Impact of the Spatial Organization of Bifunctional Metal–Zeolite Catalysts on the Hydroisomerization of Light Alkanes

Tailoring the Brønsted acidity of Ti-OH species by regulating Pt-TiO2 interaction

Bifunctional catalysts comprising metal and acid sites are commonly used for many reactions. Interfacial acid sites impact intermediate reactions more than other sites. However, controlling the type and amounts of interfacial acid sites by regulating metal-support interaction (MSI) via traditional methods is difficult. Thus, the influence of MSI on interfacial acid sites remains unclear. We prepared Pt-mTiO2/α-Al2O3 (m represents the cycle number of TiO2) catalysts via atomic layer deposition (ALD). New Brønsted acid sites were generated via Pt-TiO2 interaction, and the acidity was precisely regulated by regulating Pt-TiO2 interaction by changing the TiO2 nanolayer thickness. We chose levulinic acid (LA) hydrogenation as a model reaction. The catalytic activity varied with the TiO2 nanolayer thickness and was linearly correlated with the Ti-OH species (Brønsted acid) content. Pt-40TiO2/α-Al2O3, with the highest acid site content of 0.486 mmol/g, exhibited the best catalytic activity. Hydrogen spillover and water dissociation at the Pt-TiO2 interface promoted Ti-OH species generation.

Synergism between hierarchical MFI zeolites and alumina in alkene cross-metathesis reactions as a function of composition

Synergism between hierarchical zeolites and alumina in the preparation of active Mo catalysts, as a function of composition ratios, has been demonstrated in the cross-metathesis reaction between ethene and 2-butene. The metathesis reaction activity, reflected by ethene conversion, increases from 24.1% to 49.2% with the increase in the alumina content in composites from 10 wt% to 30 wt%. A further increase in the alumina content leads to the reduction in the metathesis activity, in which the ethene conversion decreases from 30.3% to 4.8% upon the enhanced alumina content from 50 wt% to 90 wt%. The impact of alumina content on the metathesis activity is closely associated with the interaction mode between the hierarchical ZSM-5 zeolite and alumina. TEM observation as well as EDS analysis and XPS results prove the progressive coating of alumina phase on the surface of zeolites along with the progressive enhancement of alumina content. The moderate alumina content in the composite enables the desired interaction between hierarchical zeolites and alumina, which is beneficial for the preparation of active catalysts for the alkene cross-metathesis reaction.

Steering the Metal Precursor Location in Pd/Zeotype Catalysts and Its Implications for Catalysis

Bifunctional catalysts containing a dehydrogenation–hydrogenation function and an acidic function are widely applied for the hydroconversion of hydrocarbon feedstocks obtained from both fossil and renewable resources. It is well known that the distance between the two functionalities is important for the performance of the catalyst. In this study, we show that the heat treatment of the catalyst precursor can be used to steer the location of the Pd precursor with respect to the acid sites in SAPO-11 and ZSM-22 zeotype materials when ions are exchanged with Pd(NH3)4(NO3)2. Two sets of catalysts were prepared based on composite materials of alumina with either SAPO-11 or ZSM-22. Pd was placed on/in the zeotype, followed by a calcination-reduction (CR) or direct reduction (DR) treatment. Furthermore, catalysts with Pd on the alumina binder were prepared. CR results in having more Pd nanoparticles inside the zeotype crystals, whereas DR yields more particles on the outer surface of the zeotype crystals as is confirmed using HAADF-STEM and XPS measurements. The catalytic performance in both n-heptane and n-hexadecane hydroconversion of the catalysts shows that having the Pd nanoparticles on the alumina binder is most beneficial for maximizing the isomer yields. Pd-on-zeotype catalysts prepared using the DR approach show intermediate performances, outperforming their Pd-in-zeotype counterparts that were prepared with the CR approach.

