Umwandlung von Methanol in Kohlenwasserstoffe: Wie Zeolith-Hohlräume und Porengröße die Produktselektivität bestimmen

Regulating Nonclassical Pathways of Silicalite-1 Crystallization through Controlled Evolution of Amorphous Precursors

Differentiating mechanisms of zeolite crystallization is challenging owing to the vast number of species in growth solutions. The presence of amorphous colloidal particles is ubiquitous in many zeolite syntheses, and has led to extensive efforts to understand the driving force(s) for their self-assembly and putative roles in processes of nucleation and growth. In this study, we use a combination of in situ scanning probe microscopy, particle dissolution measurements, and colloidal stability assays to elucidate the degree to which silica nanoparticles evolve in their structure during the early stages of silicalite-1 synthesis. We show how changes in precursor structure are mediated by the presence of organics, and demonstrate how these changes lead to significant differences in precursor-crystal interactions that alter preferred modes of crystal growth. Our findings provide guidelines for selectively controlling silicalite-1 growth by particle attachment or monomer addition, thus allowing for the manipulation of anisotropic rates of crystallization. In doing so, we also address a longstanding question regarding what factors are at our disposal to switch from a nonclassical to classical mechanism.

Mechanochemical Pretreatment for Efficient Solvent-Free Synthesis of SSZ-13 Zeolite

The economical and environmentally benign synthesis of SSZ-13 zeolite was possible due to the mechanochemical activation of dry reagents by planetary mill. Contrary to manual grinding in a mortar, the proposed automatized approach is scalable and reproducible. This solvent-free process provided a huge gain in product/gel ratios, significantly minimized reaction space and organic structure-directing agent use, and allowed for the elimination of agitation. Obtained materials were comparable to the product of "classical" syntheses. The use of different silica sources resulted in SSZ-13 zeolites with various characteristics: different Si/Al ratio and crystal size.

A Critical Look at Direct Catalytic Hydrogenation of Carbon Dioxide to Olefins

One of the main initiatives for fighting climate change is to use carbon dioxide as a resource instead of waste. In this respect, thermocatalytic carbon dioxide hydrogenation to high-added-value chemicals is a promising process. Among the products of this reaction (alcohols, alkanes, olefins, or aromatics), light olefins are interesting because they are building blocks for making polymers, as well as other important chemicals. Olefins are mainly produced from fossil fuel sources, but the increasing demand of plastics boosts the need to develop more sustainable synthetic routes. This review gives a critical overview of the most recent achievements in direct carbon dioxide hydrogenation to light olefins, which can take place through two competitive routes: the modified Fischer-Tropsch synthesis and methanol-mediated synthesis. Both routes are compared in terms of catalyst development, reaction performance, and reaction mechanisms. Furthermore, practical aspects of the commercialization of this reaction, such as renewable hydrogen production and carbon dioxide capture, compression, and transport, are discussed. It is concluded that, to date, the catalysts used in the carbon dioxide hydrogenation reaction give a wide product distribution, which reduces the specific selectivity to lower olefins. More efforts are needed to reach better control of the C/H surface ratio and interactions within the functionalities of the catalyst, as well as understanding the reaction mechanism and avoiding deactivation. Renewable H₂ production and carbon dioxide capture and transport technologies are being developed, although they are currently still too expensive for industrial application.

Morphology-Controlled Synthesis of H-type MFI Zeolites with Unique Stacked Structures through a One-Pot Solvent-Free Strategy

