of reagents and
precursors, crystallisation time and temperature. De-
spite remarkable efforts to rationalise the synthesis of
zeolites [1–4], the relationship between these synthesis
factors and the type of zeolite formed is not always
clearly understood. This is due to the metastable nature
of zeolites and the complexity of the synthesis mecha-nism. Combinatorial techniques can be applied in this
field in order to explore simultaneously different vari-
ables, by applying high-throughput synthesis and char-
acterisation, and computational techniques for data
1387-1811/$ - see front matter � 2004 Elsevier Inc. All rights reserved.
doi:10.1016/j.micromeso.2004.09.018
* Corresponding author. Tel.: +34 96 387 7800; fax: +34 96 387
7809.
E-mail address: [email protected] (A. Corma).
analysis (data mining). This approach has been applied
successfully in the development of new materials with
enhanced properties [5–7] and in the development of
new solid catalysts for industrial processes [8–10]. The
parallel synthesis under hydrothermal conditions [11–14] of large libraries of solid materials, i.e., zeolites
[15–19] or aluminophosphates [20], has been accom-
plished with high reproducibility and scalability, result-
ing in the discovery of new crystalline materials [21].
There is not doubt that experimental data analysis
plays an important role in the discovery and optimisa-
tion of solid materials when exploring high-dimensional
spaces. In fact, experimental relationships between syn-thesis variables and hidden patterns can be found using
data analysis, and this experimental ‘‘knowledge’’ accel-
erates the optimisation by reducing the required number
of experiments. However, the analysis of data derived
from combinatorial experimentation cannot be carried
out by classical statistical treatment due to the large
population of data and their complexity. Data mining
techniques are suitable for the analysis of these
Fig. 1. Picture of the high-throughput system employed for parallel gel
preparation.
74 M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81
experimental results and, more specifically, artificial
neural networks (ANNs) have been shown as useful
analysis tools to model data derived from combinatorial
experimentation in heterogeneous catalysis [22]. Indeed,
ANNs are complex mathematical systems [23–25] able
to find non-linear relationships in high-dimensionalexperimental spaces, giving as a result an empirical
model that can predict the experimental performance
corresponding to an input data vector.
Up to now, ANNs have not been employed for com-
prehensive modelling of multi-phase crystalline systems
considering the synthesis conditions or gel molar com-
positions as input variables. Only theoretical calcula-
tions [26] have been reported for the prediction of Si/Al ratio from batch compositions, giving poor predic-
tions and showing the limitations of theoretical methods
in this field.
In the present work, we have explored, as an example
to test the methodology, the system TEA:SiO2:Na2O:
Al2O3:H2O with crystallinity and yield of zeolite beta
as objective functions. For this study, high-throughput
experimentation tools are employed for automated syn-thesis and characterisation of a multi-level factorial de-
sign of experiments. In the second part of the work,
the capabilities of ANNs in modelling the synthesis
experimental data are investigated, considering the influ-
ence of network topology, activation functions and
training algorithms. Finally, the ANN prediction per-
formance is compared with the performance obtained
by means of a classical statistical treatment of results.
2. Experimental
2.1. Synthesis procedure
The molar gel composition was explored by varying
the following molar ratios: Na/(Si + Al), TEA/(Si + Al),OH/(Si + Al) and H2O/(Si + Al), while Si/Al ratio was
fixed. Synthesis gels were prepared using an in-house
developed robotic system (Fig. 1) composed of: (i) ro-
botic arm (SCORBOT-ER 4pc), for handling of vials
and solid weighting (range 20–1000mg), (ii) stirring sta-
tion for gel stirring and solvent evaporation by IR heat-
ing and Air/N2 sweep flow and (iii) liquid dosing station
equipped with seven calibrated syringe pumps (range of10–5000mg) and an analytical balance.
The reagents in the synthesis were tretraethylammo-
nium hydroxide (aq. solution 35% Aldrich), tretraethy-
lammonium bromide (98% Aldrich), sodium hydroxide
(99.9% Scharlau), sodium chloride (99.9% Fluka),
LUDOX (40wt% Aldrich) and sodium aluminate (pure
Carlo Erba). Gel synthesis was done inside Teflon vials
(3ml), which were finally inserted in a multi-autoclave of15 positions and sealed with a Teflon-lined stainless steel
tip. Crystallisation is carried out at 140 �C during 24h
under agitation by rotation. The samples were washed
and centrifuged at 6000rpm and finally dried at 100 �Covernight. Finally, the samples were weighted and char-
acterised by XRD using a multi-sample Phillips X�Pertdiffractometer employing CuKa radiation. Crystallinityof beta zeolite was calculated integrating the area of
the diffractograms between 22� and 23�, and normalisingthis value with respect to a reference sample (CP806
from PQ).
