Preparation of MAZ-Type Zeolite with High Silica

The Si/Al molar ratio of MAZ aluminosilicate zeolite prepared by the direct hydrothermal method is generally less than five, thus giving rise to poor thermal and hydrothermal stability for this low-silica zeolite. With the purpose of enhancing the Si/Al molar ratio of MAZ zeolite, post-synthesized methods including acetic acid treatment and steaming treatment, as well as interzeolite transformation from FAU zeolite, were employed to prepare MAZ zeolite with high silica. It was found that steaming treatment was more effective in increasing the Si/Al molar ratio in comparison with acetic acid treatment, affording a maximum Si/Al molar ratio of 16.9 along with a preserved crystallinity of approximately 75%. Additionally, high-silica MAZ zeolite with a Si/Al molar ratio of up to 7.3 was also capable of being directly hydrothermally synthesized using interzeolite transformation from FAU zeolite.

Competition between Mononuclear and Binuclear Copper Sites across Different Zeolite Topologies

A key challenge for metal-exchanged zeolites is the determination of metal cation speciation and nuclearity under synthesis and reaction conditions. Copper-exchanged zeolites, which are widely used in automotive emissions control and potential catalysts for partial methane oxidation, have in particular evidenced a wide variety of Cu structures that are observed to change with exposure conditions, zeolite composition, and topology. Here, we develop predictive models for Cu cation speciation and nuclearity in CHA, MOR, BEA, AFX, and FER zeolite topologies using interatomic potentials, quantum chemical calculations, and Monte Carlo simulations to interrogate this vast configurational and compositional space. Model predictions are used to rationalize experimentally observed differences between Cu-zeolites in a wide-body of literature, including nuclearity populations, structural variations, and methanol per Cu yields. Our results show that both topological features and commonly observed Al-siting biases in MOR zeolites increase the population of binuclear Cu sites, explaining the small population of mononuclear Cu sites observed in these materials relative to other zeolites such as CHA and BEA. Finally, we used a machine learning classification model to determine the preference to form mononuclear or binuclear Cu sites at different Al configurations in 200 zeolites in the international zeolite database. Model results reveal several zeolite topologies at extreme ends of the mononuclear vs binuclear spectrum, highlighting synthetic options for realization of zeolites with strong Cu nuclearity preferences.

Recent Advances in the Catalytic Conversion of Methane to Methanol: From the Challenges of Traditional Catalysts to the Use of Nanomaterials and Metal-Organic Frameworks

Methane and carbon dioxide are the main contributors to global warming, with the methane effect being 25 times more powerful than carbon dioxide. Although the sources of methane are diverse, it is a very volatile and explosive gas. One way to store the energy content of methane is through its conversion to methanol. Methanol is a liquid under ambient conditions, easy to transport, and, apart from its use as an energy source, it is a chemical platform that can serve as a starting material for the production of various higher-value products. Accordingly, the transformation of methane to methanol has been extensively studied in the literature, using traditional catalysts as different types of zeolites. However, in the last few years, a new generation of catalysts has emerged to carry out this transformation with higher conversion and selectivity, and more importantly, under mild temperature and pressure conditions. These new catalysts typically involve the use of a highly porous supporting material such as zeolite, or more recently, metal-organic frameworks (MOFs) and graphene, and metallic nanoparticles or a combination of different types of nanoparticles that are the core of the catalytic process. In this review, recent advances in the porous supports for nanoparticles used for methane oxidation to methanol under mild conditions are discussed.

Assessing the Productivity of the Direct Conversion of Methane-to-Methanol over Copper-Exchanged Zeolite Omega (MAZ) via Oxygen Looping

The methane-to-methanol (MtM) conversion via the oxygen looping approach using copper-exchanged zeolites has been extensively studied over the last decade. While a lot of research has focussed on maximizing yield and selectivity, little has been directed toward productivity-a metric far more meaningful for evaluating industrial potential. Using copper-exchanged zeolite omega (Cu-omega), a material highly active and selective for the MtM conversion using the isothermal oxygen looping approach, we show that this material exhibits unprecedented potential for industrial valorization. In doing so, we also present a novel methodology combining operando XAS and mass spectrometry for the screening of materials for the MtM conversion in oxygen looping mode.