H-type aluminosilicate zeolites are extensively used as solid-acid catalysts and support materials in industrial catalysis. However, the conventional synthesis methods involving hydrothermal syntheses and ion-exchange processes suffer from severe water pollution and toxic gas emissions. Herein, H-type MFI zeolite catalysts with a unique stacked structure were directly synthesized in the presence of NH₄ F and with the help of zeolite confinement through a solvent-free route without further ion-exchange procedures. A range of ex situ and in situ characterization procedures were used to provide evidence of the simultaneous use of pre-made ZSM-5 and NH₄ F as a confined Al source and mineralizer, respectively. The confined zeolite framework of ZSM-5 prevented the formation of AlF_x species between NH₄ F and Al atoms, ensuring that the prepared samples had desirable acidic properties. Moreover, the resulting morphology could be controlled by using different silica substrates. The obtained H-type MFI zeolites showed excellent catalytic performance in methanol-to-gasoline reactions owing to their unique structure and directly exposed acidic sites. The developed one-pot strategy provides an alternative method for the facile synthesis of H-type zeolites with defined morphology.

Selective Transformation of CO2 and H2 into Lower Olefins over In2 O3 -ZnZrOx /SAPO-34 Bifunctional Catalysts

Because lower olefins (C₂ ⁼ -C₄ ⁼ ) are important bulk petrochemicals, their direct production from CO₂ hydrogenation is highly attractive. However, the selectivity towards C₂ ⁼ -C₄ ⁼ by the modified Fischer-Tropsch synthesis is restricted to 56.7 % with high undesired methane selectivity. Here, a series of bifunctional catalysts containing In₂ O₃ -ZnZrO_x oxides and various SAPO-34 zeolites with different crystal sizes (0.4-1.5 μm) and pore structures was developed for the production of lower olefins by CO₂ hydrogenation. The C₂ ⁼ -C₄ ⁼ selectivity reached as high as 85 % among all hydrocarbons with very low CH₄ selectivity of only 1 % at a CO₂ conversion of 17 %. This demonstrated that the small crystal size, hierarchical pore structure, and appropriate amount of Brønsted acid sites of SAPO-34 endowed the bifunctional catalysts with high C₂ ⁼ -C₄ ⁼ selectivity. This work shows an efficient way for developing bifunctional catalysts for direct CO₂ hydrogenation to lower olefins.

Mesoporogen-Free Synthesis of Hierarchical SAPO-34 with Low Template Consumption and Excellent Methanol-to-Olefin Conversion

Significant interest has emerged in the development of nanometer-sized and hierarchical silicoaluminophosphate zeolites (SAPO-34) because of their enhanced accessibility and improved catalytic activity for methanol-to-olefin (MTO) conversion. A series of nanometer-sized SAPO-34 catalysts with tunable hierarchical structures was synthesized in a Al₂ O₃ /H₃ PO₄ /SiO₂ /triethylamine(TEA)/H₂ O system by using a mesoporogen-free nanoseed-assisted method. The nanometer-sized hierarchical S_H -3.0 catalyst (TEA/Al₂ O₃ =3.0) possessed the highest crystallinity, highest abundance of intracrystalline meso-/macropores, and the most suitable acidity among all obtained catalysts, showing the highest ethylene and propylene selectivity of 85.4 %. This is the highest reported selectivity for MTO reactions under similar conditions. Detailed analysis of the coke produced during the reaction revealed that the small-sized methyl-substituted benzene and bulky methyl-substituted pyrene were mainly located inside the crystals instead of on the surface of the crystals, which provided further insight into understanding the deactivation of the SAPO-34 catalyst during MTO reaction. Significantly, the simple and cost-effective synthetic process and superb catalytic performance of the nanometer-sized hierarchical SAPO-34 is promising for their practical large-scale application for MTO conversion.

Assembly of Sub-Crystals on the Macroscale and Construction of Composite Building Units on the Microscale for SAPO-34

The nucleation and growth of SAPO-34 crystals with triethylamine (TEA) as a single template was monitored with ex situ time-resolved characterization methods. The investigation focused on the evolution of the intermediate phases at different crystallization stages of SAPO-34. The morphology transformation of the intermediate phases at different crystallization times revealed the unique self-assembly process of the sub-crystals. The cubic SAPO-34 crystals can be constructed from eight pyramidal subunits. Additionally, the construction order of cha cages and double-six-membered ring (d6r) units in the initial crystallization stage was determined. The appearance of cha cages prior to d6r units can be attributed to the structure-directing effect of protonated TEA, which is charge balanced with the negative charge of the framework from Si incorporation. Further analysis showed that Si species were incorporated into the framework by direct participation in the initial crystallization stage and substitution for framework P atoms during the later stage.