Toward n-Alkane Hydroisomerization Reactions: High-Performance Pt-Al2O3/SAPO-11 Single-Atom Catalysts with Nanoscale Separated Metal-Acid Centers and Ultralow Platinum Content

Long-chain n-alkane hydroisomerization reaction plays a vital role in petrochemical and coal chemical industries, which could produce high-quality hydrocarbon fuels and lubricant base oils for modern transportation and mechanical drive. However, minimizing precious metal usage while maintaining the catalyst performance remains a great challenge. Herein, a novel bifunctional catalyst toward n-alkane hydroisomerization reactions, Pt-Al₂O₃/SAPO-11 (Pt-A/S11) featuring nanoscale separated metal-acid active centers has been synthesized via a simple two-step procedure. In detail, Pt species was first loaded on the nanometer-sized alumina matrices through an incipient wetness impregnation method and then mixed with SAPO-11 molecular sieve to form the composite catalyst. Importantly, 0.015Pt-A/S11 catalyst with the ever-reported lowest Pt loading amount of 0.015 wt % exhibits an extraordinarily high isomer yield of 85.8% compared to previous published results and the traditional Pt-SAPO-11/Al₂O₃ (Pt-S11/A) catalyst accompanying with the direct contact between metal and acid sites (65.6%). It has been confirmed that the Pt species in 0.015Pt-A/S11 samples exist in single-atom form, leading to an excellent hydroisomerization performance. The possible reaction processes have been discussed to elucidate the exemplary catalytic performance of the synthesized Pt-A/S11 catalysts with nanoscale intimacy of metal-acid sites.

Mechanistic classification and benchmarking of polyolefin depolymerization over silica-alumina-based catalysts

Carbon-carbon bond cleavage mechanisms play a key role in the selective deconstruction of alkanes and polyolefins. Here, we show that the product distribution, which encompasses carbon range and formation of unsaturated and isomerization products, serves as a distinctive feature that allows the reaction pathways of different catalysts to be classified. Co, Ni, or Ru nanoparticles immobilized on amorphous silica-alumina, Zeo-Y and ZSM-5, were evaluated as catalysts in the deconstruction of n-hexadecane model substrate with hydrogen to delineate between different mechanisms, i.e., monofunctional- (acid site dominated) or bifunctional-hydrocracking (acid site & metal site) versus hydrogenolysis (metal site dominated), established from the product distributions. The ZSM-5-based catalysts were further studied in the depolymerization of polyethylene. Based on these studies, the catalysts are plotted on an activity-mechanism map that functions as an expandable basis to benchmark catalytic activity and to identify optimal catalysts that afford specific product distributions. The systematic approach reported here should facilitate the acceleration of catalyst discovery for polyolefin depolymerization.

Product distributions have been used to classify the depolymerization pathways of polyolefins catalyzed by silica-alumina-based catalysts to construct an activity-mechanism map as a benchmarking tool to facilitate catalyst discovery.

Mechanistic insights into positional and skeletal isomerization of cyclohexene in the H-BEA zeolite

The isomerization of cycloalkenes via the formation of carbenium cations assisted by the Brønsted acid site (BAS) in zeolites is the vital reaction step in hydrocracking and hydroisomerization processes of the petrochemical industry. To understand the acid-catalyzed positional isomerization and skeletal isomerization of cycloalkenes via carbenium intermediates, a series of ab initio molecular dynamics (AIMD) simulations of cyclohexene within the H-BEA zeolite have been carried out. AIMD simulations combined with the enhanced sampling technique reveal that the half-chair conformer is the most stable conformation for cyclohexene within H-BEA. Free energy landscapes characterizing protonation/deprotonation, positional isomerization, and skeletal isomerization of cyclohexene have been mapped out at 413 K. The free energy barrier for the formation of carbenium is calculated to be 44 kJ mol^-1. The skeletal isomerization of cyclohexene to methylcyclopentylium via the protonated cyclopropane transition state involves four stages with a total free energy barrier of 134 kJ mol^-1. Further geometrical analysis provides additional information about the structural origin of free energy barriers.

