Impact of Pore Connectivity on the Design of Long-Lived Zeolite Catalysts

Synthesis of Mesoporous Zeolites and Their Opportunities in Heterogeneous Catalysis

Currently, zeolites are one of the most important classes of heterogeneous catalysts in chemical industries owing to their unique structural characteristics such as molecular-scale size/shape-selectivity, heterogenized single catalytic sites in the framework, and excellent stability in harsh industrial processes. However, the microporous structure of conventional zeolite materials limits their applications to small-molecule reactions. To alleviate this problem, mesoporous zeolitic frameworks were developed. In the last few decades, several methods have been developed for the synthesis of mesoporous zeolites; these zeolites have demonstrated greater lifetime and better performance than their bulk microporous counterparts in many catalytic processes, which can be explained by the rapid diffusion of reactant species into the zeolite framework and facile accessibility to bulky molecules through the mesopores. Mesoporous zeolites provide versatile opportunities not only in conventional chemical industries but also in emerging catalysis fields. This review presents many state-of-the-art mesoporous zeolites, discusses various strategies for their synthesis, and details their contributions to catalytic reactions including catalytic cracking, isomerization, alkylation and acylation, alternative fuel synthesis via methanol-to-hydrocarbon (MTH) and Fischer–Tropsch synthesis (FTS) routes, and different fine-chemical syntheses.

Diffusion and catalyst efficiency in hierarchical zeolite catalysts

The preparation of hierarchical zeolites with reduced diffusion limitation and enhanced catalyst efficiency has become a vital focus in the field of zeolites and porous materials chemistry within the past decades. This review will focus on the diffusion and catalyst efficiency of hierarchical zeolites and industrial catalysts. The benefits of diffusion and catalyst efficiency at two levels of hierarchies (zeolitic component level and industrial catalyst level) from a chemical reaction engineering point of view will be analysed. At zeolitic component level, three types of mesopores based on the strategies applied toward enhancing the catalyst effectiveness factor are presented: (i) 'functional mesopores' (raising effective diffusivity); (ii) 'auxiliary mesopores' (decreasing diffusion length); and (iii) 'integrated mesopores' (a combination thereof). At industrial catalyst level, location and interconnectivity among the constitutive components are revealed. The hierarchical pore interconnectivity in multi-component zeolite based industrial catalysts is exemplified by fluid catalytic cracking and bi-functional hydroisomerization catalysts. The rational design of industrial zeolite catalysts at both hierarchical zeolitic component and catalyst body levels can be fully comprehended using the advanced in situ and/or operando spectroscopic, microscopic and diffraction techniques.

Micron-Sized Zeolite Beta Single Crystals Featuring Intracrystal Interconnected Ordered Macro-Meso-Microporosity Displaying Superior Catalytic Performance

Zeolite Beta single crystals with intracrystalline hierarchical porosity at macro-, meso-, and micro-length scales can effectively overcome the diffusion limitations in the conversion of bulky molecules. However, the construction of large zeolite Beta single crystals with such porosity is a challenge. We report herein the synthesis of hierarchically ordered macro-mesoporous single-crystalline zeolite Beta (OMMS-Beta) with a rare micron-scale crystal size by an in situ bottom-up confined zeolite crystallization strategy. The fully interconnected intracrystalline macro-meso-microporous hierarchy and the micron-sized single-crystalline nature of OMMS-Beta lead to improved accessibility to active sites and outstanding (hydro)thermal stability. Higher catalytic performances in gas-phase and liquid-phase acid-catalyzed reactions involving bulky molecules are obtained compared to commercial Beta and nanosized Beta zeolites. The strategy has been extended to the synthesis of other zeolitic materials, including ZSM-5, TS-1, and SAPO-34.

Hybrid catalysts based on N-heterocyclic carbene anchored on hierarchical zeolites

Hybrid materials have been synthesized by anchoring a N-heterocyclic carbene (NHC) precursor on different inorganic zeolitic supports with hierarchical porosity, in particular hierarchical HZSM-5 and SAPO-5. Hierarchical porous inorganic supports have been obtained both by top-down and bottom-up approaches and the role of hierarchical porosity has been evaluated. A detailed physico-chemical characterization has been performed on the organic-inorganic hybrids using a multi-technique approach (XRD, volumetric and thermogravimetric analysis, ssNMR and FTIR) in order to establish a structure-property relationship. The hybrids were tested in the benzoin condensation reaction of furfural, a base catalyzed reaction.