Understanding C-H activation in light alkanes over Cu-MOR zeolites by coupling advanced spectroscopy and temperature-programmed reduction experiments

The direct activation of methane to methanol (MTM) proceeds through a chemical-looping process over Cu-oxo sites in zeolites. Herein, we extend the overall understanding of oxidation reactions over metal-oxo sites and C-H activation reactions by pinpointing the evolution of Cu species during reduction. To do so, a set of temperature-programmed reduction experiments were performed with CH4, C2H6, and CO. With a temperature ramp, the Cu reduction could be accelerated to detect changes in Cu speciation that are normally not detected due to the slow CH4 adsorption/interaction during MTM (∼200 °C). To follow the Cu-speciation with the three reductants, X-ray absorption spectroscopy (XAS), UV-vis and FT-IR spectroscopy were applied. Multivariate curve resolution alternating least-square (MCR-ALS) analysis was used to resolve the time-dependent concentration profiles of pure Cu components in the X-ray absorption near edge structure (XANES) spectra. Within the large datasets, as many as six different CuII and CuI components were found. Close correlations were found between the XANES-derived CuII to CuI reduction, CH4 consumption, and CO2 production. A reducibility-activity relationship was also observed for the Cu-MOR zeolites. Extended X-ray absorption fine structure (EXAFS) spectra for the pure Cu components were furthermore obtained with MCR-ALS analysis. With wavelet transform (WT) analysis of the EXAFS spectra, we were able to resolve the atomic speciation at different radial distances from Cu (up to about 4 Å). These results indicate that all the CuII components consist of multimeric CuII-oxo sites, albeit with different Cu-Cu distances.

Copper-zeolites Prepared by Solid-state Ion Exchange - Characterization and Evaluation for the Direct Conversion of Methane to Methanol

Direct conversion of methane to methanol (MTM) over Cu-zeolites is a so-called “dream reaction” for the chemical industry. There is still a lot that can be done in order to optimize the reaction by e.g. achieving a deeper understanding of the reaction mechanism and the nature of the Cu-sites. In this study, we investigated a solid-state ion exchange method to incorporate CuI ions into zeolites (MOR, BEA, ZSM-5 and FAU), as a more scalable technique. The solid-state ion exchange led to a Cu/Al ration of about 0.8, however with a heterogeneous distribution of Cu. Regardless, Fourier transform-infrared spectroscopy still revealed that most Brønsted acid sites were exchanged in all four samples. Further, CH4-temperature programmed reaction experiments showed that some Cu-sites formed were reactive towards CH4, with CuI-MOR and CuI-FAU having the largest CH4 consumption. Ultimately, the CuI-zeolites were tested in the MTM reaction and proved capable of producing methanol, even without the presence of Brønsted sites. A MOR with lower Cu/Al ratio (0.30) was also tested for comparison, and as this sample obtained a much higher productivity than the CuI-MOR with high Cu-loading (0.10 vs. 0.03 molMeOH/molCu), it was demonstrated that some fine-tuning is necessary to obtain the active Cu sites for methane activation.

Influence of ion mobility on the redox and catalytic properties of Cu ions in zeolites

This contribution aims at analysing the current understanding about the influence of Al distribution, zeolite topology, ligands/reagents and oxidation state on ions mobility in Cu-zeolites, and its relevance toward reactivity of the metal sites. The concept of Cu mobilization has been originally observed in the presence of ammonia, favouring the activation of oxygen by formation of NH3 oxo-bridged complexes in zeolites and opening a new perspective about the chemistry in single-site zeolite-based catalysts, in particular in the context of the NH3-mediated Selective Catalytic Reduction of NO x (NH3-SCR) processes. A different mobility of bare Cu+/Cu2+ ions has been documented too, showing for Cu+ a better mobilization than for Cu2+ also in absence of ligands. These concepts can have important consequences for the formation of Cu-oxo species, active and selective in other relevant reactions, such as the direct conversion of methane to methanol. Here, assessing the structure, the formation pathways and reactivity of Cu-oxo mono- or multimeric moieties still represents a challenging playground for chemical scientists. Translating the knowledge about Cu ions mobility and redox properties acquired in the context of NH3-SCR reaction into the field of direct conversion of methane to methanol can have important implications for a better understanding of transition metal ions redox properties in zeolites and for an improved design of catalysts and catalytic processes.