Metal-Acid Bifunctional Catalysts toward Tandem Reaction: One-Step Hydroalkylation of Benzene to Cyclohexylbenzene

The one-step hydroalkylation of benzene to cyclohexylbenzene (CHB) is a technically challenging and economically interesting reaction with great industrial importance, where bifunctional catalysts play a crucial role in such a tandem reaction. In this work, we report H₃PW₁₂O₄₀ (HPW) modified Ni nanoparticles (NPs) supported on mixed metal oxides (Ni/MMOs), which are featured by HPW species localized on the surface of Ni NPs (denoted as HPW-Ni/MMOs). The optimal catalyst (0.3HPW-Ni/MMOs) exhibits a satisfactory catalytic performance toward benzene hydroalkylation to CHB with a CHB yield of up to 41.2%, which is the highest standard among previously reported catalysts to date. A combination investigation based on HR-TEM, XPS, XANES, and in situ FT-IR verified the electron transfer from the W atom to the adjacent Ni atom, which facilitated the formation and desorption of cyclohexene (CHE) from Ni followed by the alkylation reaction of benzene and CHE at the interfacial Brønsted (B) acid sites of HPW, accounting for the significantly enhanced catalytic behavior. It is proposed that the HPW-Ni interface structure in xHPW-Ni/MMOs samples provides unique adsorption sites for benzene and CHE with a moderate adsorption strength, which serve as the intrinsic active center for this reaction: the Ni site promotes the hydrogenation of benzene to CHE, while the B acid site in HPW facilitates the alkylation of CHE and benzene to produce CHB. This work provides a fundamental understanding of the metal-acid synergistic catalysis toward the hydroalkylation reaction, which can be extended to the design and preparation of high-performance catalysts used in tandem reactions.

Maximizing noble metal utilization in solid catalysts by control of nanoparticle location

Maximizing the utilization of noble metals is crucial for applications such as catalysis. We found that the minimum loading of platinum for optimal performance in the hydroconversion of n -alkanes for industrially relevant bifunctional catalysts could be reduced by a factor of 10 or more through the rational arranging of functional sites at the nanoscale. Intentionally depositing traces of platinum nanoparticles on the alumina binder or the outer surface of zeolite crystals, instead of inside the zeolite crystals, enhanced isomer selectivity without compromising activity. Separation between platinum and zeolite acid sites preserved the metal and acid functions by limiting micropore blockage by metal clusters and enhancing access to metal sites. Reduced platinum nanoparticles were more active than platinum single atoms strongly bonded to the alumina binder.

Tandem catalysis with double-shelled hollow spheres

Metal-zeolite composites with metal (oxide) and acid sites are promising catalysts for integrating multiple reactions in tandem to produce a wide variety of wanted products without separating or purifying the intermediates. However, the conventional design of such materials often leads to uncontrolled and non-ideal spatial distributions of the metal inside/on the zeolites, limiting their catalytic performance. Here we demonstrate a simple strategy for synthesizing double-shelled, contiguous metal oxide@zeolite hollow spheres (denoted as MO@ZEO DSHSs) with controllable structural parameters and chemical compositions. This involves the self-assembly of zeolite nanocrystals onto the surface of metal ion-containing carbon spheres followed by calcination and zeolite growth steps. The step-by-step formation mechanism of the material is revealed using mainly in situ Raman spectroscopy and X-ray diffraction and ex situ electron microscopy. We demonstrate that it is due to this structure that an Fe₂O₃@H-ZSM-5 DSHSs-showcase catalyst exhibits superior performance compared with various conventionally structured Fe₂O₃-H-ZSM-5 catalysts in gasoline production by the Fischer-Tropsch synthesis. This work is expected to advance the rational synthesis and research of hierarchically hollow, core-shell, multifunctional catalyst materials.

Ammonia pools in zeolites for direct fabrication of catalytic centers

Reduction process is a key step to fabricate metal-zeolite catalysts in catalytic synthesis. However, because of the strong interaction force, metal oxides in zeolites are very difficult to be reduced. Existing reduction technologies are always energy-intensive, and inevitably cause the agglomeration of metallic particles in metal-zeolite catalysts or destroy zeolite structure in severe cases. Herein, we disclose that zeolites after ion exchange of ammonium have an interesting and unexpected self-reducing feature. It can accurately control the reduction of metal-zeolite catalysts, via in situ ammonia production from ‘ammonia pools’, meanwhile, restrains the growth of the size of metals. Such new and reliable ammonia pool effect is not influenced by topological structures of zeolites, and works well on reducible metals. The ammonia pool effect is ultimately attributed to an atmosphere-confined self-regulation mechanism. This methodology will significantly promote the fabrication for metal-zeolite catalysts, and further facilitate design and development of low-cost and high-activity catalysts.