2.2. Reproducibility
Reproducibility of the automated synthesis of betazeolite was carried out following the experimental proce-
dure and tools depicted above. A single gel composition
(SiO2:0.08NaAlO2:0.19NaCl:0.43TEAOH:0.037TEABr:
10.8H2O) was prepared 15 times in parallel and was let
to crystallise simultaneously inside the multi-autoclave
for 24h. The values of crystallinity of beta zeolite sam-
ples obtained have a standard deviation of ±4%. This
value includes the deviations produced during gel syn-thesis, crystallisation and XRD characterisation.
3. High-throughput synthesis results
In order to optimise the preparation conditions for
the synthesis of beta zeolite, a factorial design (32 · 42)was employed for exploring different molar gel composi-tion (Table 1). This experimental design considers the
following four molar ratios (level): Na/(Si + Al) (3)
ranging from 0 to 0.5; TEA/(Si + Al) (4) from 0.1 to
Table 1
Molar rates between gel components and variation range explored by
the factorial design
Factor Lower level Upper level Number of levels
Na/(Si + Al) 0 0.5 3
TEA/(Si + Al) 0.1 0.6 4
OH�/(Si + Al) 0.15 0.52 4
H2O/(Si + Al) 5 15 3
Si/Al 12.5 1
M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81 75
0.6; OH�/(Si + Al) (4) from 0.15 to 0.52; and H2O/
(Si + Al) (3) from 5 to 15. The total number of samples
synthesised considering this factorial design was 144.
The synthesis were carried out following a randomised
sequence in order to provide protection against the ef-fects of lurking variables. In the explored space, only
two types of crystalline materials were obtained corre-
sponding with two different XRD pattern. These materi-
als were zeolite beta and another dense material (named
as UDM). Fig. 2 shows all the measured XRD for amor-
phous samples, beta phase, UDM phase and the
mixtures of both phases. A phase diagram for the exper-
imental space explored is shown in Fig. 3. The influenceof the different variables on the final crystallinity of the
zeolite beta can be observed in Fig. 4, being possible to
identify the compositional ranges that give highly crys-
Fig. 2. XRD diagrams obtained by hi
talline beta zeolite. They are: (a) range at low H2O/
(Si + Al) ratios, which corresponds to gels with high
concentration of nuclei leading to higher crystallisation
rates, (b) range with intermediate OH�/(Si + Al) ratio,
in where the concentration of OH� allows the solution
of the silica precursors and the crystallisation of sili-ceous nuclei that induce the formation of the beta struc-
ture, (c) range with medium-high TEA/(Si + Al) ratio, in
which the SDA concentration allows the nucleation of
beta zeolite and (d) zone with medium-low Na/(Si + Al)
ratio, in where this sodium cation concentration allows
the proper nucleation maintaining high growth rates.
The influence of the different factors on beta crystallinity
and the second order interactions between factors aresummarised in the Pareto diagram of Fig. 5. Pareto
diagram displays a frequency histogram where the
length of each bar on the chart is proportional to the
absolute value of its associated estimated effect or
the standardised effect. This factorial analysis was done
using Statgraphics Plus 5.1.
Regarding the formation of the UDM phase, this is
favoured at low OH� /(Si + Al) and high TEA/(Si + Al)ratios, independent of the water and sodium concentra-
tions. This material is formed when there are not enough
mineral agents to dissolve silica and aluminium, and
there is an excess of organic in the gel.
gh-throughput experimentation.
LOW Na/(Si+Al)
MEDIUM Na/(Si+Al)
HIGH Na/(Si+Al)
0.52
0.40
0.27
5
5
2
0
7
5
10
2
0.40
0.27
0.15
15
0.10 0.27 0.43 0.60 0.10 0.27 0.43 0.60 0.10 0.27 0.43 0.60
TEA/(Si+Al)
OH
— /(Si+
Al)
H2O
/(Si+Al)
Amorphous Beta UDM Mixture
0.1
0.5
0.4
0.2
0.1
0.5
Fig. 3. Phase diagram for the experimental space explored.
76 M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81
4. Neural network modelling
4.1. Neural network fundamentals
Artificial neural networks consist of a number of sim-
ple interconnected processing units, also called neurons,
which are analogous to the biological neurons. Thoseunits can be organised by different ways, defining the
neural network topology [27].
The basic unit of a neural network is composed of: (i)
a set of connections or inputs xj(t), each of which is char-
acterised by a synaptic weight wij, that represents the
intensity of interactions between each neuron j of a pre-
vious level and the actual neuron i; (ii) a propagation-
rule, which determines the effective input of neuron k
from all individual inputs to this neuron; (iii) an activa-
tion function Fk, that determines the output yk of neuron
k by means of its level of excitation [28].