Selective Formation of α-Fe(II) Sites on Fe-Zeolites through One-Pot Synthesis

α-Fe(II) active sites in iron zeolites catalyze N₂O decomposition and form highly reactive α-O that selectively oxidizes unreactive hydrocarbons, such as methane. How these α-Fe(II) sites are formed remains unclear. Here different methods of iron introduction into zeolites are compared to derive the limiting factors of Fe speciation to α-Fe(II). Postsynthetic iron introduction procedures on small pore zeolites suffer from limited iron diffusion and dispersion leading to iron oxides. In contrast, by introducing Fe(III) in the hydrothermal synthesis mixture of the zeolite (one-pot synthesis) and the right treatment, crystalline CHA can be prepared with >1.6 wt % Fe, of which >70% is α-Fe(II). The effect of iron on the crystallization is investigated, and the intermediate Fe species are tracked using UV-vis-NIR, FT-IR, and Mössbauer spectroscopy. These data are supplemented with online mass spectrometry in each step, with reactivity tests in α-O formation and with methanol yields in stoichiometric methane activation at room temperature and pressure. We recover up to 134 μmol methanol per gram in a single cycle through H₂O/CH₃CN extraction and 183 μmol/g through steam desorption, a record yield for iron zeolites. A general scheme is proposed for iron speciation in zeolites through the steps of drying, calcination, and activation. The formation of two cohorts of α-Fe(II) is discovered, one before and one after high temperature activation. We propose the latter cohort depends on the reshuffling of aluminum in the zeolite lattice to accommodate thermodynamically favored α-Fe(II).

Identification of Kinetic and Spectroscopic Signatures of Copper Sites for Direct Oxidation of Methane to Methanol

Copper-exchanged zeolites of different topologies possess high activity in the direct conversion of methane to methanol via the chemical looping approach. Despite a large number of studies, identification of the active sites, and especially their intrinsic kinetic characteristics remain incomplete and ambiguous. In the present work, we collate the kinetic behavior of different copper species with their spectroscopic identities and track the evolution of various copper motifs during the reaction. Using time-resolved UV/Vis and in situ EPR, XAS, and FTIR spectroscopies, two types of copper monomers were identified, one of which is active in the reaction with methane, in addition to a copper dimeric species with the mono-μ-oxo structure. Kinetic measurements showed that the reaction rate of the copper monomers is somewhat slower than that of the dicopper mono-μ-oxo species, while the activation energy is two times lower.

Methane to Methanol through Heterogeneous Catalysis and Plasma Catalysis

Direct oxidation of methane to methanol (DOMTM) is attractive for the increasing industrial demand of feedstock. In this review, the latest advances in heterogeneous catalysis and plasma catalysis for DOMTM are summarized, with the aim to pinpoint the differences between both, and to provide some insights into their reaction mechanisms, as well as the implications for future development of highly selective catalysts for DOMTM.

Copper-exchanged large-port and small-port mordenite (MOR) for methane-to-methanol conversion

Zeolite mordenite (MOR) is one of the most studied zeolites for the stepwise direct conversion of methane to methanol, but it also can exist in two forms: large port and small port. Here we report that the synthesis and selection of the parent mordenite is critical for optimizing productivity, and that large-port mordenite outperforms small-port mordenite for the stepwise conversion of methane to methanol.

The synthesis and selection of large-port mordenite is critical for optimizing productivity for the direct conversion of methane to methanol.

Selective oxidation of methane to methanol on dispersed copper on alumina from readily available copper(ii) formate

The direct conversion of methane to methanol attracts increasing interest due to the availability of low-cost methane from natural gas.

Active sites and mechanisms in the direct conversion of methane to methanol using Cu in zeolitic hosts: a critical examination

In this critical review we examine the current state of our knowledge in respect of the nature of the active sites in copper containing zeolites for the selective conversion of methane to methanol.

Cu oxo nanoclusters for direct oxidation of methane to methanol: formation, structure and catalytic performance

Cu oxo nanoclusters hosted in microporous solids have emerged in the past decades as promising materials for catalyzing the selective conversion of methane to methanol.

Unwanted effects of X-rays in surface grafted copper(ii) organometallics and copper exchanged zeolites, how they manifest, and what can be done about them

Commonly applied powder densities at modern X-ray spectroscopy resources have the capacity to affect, in a deleterious manner, the results obtained from a measurement on copper(ii) containing materials.

Comparative performance of Cu-zeolites in the isothermal conversion of methane to methanol

A series of zeolites were screened for the direct conversion of methane to methanol under isothermal low-temperature stepwise conditions; of the screened zeolites, omega zeolite (MAZ) showed superior performance.