Reduction process is a key step to fabricate metal zeolite catalysts, but existing reduction technologies are always energy intensive and inevitably cause the agglomeration of metallic particles or destroy zeolite structure. Here the authors find that zeolites after ion exchange of ammonium display an interesting and unexpected self-reducing feature.

Mercaptosilane-assisted synthesis of highly dispersed and stable Pt nanoparticles on HL zeolites for enhancing hydroisomerization of n-hexane

Pt/HL-SH catalysts were synthesized by a facile mercaptosilane-assisted in situ synthesis approach and exhibited better catalytic performance in n-hexane hydroisomerization.

Investigation of n-Heptane Hydroisomerization over Alkali-acid-treated Hierarchical Pt/ZSM-22 Zeolites

The design of various hierarchical and morphology ZSM-22 zeolite catalysts is attempted through the post-treatment of different concentrations of NaOH and subsequently, deals with HCl solution including fluosilicic acid (H2SiF6)...

Boosting propane dehydroaromatization by confining PtZn alloy nanoparticles within H-ZSM-5 crystals

A Pt–Zn@H-ZSM-5 catalyst with Pt–Zn alloy nanoparticles confined in H-ZSM-5 crystals exhibits a significantly improved performance in the propane dehydroaromatization reaction.

Advances in Catalytic Applications of Zeolite-Supported Metal Catalysts

Zeolites possessing large specific surface areas, ordered micropores, and adjustable acidity/basicity have emerged as ideal supports to immobilize metal species with small sizes and high dispersities. In recent years, the zeolite-supported metal catalysts have been widely used in diverse catalytic processes, showing excellent activity, superior thermal/hydrothermal stability, and unique shape-selectivity. In this review, a comprehensive summary of the state-of-the-art achievements in catalytic applications of zeolite-supported metal catalysts are presented for important heterogeneous catalytic processes in the last five years, mainly including 1) the hydrogenation reactions (e.g., CO/CO₂ hydrogenation, hydrogenation of unsaturated compounds, and hydrogenation of nitrogenous compounds); 2) dehydrogenation reactions (e.g., alkane dehydrogenation and dehydrogenation of chemical hydrogen storage materials); 3) oxidation reactions (e.g., CO oxidation, methane oxidation, and alkene epoxidation); and 4) other reactions (e.g., hydroisomerization reaction and selective catalytic reduction of NO_x with ammonia reaction). Finally, some current limitations and future perspectives on the challenge and opportunity for this subject are pointed out. It is believed that this review will inspire more innovative research on the synthesis and catalysis of zeolite-supported metal catalysts and promote their future developments to meet the emerging demands for practical applications.

Zeolite-Tailored Active Site Proximity for the Efficient Production of Pentanoic Biofuels

Biofuel production can alleviate reliance on fossil resources and thus carbon dioxide emission. Hydrodeoxygenation (HDO) refers collectively to a series of important biorefinery processes to produce biofuels. Here, well-dispersed and ultra-small Ru metal nanoclusters (ca. 1 nm), confined within the micropores of zeolite Y, provide the required active site intimacy, which significantly boosts the chemoselectivity towards the production of pentanoic biofuels in the direct, one-pot HDO of neat ethyl levulinate. Crucial for improving catalyst stability is the addition of La, which upholds the confined proximity by preventing zeolite lattice deconstruction during catalysis. We have established and extended an understanding of the "intimacy criterion" in catalytic biomass valorization. These findings bring new understanding of HDO reactions over confined proximity sites, leading to potential application for pentanoic biofuels in biomass conversion.