Bridging the Gap between the Direct and Hydrocarbon Pool Mechanisms of the Methanol-to-Hydrocarbons Process

After a prolonged effort over many years, the route for the formation of a direct carbon-carbon (C-C) bond during the methanol-to-hydrocarbon (MTH) process has very recently been unveiled. However, the relevance of the "direct mechanism"-derived molecules (that is, methyl acetate) during MTH, and subsequent transformation routes to the conventional hydrocarbon pool (HCP) species, are yet to be established. This important piece of the MTH chemistry puzzle is not only essential from a fundamental perspective, but is also important to maximize catalytic performance. The MTH process was probed over a commercially relevant H-SAPO-34 catalyst, using a combination of advanced solid-state NMR spectroscopy and operando UV/Vis diffuse reflectance spectroscopy coupled to an on-line mass spectrometer. Spectroscopic evidence is provided for the formation of (olefinic and aromatic) HCP species, which are indeed derived exclusively from the direct C-C bond-containing acetyl group of methyl acetate. New mechanistic insights have been obtained from the MTH process, including the identification of hydrocarbon-based co-catalytic organic reaction centers.

A Systematic Study of Isomorphically Substituted H-MAlPO-5 Materials for the Methanol-to-Hydrocarbons Reaction

Substituting metals for either aluminum or phosphorus in crystalline, microporous aluminophosphates creates Brønsted acid sites, which are well known to catalyze several key reactions, including the methanol to hydrocarbons (MTH) reaction. In this work, we synthesized a series of metal-substituted aluminophosphates with AFI topology that differed primarily in their acid strength and that spanned a predicted range from high Brønsted acidity (H-MgAlPO-5, H-CoAlPO-5, and H-ZnAlPO-5) to medium acidity (H-SAPO-5) and low acidity (H-TiAlPO-5 and H-ZrAlPO-5). The synthesis was aimed to produce materials with homogenous properties (e.g. morphology, crystallite size, acid-site density, and surface area) to isolate the influence of metal substitution. This was verified by extensive characterization. The materials were tested in the MTH reaction at 450 °C by using dimethyl ether (DME) as feed. A clear activity difference was found, for which the predicted stronger acids converted DME significantly faster than the medium and weak Brønsted acidic materials. Furthermore, the stronger Brønsted acids (Mg, Co and Zn) produced more light alkenes than the weaker acids. The weaker acids, especially H-SAPO-5, produced more aromatics and alkanes, which indicates that the relative rates of competing reactions change upon decreasing the acid strength.

Confined Carbon Mediating Dehydroaromatization of Methane over Mo/ZSM-5

Non-oxidative dehydroaromatization of methane (MDA) is a promising catalytic process for direct valorization of natural gas to liquid hydrocarbons. The application of this reaction in practical technology is hindered by a lack of understanding about the mechanism and nature of the active sites in benchmark zeolite-based Mo/ZSM-5 catalysts, which precludes the solution of problems such as rapid catalyst deactivation. By applying spectroscopy and microscopy, it is shown that the active centers in Mo/ZSM-5 are partially reduced single-atom Mo sites stabilized by the zeolite framework. By combining a pulse reaction technique with isotope labeling of methane, MDA is shown to be governed by a hydrocarbon pool mechanism in which benzene is derived from secondary reactions of confined polyaromatic carbon species with the initial products of methane activation.