Visualizing pore architecture and molecular transport boundaries in catalyst bodies with fluorescent nanoprobes

The performances of porous materials are closely related to the accessibility and interconnectivity of their porous domains. Visualizing pore architecture and its role on functionality-for example, mass transport-has been a challenge so far, and traditional bulk and often non-visual pore measurements have to suffice in most cases. Here, we present an integrated, facile fluorescence microscopy approach to visualize the pore accessibility and interconnectivity of industrial-grade catalyst bodies, and link it unequivocally with their catalytic performance. Fluorescent nanoprobes of various sizes were imaged and correlated with the molecular transport of fluorescent molecules formed during a separate catalytic reaction. A direct visual relationship between the pore architecture-which depends on the pore sizes and interconnectivity of the material selected-and molecular transport was established. This approach can be applied to other porous materials, and the insight gained may prove useful in the design of more efficient heterogeneous catalysts.

Interconnected Hierarchical ZSM-5 with Tunable Acidity Prepared by a Dealumination-Realumination Process: A Superior MTP Catalyst

ZSM-5 that uses TPAOH as a template has an Al-rich exterior and defective Si-rich interior; thus, a simple base leaching selectively removed the Si-rich interior while the Al-rich exterior was protected. This catalyst showed no change in stability comparing with parent ZSM-5 during the MTP reaction that was attributed to the enclosed hollow structure and richly acidic outer shell. A preliminary fluorination, however, both removed defective Si-sites and caused distortion in tetrahedral aluminum that made the outer shell susceptible to alkaline treatment. These distorted tetrahedral Al were mostly leached out by NaOH in 1 min. Furthermore, aluminum in the filtrate was slowly redeposited onto the zeolite, serving as external pore-directing agents to control silicon dissolution from the Si-rich interior. This dealumination-realumination alkaline treatment process led to a higher solid yield and a uniform opened-mesopore structure with mesopores around 13 nm in diameter. This material was characterized by SEM, TEM, N₂ adsorption, and mercury porosimetry. In addition, NH₃-TPD, OH-IR, ²⁷Al MAS NMR, and ¹H MAS NMR results demonstrated that the reinserted Al were unlike the framework Al, contributing less to acidity. The dealumination-realumination process, therefore, was also capable of tuning the acidity of the mesoporous ZSM-5. This mesoporous catalyst exhibited a longer lifetime and a higher propylene selectivity than other catalysts with an enclosed mesopore structure.

Impact of hierarchical pore structure on the catalytic performances of MFI zeolites modified by ZnO for the conversion of methanol to aromatics

The increase in the pore hierarchy of ZnO/hierarchical H-ZSM-5 catalysts increased the catalyst stability and the yield of aromatics, particularly BTX, from methanol.

Controllable fabrication of single-crystalline, ultrafine and high-silica hierarchical ZSM-5 aggregates via solid-like state conversion

Single-crystalline, ultrafine and high-silica HA-ZSM-5 aggregates were directly synthesizedviaSSC method using HTAB as the mesoporogen through a S-1 seed-induced route.

Engineering of ZSM-5 zeolite crystals for enhanced lifetime in the production of light olefins via 2-methyl-2-butene cracking

ZSM-5 zeolites are tailored for the production of light olefinsvia2-methyl-2-butene cracking.

A self-supported SS-fiber@meso-HZSM-5 core–shell catalyst via caramel-assistant synthesis toward prolonged lifetime for the methanol-to-propylene reaction

Self-supported SS-fiber@meso-HZSM-5 core–shell catalyst prepared by caramel-assistant hydrothermal synthesis, delivered dramatically prolonged lifetime for MTP reaction due to its hierarchical design and favourably-tuned acidic properties.