Activation and conversion of alkanes in the confined space of zeolite-type materials

Microporous zeolite-type materials, with crystalline porous structures formed by well-defined channels and cages of molecular dimensions, have been widely employed as heterogeneous catalysts since the early 1960s, due to their wide variety of framework topologies, compositional flexibility and hydrothermal stability. The possible selection of the microporous structure and of the elements located in framework and extraframework positions enables the design of highly selective catalysts with well-defined active sites of acidic, basic or redox character, opening the path to their application in a wide range of catalytic processes. This versatility and high catalytic efficiency is the key factor enabling their use in the activation and conversion of different alkanes, ranging from methane to long chain n-paraffins. Alkanes are highly stable molecules, but their abundance and low cost have been two main driving forces for the development of processes directed to their upgrading over the last 50 years. However, the availability of advanced characterization tools combined with molecular modelling has enabled a more fundamental approach to the activation and conversion of alkanes, with most of the recent research being focused on the functionalization of methane and light alkanes, where their selective transformation at reasonable conversions remains, even nowadays, an important challenge. In this review, we will cover the use of microporous zeolite-type materials as components of mono- and bifunctional catalysts in the catalytic activation and conversion of C₁⁺ alkanes under non-oxidative or oxidative conditions. In each case, the alkane activation will be approached from a fundamental perspective, with the aim of understanding, at the molecular level, the role of the active sites involved in the activation and transformation of the different molecules and the contribution of shape-selective or confinement effects imposed by the microporous structure.

Incorporation of Active Metal Species in Crystalline Porous Materials for Highly Efficient Synergetic Catalysis

The design and development of efficient catalytic materials with synergistic catalytic sites always has long been known to be a thrilling and very dynamic research field. Crystalline porous materials (CPMs) mainly including metal-organic frameworks and zeolites with high scientific and industrial impact have recently been the subject of extensive research due to their essential role in modern chemical industrial processes. The rational incorporation of guest species in CPMs can synergize the respective strengths of these components and allow them to collaborate with each other for synergistic catalysis, leading to enhanced catalytic activity, selectivity, and stability in a broad range of catalytic processes. In this review, the recent advances in the development of CPMs-confined active metal species, including metal nanoparticles, metal/metal oxides heteroparticles, metal oxide, subnanometric metal clusters, and polyoxometalates, for heterogeneous catalysis, with a particular focus on synergistic effects between active components that result in an enhanced performance are highlighted. Insights into catalysts design strategies, host-guest interactions, and structure-property relationships have been illustrated in detail. Finally, the existing challenges and possible development directions in CPMs-based encapsulation-structured synergistic catalysts are discussed.

Control and Impact of Metal Loading Heterogeneities at the Nanoscale on the Performance of Pt/Zeolite Y Catalysts for Alkane Hydroconversion

The preparation of zeolite-based bifunctional catalysts with low noble metal loadings while maintaining optimal performance has been studied. We have deposited 0.03 to 1.0 wt % Pt on zeolite H-USY (Si/Al ∼ 30 at./at.) using either platinum(II) tetraammine nitrate (PTA, Pt(NH₃)₄(NO₃)₂) or hexachloroplatinic(IV) acid (CPA, H₂PtCl₆·6H₂O) and studied the nanoscale Pt loading heterogeneities and global hydroconversion performance of the resulting Pt/Y catalysts. Pt/Y samples prepared with PTA and a global Pt loading as low as 0.3 wt % Pt (n_Pt/n_A = 0.08 mol/mol, where n_Pt is the number of Pt surface sites and n_A is the number of acid sites) maintained catalytic performance during n-heptane (T = 210–350 °C, P = 10 bar) as well as n-hexadecane (T = 170–280 °C, P = 5 bar) hydroisomerization similar to a 1.0 wt % Pt sample. For Pt/Y catalysts prepared with CPA, a loading of 0.3 wt % Pt (n_Pt/n_A = 0.08 mol/mol) sufficed for n-heptane hydroisomerization, whereas a detrimental effect on n-hexadecane hydroisomerization was observed, in particular undesired secondary cracking occurred to a significant extent. The differences between PTA and CPA are explained by differences in Pt loading per zeolite Y crystal (size ∼ 500 nm), shown from extensive transmission electron microscopy energy-dispersive X-ray spectroscopy experiments, whereby crystal-based n_Pt/n_A ratios could be determined. From earlier studies, it is known that the Al content per crystal of USY varied tremendously and that PTA preferentially is deposited on crystals with higher Al content due to ion-exchange with zeolite protons. Here, we show that this preferential deposition of PTA on Al-rich crystals led to a more constant value of n_Pt/n_A ratio from one zeolite crystal to another, which was beneficial for catalytic performance. Use of CPA led to a large variation of Pt loading independent of Al content, giving rise to larger variations of n_Pt/n_A ratio from crystal to crystal that negatively affected the catalytic performance. This study thus shows the impact of local metal loading variations at the zeolite crystal scale (nanoscale) caused by different interactions of metal precursors with the zeolite, which are essential to design and synthesize optimal catalysts, in particular at low noble metal loadings.