Characterization at the Level of Individual Crystals: Single-Crystal MFI Type Zeolite Grains

Electron-diffraction data on the zeolites Silicalite-1 and ZSM-5 (both MFI framework type) were collected from individual grains of about 150×100×50 nm³ . Crystals were synthesized with tetrapropylammonium as structure-directing agent. The resolution extended to about 0.8 Å for Silicalite-1 and about 0.9-1.0 Å for ZSM-5 crystals. Analysis of several data sets showed that at the nanometre-scale, these zeolite crystals are single crystals and not intergrown.

On the Role of Acidity in Bulk and Nanosheet [T]MFI (T=Al3+, Ga3+, Fe3+, B3+) Zeolites in the Methanol-to-Hydrocarbons Reaction

The influence of framework substituents (Al³⁺, Ga³⁺, Fe³⁺ and B³⁺) and morphology (bulk vs. nanometer‐sized sheets) of MFI zeolites on the acidity and catalytic performance in the methanol‐to‐hydrocarbons (MTH) reaction was investigated. The Brønsted acid density and strength decreased in the order Al(OH)Si>Ga(OH)Si>Fe(OH)Si≫B(OH)Si. Pyridine ¹⁵N NMR spectra confirmed the differences in the Brønsted and Lewis acid strengths but also provided evidence for site heterogeneity in the Brønsted acid sites. Owing to the lower efficiency with which tervalent ions can be inserted into the zeolite framework, sheet‐like zeolites exhibited lower acidity than bulk zeolites. The sheet‐like Al‐containing MFI zeolite exhibited the greatest longevity as a MTH catalyst, outperforming its bulk [Al]MFI counterpart. Although the lower acidity of bulk [Ga]MFI led to a better catalytic performance than bulk [Al]MFI, the sheet‐like [Ga]MFI sample was found to be nearly inactive owing to lower and heterogeneous Brønsted acidity. All Fe‐ and B‐substituted zeolite samples displayed very low catalytic performance owing to their weak acidity. Based on the product distribution, the MTH reaction was found to be dominated by the olefins‐based catalytic cycle. The small contribution of the aromatics‐based catalytic cycle was larger for bulk zeolite than for sheet‐like zeolite, indicating that shorter residence time of aromatics can explain the lower tendency toward coking and enhanced catalyst longevity.

Probing Zeolite Crystal Architecture and Structural Imperfections using Differently Sized Fluorescent Organic Probe Molecules

A micro‐spectroscopic method has been developed to probe the accessibility of zeolite crystals using a series of fluorescent 4‐(4‐diethylaminostyryl)‐1‐methylpyridinium iodide (DAMPI) probes of increasing molecular size. Staining large zeolite crystals with MFI (ZSM‐5) topology and subsequent mapping of the resulting fluorescence using confocal fluorescence microscopy reveal differences in structural integrity: the 90° intergrowth sections of MFI crystals are prone to develop structural imperfections, which act as entrance routes for the probes into the zeolite crystal. Polarization‐dependent measurements provide evidence for the probe molecule's alignment within the MFI zeolite pore system. The developed method was extended to BEA (Beta) crystals, showing that the previously observed hourglass pattern is a general feature of BEA crystals with this morphology. Furthermore, the probes can accurately identify at which crystal faces of BEA straight or sinusoidal pores open to the surface. The results show this method can spatially resolve the architecture‐dependent internal pore structure of microporous materials, which is difficult to assess using other characterization techniques such as X‐ray diffraction.

Effects of the Functionalization of the Ordered Mesoporous Carbon Support Surface on Iron Catalysts for the Fischer-Tropsch Synthesis of Lower Olefins