Two important features of neural networks are the
ability of supplying fast answers to a problem and
the capability of generalising their answers, providing
acceptable results for unknown pattern. In this way,
they need to learn about the problem under study andthis learning is commonly named training process. Dur-
ing this training process, neural networks are supplied
with a set of samples belonging to the problem domain.
Then they establish mathematical correlations between
the samples [29] and large quantity of information and
time are required for analysis and processing.
One of the most well known structures of neuronal
networks for supervised learning is the multi-layer per-
ceptron (Fig. 6), which is generally used for classification
and prediction problems. In the multi-layer perceptron,
neurons are grouped into layers or levels, so each input
of a neuron is composed of the outputs of the neurons of
the previous level. And the neurons in the input layertake as input all the problem data. The number of nodes
at the input and output layers are determined by the
problem features.
4.2. Neural network model optimisation
Artificial neural networks are applied here for pre-
dicting formation and crystallinity of zeolite beta andcompeting phases on the bases of molar gel composi-
tions. Input variables to the neural networks were:
Na/(Si + Al), TEA/(Si + Al), OH�/(Si + Al) and H2O/
(Si + Al), while output variables were crystallinity of
beta zeolite and UDM material.
A total number of 144 samples were available for this
study. In order to minimise the effect of experimental
error in theANN training process and testing, experimen-tal data were randomly divided three times (groups A, B
and C) into three data sets: training data (100 samples),
validation data (20 samples) and test data (24 samples).
The prediction performance for each new ANN was cal-
culated considering the independent training and testing
using each data group (A, B, C).
Fig. 4. Influence of the four factors in the final crystallinity of the zeolite beta.
Fig. 5. Pareto diagram showing the influence of the different factors (A, B, C, D) in beta crystallinity and the second-order interactions between
factors (AB, BC, . . .).
M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81 77
Table 2
Neural network topologies employed for the optimisation of the neural
network model
Name ANN topology
Input
layer
1st hidden
layer
2nd hidden
layer
Output
layer
4_2_2 4 2 – 2
4_3_2 4 3 – 2
4_4_2 4 4 – 2
4_6_2 4 6 – 2
4_10_2 4 10 – 2
4_4_2_2 4 4 2 2
4_8_4_2 4 8 4 2
All those topologies were studied with logistic and tangential activa-
tion functions in hidden nodes, respectively.
Fig. 6. Selected neural network with a topology composed of four
nodes in the input layer, 10 nodes in the hidden layer and two nodes in
the output layer.
78 M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81
Using supervised learning, an incremental method
was applied and different neural network topologies
based on the multi-layer perceptron were tested. Start-
ing with one single hidden layer and few neurons, the
topology was modified by increasing the number of neu-
rons and the number of hidden layers. The inputs of the
network were the gel composition (see molar ratios
given above), and the outputs were the crystallinity ofeach phase. Different experiments were also carried
out with the algorithms more suitable for the multi-
layer perceptron. Specifically, neural networks were
trained with backpropagation (learning factor a = 0.2;
0.5; 0.8) and backpropagation with momentum
(a = 0.2; 0.5; 0.8 and momentum term l = 0.2; 0.5;
0.8, respectively). Moreover, logistic and tangential sig-
moidal activation functions were independently used inneurons of hidden layers. In Table 2, the neural network
topologies used in the study are summarised. A total
number of 14 ANN topologies was employed, each of
them trained with 12 different training algorithms and
using the three data groups (A, B, C). Therefore, the
total number of models obtained by training was 504
(14 · 12 · 3).Through the training process, an analysis of the mean
square error (MSE) for the validation samples is taken
each 1000 cycles. If MSE gets worse, the training process
is stopped otherwise the process continues up to 5000cycles.
4.3. Modelling results
In Table 3, the five best and five worst average results
of the training and test made with the three groups of
samples are displayed. It can be seen that neural net-
works using logistic activation functions provide betterresults than when using tangential activation functions.
Moreover, when comparing the mean absolute values
provided for test and training samples, the best pre-
dictions are obtained with a neural network with
logistic activation function in hidden nodes, trained with
backpropagation algorithm with momentum (a = 0.5,
l = 0.8), and a topology composed of four nodes in
the input layer, 10 nodes in the hidden layer and twonodes in the output layer (Fig. 6). This ANN provides
good prediction results for training and test samples
and, therefore, is able to predict properly the crystallin-
ity of the two competing phases with low deviations.
This can directly be observed in Fig. 7, where the predic-
tions for training, validation and test samples (group A)
are plotted.