Characterization of a Molecule Partially Confined at the Pore Mouth of a Zeotype

We investigate the interaction between a molecule and a pore mouth-a critical step in adsorption processes-by characterizing the conformation of a macrocyclic calix[4]arene-Ti^IV complex, which is grafted on the external surface of a zeotype (*-SVY). X-ray absorption and ¹³ C{¹ H} CPMAS NMR spectroscopies independently detect a unique conformation of this complex when it is grafted at crystallographically equivalent locations that lie at the interface of 7 Å hemispherical microporous cavities and the external surface. Electronic structure calculations support the presence of this unique conformation, and suggest that it is brought about by a specific orientation of the macrocycle that maximizes non-covalent interactions between calix[4]arene upper-rim tert-butyl substituents and the microporous-cavity walls. Our comparative study provides a rare "snapshot" of a molecule partially confined at a pore mouth, an essential intermediate for adsorption into micropores, and demonstrates how surrounding environment controls this confinement in a sensitive fashion.

A hierarchically multifunctional integrated catalyst with intimate and synergistic active sites for one-pot tandem catalysis

As a typical process-intensive strategy, a tandem reaction driven by a multifunctional catalyst is a paragon of the green catalytic process.

Influence of Nanoscale Intimacy and Zeolite Micropore Size on the Performance of Bifunctional Catalysts for n-Heptane Hydroisomerization

In this study, Pt nanoparticles on zeolite/γ-Al₂O₃ composites (50/50 wt) were located either in the zeolite or on the γ-Al₂O₃ binder, hereby varying the average distance (intimacy) between zeolite acid sites and metal sites from “closest” to “nanoscale”. The catalytic performance of these catalysts was compared to physical mixtures of zeolite and Pt/γ-Al₂O₃ powders, which provide a “microscale” distance between sites. Several beneficial effects on catalytic activity and selectivity for n-heptane hydroisomerization were observed when Pt nanoparticles are located on the γ-Al₂O₃ binder in nanoscale proximity with zeolite acid sites, as opposed to Pt nanoparticles located inside zeolite crystals. On ZSM-5-based catalysts, mostly monobranched isomers were produced, and the isomer selectivity of these catalysts was almost unaffected with an intimacy ranging from closest to microscale, which can be attributed to the high diffusional barriers of branched isomers within ZSM-5 micropores. For composite catalysts based on large-pore zeolites (zeolite Beta and zeolite Y), the activity and selectivity benefitted from the nanoscale intimacy with Pt, compared to both the closest and microscale intimacies. Intracrystalline gradients of heptenes as reaction intermediates are likely contributors to differences in activity and selectivity. This paper aims to provide insights into the influence of the metal–acid intimacy in bifunctional catalysts based on zeolites with different framework topologies.

In Situ Encapsulation of Pt Nanoparticles within Pure Silica TON Zeolites for Space-Confined Selective Hydrogenation

Straightforward encapsulation of Pt clusters (∼2 nm) into the pure silica TON-type zeolite (ZSM-22) was reached in a dry gel conversion route, where the ionic liquid template was removed via the hydrocracking-calcination-reduction approach. The obtained Pt@ZSM-22 series possessed high crystallinity, large surface area, and ultrafine Pt clusters inside the zeolite crystals. They exhibited remarkable activity in the semi-hydrogenation of phenylacetylene into styrene; the lead sample with 0.2 wt % Pt loading afforded a large turnover number up to 117,787. The preferential high affinity of the pure silica ZSM-22-encapsulated Pt clusters toward the substrate phenylacetylene rather than the hydrogenated product was derived from the unique space-confinement effect of zeolite microchannels, which is responsible for such excellent performance.