The importance of heat effects in the methanol to hydrocarbons reaction over ZSM-5: on the role of mesoporosity on catalyst performance

Interpretation of catalytic performance during the MTH process is hampered by heat transport phenomena.

Oxygen-containing coke species in zeolite-catalyzed conversion of methanol to hydrocarbons

Oxygen-containing coke species are identified during methanol-to-hydrocarbons reactions, and their influence on the deactivation of catalyst is investigated.

Hierarchical ZSM-5 zeolite with uniform mesopores and improved catalytic properties

Uniform mesopores are generated in hierarchical ZSM-5 by a mesopore narrowing treatment, showing enhanced activity in the acylation of 2-methoxynaphthalene.

Hierarchical ZSM-11 zeolite prepared by alkaline treatment with mixed solution of NaOH and CTAB: characterization and application for alkylation of benzene with dimethyl ether

The composite effects of NaOH and CTAB regulated the porosity and acidity of ZSM-11 samples, which affected the reaction stability.

Structural analysis of IPC zeolites and related materials using positron annihilation spectroscopy and high-resolution argon adsorption

Precise pore size analysis of isoreticular series of UTL related zeolites is performed using high-resolution argon adsorption and positron annihilation spectroscopy.

Transport properties of hierarchical micro–mesoporous materials

This work provides an overview of different experimental techniques of diffusion measurements in porous materials and discusses transport properties of several classes of hierarchically organized micro-mesoporous materials.

Assessing structural correlations and heterogeneity length scales in functional porous polymers from physical reconstructions

A general, model-free, quantitative approach to the key morphological properties of a porous polymer monolith is presented. After 3D reconstruction, image-based analysis delivers detailed spatial and spatially correlated information on the structural heterogeneities in the void space and the polymer skeleton. Identified heterogeneities, which limit the monolith's performance in targeted applications, are traced back to the preparation process.

Structural analysis of hierarchically organized zeolites

Advances in materials synthesis bring about many opportunities for technological applications, but are often accompanied by unprecedented complexity. This is clearly illustrated by the case of hierarchically organized zeolite catalysts, a class of crystalline microporous solids that has been revolutionized by the engineering of multilevel pore architectures, which combine unique chemical functionality with efficient molecular transport. Three key attributes, the crystal, the pore and the active site structure, can be expected to dominate the design process. This review examines the adequacy of the palette of techniques applied to characterize these distinguishing features and their catalytic impact.

Porosity-Acidity Interplay in Hierarchical ZSM-5 Zeolites for Pyrolysis Oil Valorization to Aromatics

The properties of crude bio-oils attained by the pyrolysis of lignocellulosic biomass can be greatly enhanced by means of catalytic upgrading. Here, we demonstrate an efficient process concept coupling the production of pyrolysis oil from pine wood with a consecutive catalytic upgrading step over hierarchically structured ZSM-5 zeolites to attain aromatic-rich bio-oils. The selective upgrading of these complex mixtures is shown to be tightly connected to the extent of mesopore development and the density of Brønsted acid sites at the mesopore surface. A full product analysis enables elucidation of the impact of mesopore introduction and the acidic properties on the complex reaction network. The preferential occurrence of decarbonylation reactions in hierarchical zeolites versus dehydration transformations in the bulk counterparts is believed to be decisive in promoting increased aromatics formation.

Probing zeolites by vibrational spectroscopies

This review addresses the most relevant aspects of vibrational spectroscopies (IR, Raman and INS) applied to zeolites and zeotype materials. Surface Brønsted and Lewis acidity and surface basicity are treated in detail. The role of probe molecules and the relevance of tuning both the proton affinity and the steric hindrance of the probe to fully understand and map the complex site population present inside microporous materials are critically discussed. A detailed description of the methods needed to precisely determine the IR absorption coefficients is given, making IR a quantitative technique. The thermodynamic parameters of the adsorption process that can be extracted from a variable-temperature IR study are described. Finally, cutting-edge space- and time-resolved experiments are reviewed. All aspects are discussed by reporting relevant examples. When available, the theoretical literature related to the reviewed experimental results is reported to support the interpretation of the vibrational spectra on an atomic level.