The prediction goodness of the ANN model wascompared with that obtained using a multi-variable
quadratic model, with the following quadratic equation:
Crystallinity ¼ aþX4
i¼1bi � factori
þX4
i¼1
X4
j¼1ci;j � factori � factorj:
In Fig. 8, the predicted and experimental values for the
crystallinity of beta and UDM obtained with the ANNmodel and the multi-variable quadratic model are dis-
played. There the goodness of the ANN prediction can
again be observed for both variables, whereas the qua-
dratic model exhibits a poor prediction performance in
both cases.
Using the ANN model, the molar gel composition
that maximises the crystallinity of beta zeolite was calcu-
lated: Na/(Si + Al) 0.214, TEA/(Si + Al) 0.600, OH�/(Si + Al) 0.388 and H2O/(Si + Al) 12.8. When constrain-
ing the beta optimisation to values that minimise the re-
quired concentration of TEA, the results were: Na/
(Si + Al) 0.25, TEA/(Si + Al) 0.243, OH�/(Si + Al)
0.414 and H2O/(Si + Al) 5.
BETA
0
20
40
60
80
100
120
0 20 40 60 80 100 120
Pre
dict
ed
UDM
0
20
40
60
80
100
0 20 40 60 80
Pre
dict
ed
100Experimental
Experimental
Fig. 7. Beta and UDM prediction performance of selected neural network for training data (squares) and validation and test data (triangles). NN
with four input nodes, 10 nodes in hidden layer and two output nodes, using logistic function in hidden nodes. Trained with 100 samples, employing
backpropagation algorithm with momentum (a = 0.5, l = 0.8) and validated with 20 samples and tested with 24 samples.
Table 3
Mean absolute prediction errors for different ANN topologies and different training algorithms
Network Neural network training process Cycles Mean absolute errors
Test data Train data
Act. function Training algorithm BETA UDM Mean BETA UDM Mean
4_8_4_2 Logistic BackMom a = 0.8, l = 0.5 1000 11.86 5.93 8.89 3.52 3.83 3.68
4_8_4_2 Logistic BackMom a = 0.8, l = 0.2 5000 11.17 6.67 8.92 3.01 3.25 3.13
4_10_2 Logistic BackMom a = 0.5, l = 0.8 5000 9.67 8.31 8.99 2.21 2.17 2.19
4_4_2 Logistic BackMom a = 0.5, l = 0.5 1000 12.81 5.35 9.08 7.17 4.90 6.03
4_10_2 Logistic Backpropagation a = 0.5 5000 12.40 5.76 9.08 3.23 4.49 3.86
4_4_2 Tangential BackMom a = 0.5, l = 0.8 4000 21.06 10.91 15.99 4.15 4.21 4.18
4_8_4_2 Tangential BackMom a = 0.8, l = 0.5 3000 24.12 8.86 16.49 13.26 3.72 8.49
4_10_2 Tangential BackMom a = 0.8, l = 0.8 1000 24.60 9.34 16.97 9.91 3.54 6.73
4_4_2_2 Tangential BackMom a = 0.8, l = 0.8 2000 25.32 9.95 17.64 20.36 9.36 14.86
4_8_4_2 Tangential BackMom a = 0.8, l = 0.8 2000 25.45 10.07 17.76 18.23 8.58 13.40
Five best and five worst prediction errors for test data are shown. Prediction errors in training data for those same ANN are also shown.
M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81 79
5. Conclusions
This work illustrates the integration of high-
throughput tools for synthesis of solid materials and
data mining techniques in the discovery and optimisa-
tion of new microporous materials. As an example,
the crystallinity of zeolite beta was optimised by
exploring simultaneously synthesis gels with different
molar compositions. The experimental work has been
accomplished using automated systems for synthesis
and characterisation. The final crystalline phase and
its crystallinity can be successfully modelled using arti-
ficial neural networks, obtaining high-quality predic-
tions.
BETA
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141
BETA
experimental NN prediction
BETA
-40.00
-20.00
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141
Samples
BETA
experimental multi-variable quadratic model
UDM
0.00
20 .00
40 .00
60 .00
80 .00
100 .00
120 .00
1 112 1 31 41 51 61 71 81 91 101 111 121 131 141
Samples
UD M
exper iment al NN prediction
UDM
-20.00
0.00
20.00
40.00
60.00
80.00
100.00
120.00
1 11 21 31 41 51 61 71 81 91 101 111 121 131 141Samples
UDM
experimental multi-variable quadratic model
Samples
Fig. 8. Crystallinity predictions for 144 samples obtained with the selected ANN model (squares) and the multi-variable quadratic model (triangles)
for beta and UDM crystallinity.
80 M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81
M. Moliner et al. / Microporous and Mesoporous Materials 78 (2005) 73–81 81
Acknowledgment
Financial support from Spanish government
(MAT2003-07945-C02-01 and grants TIC2003-07369-
C02-01, CICYT DPI2002-04434-C04-02, FPU AP2001-
1516) is gratefully acknowledged.
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