Ordered mesoporous carbon (CMK‐3) with different surface modifications is applied as a support for Fe‐based catalysts in the Fischer–Tropsch to olefins synthesis (FTO) with and without sodium and sulfur promoters. Different concentrations of functional groups do not affect the size (3–5 nm) of Fe particles in the fresh catalysts but iron (carbide) supported on N‐enriched CMK‐3 and a support with a lower concentration of functional groups show higher catalytic activity under industrially relevant FTO conditions (340 °C, 10 bar, H₂/CO=2) compared to a support with an O‐enriched surface. The addition of promoters leads to more noticeable enhancements of the catalytic activity (3–5 times higher) and the selectivity to C₂–C₄ olefins (≈2 times higher) than surface functionalization of the support. Nitrogen surface functionalization and removal of surface groups before impregnation and calcination, however, further increase the activity of the catalysts in the presence of promoters. The confinement of the Fe nanoparticles in the mesopores of CMK‐3 restricts but does not fully prevent particle growth and, consequently, the decrease of activity under FTO conditions.

Effect of Feedstock and Catalyst Impurities on the Methanol-to-Olefin Reaction over H-SAPO-34

Operando UV/Vis spectroscopy with on-line mass spectrometry was used to study the effect of different types of impurities on the hydrocarbon pool species and the activity of H-SAPO-34 as a methanol-to-olefins (MTO) catalyst. Successive reaction cycles with different purity feedstocks were studied, with an intermittent regeneration step. The combined study of two distinct impurity types (i.e., feed and internal impurities) leads to new insights into MTO catalyst activation and deactivation mechanisms. In the presence of low amounts of feed impurities, the induction and active periods of the process are prolonged. Feed impurities are thus beneficial in the formation of the initial hydrocarbon pool, but also aid in the unwanted formation of deactivating coke species by a separate, competing mechanism favoring coke species over olefins. Further, feedstock impurities strongly influence the location of coke deposits, and thus influence the deactivation mechanism, whereas a study of the organic impurities retained after calcination reveals that these species are less relevant for catalyst activity and function as "seeds" for coke formation only.

Assembly line synthesis of isoprene from formaldehyde and isobutene over SiO2-supported MoP catalysts with active deposited carbon

Isoprene was synthesized over MoP catalysts with active carbonaceous deposits in an “assembly line” process.

Initial Carbon-Carbon Bond Formation during the Early Stages of the Methanol-to-Olefin Process Proven by Zeolite-Trapped Acetate and Methyl Acetate

Methanol-to-olefin (MTO) catalysis is a very active field of research because there is a wide variety of sometimes conflicting mechanistic proposals. An example is the ongoing discussion on the initial C-C bond formation from methanol during the induction period of the MTO process. By employing a combination of solid-state NMR spectroscopy with UV/Vis diffuse reflectance spectroscopy and mass spectrometry on an active H-SAPO-34 catalyst, we provide spectroscopic evidence for the formation of surface acetate and methyl acetate, as well as dimethoxymethane during the MTO process. As a consequence, new insights in the formation of the first C-C bond are provided, suggesting a direct mechanism may be operative, at least in the early stages of the MTO reaction.

Coke Formation in a Zeolite Crystal During the Methanol-to-Hydrocarbons Reaction as Studied with Atom Probe Tomography

Understanding the formation of carbon deposits in zeolites is vital to developing new, superior materials for various applications, including oil and gas conversion processes. Herein, atom probe tomography (APT) has been used to spatially resolve the 3D compositional changes at the sub‐nm length scale in a single zeolite ZSM‐5 crystal, which has been partially deactivated by the methanol‐to‐hydrocarbons reaction using ¹³C‐labeled methanol. The results reveal the formation of coke in agglomerates that span length scales from tens of nanometers to atomic clusters with a median size of 30–60 ¹³C atoms. These clusters correlate with local increases in Brønsted acid site density, demonstrating that the formation of the first deactivating coke precursor molecules occurs in nanoscopic regions enriched in aluminum. This nanoscale correlation underscores the importance of carefully engineering materials to suppress detrimental coke formation.

Single-Pass Catalytic Conversion of Syngas into Olefins via Methanol

All together now: Combination in a single reactor of the catalysts for converting syngas into methanol and methanol into olefins was recently reported by Cheng et al. This approach considerably simplifies the catalytic conversion of natural gas.