Effects of Coke Deposits on the Catalytic Performance of Large Zeolite H-ZSM-5 Crystals during Alcohol-to-Hydrocarbon Reactions as Investigated by a Combination of Optical Spectroscopy and Microscopy

Addition of Pore-Forming Agents and Their Effect on the Pore Architecture and Catalytic Behavior of Shaped Zeolite-Based Catalyst Bodies

Porous materials, such as solid catalysts, are used in various chemical reactions in industry to produce chemicals, materials, and fuels. Understanding the interplay between pore architecture and catalytic behavior is of great importance for synthesizing a better industrial-grade catalyst material. In this study, we have investigated the modification of the pore architecture of zeolite-based alumina-bound shaped catalyst bodies via the addition of different starches as pore-forming agents. A combination of microscopy techniques allowed us to visualize the morphological changes induced and make a link between pore architecture, molecular transport, and catalytic performance. As for the catalytic performance in the methanol-to-hydrocarbons (MTH) reaction, pore-forming agents resulted in up to ∼12% higher conversion, an increase of 74% and 77% in yield (14% and 13% compared to 8.6% and 7.7% of the reference sample in absolute yields) toward ethylene and propylene, respectively, and an improved lifetime of the catalyst materials.

Carbocation chemistry confined in zeolites: spectroscopic and theoretical characterizations

Acid-catalyzed reactions inside zeolites are one type of broadly applied industrial reactions, where carbocations are the most common intermediates of these reaction processes, including methanol to olefins, alkene/aromatic alkylation, and hydrocarbon cracking/isomerization. The fundamental research on these acid-catalyzed reactions is focused on the stability, evolution, and lifetime of carbocations under the zeolite confinement effect, which greatly affects the efficiency, selectivity and deactivation of zeolite catalysts. Therefore, a profound understanding of the carbocations confined in zeolites is not only beneficial to explain the reaction mechanism but also drive the design of new zeolite catalysts with ideal acidity and cages/channels. In this review, we provide both an in-depth understanding of the stabilization of carbocations by the pore confinement effect and summary of the advanced characterization methods to capture carbocations in zeolites, including UV-vis spectroscopy, solid-state NMR, fluorescence microscopy, IR spectroscopy and Raman spectroscopy. Also, we clarify the relationship between the activity and stability of carbocations in zeolite-catalyzed reactions, and further highlight the role of carbocations in various hydrocarbon conversion reactions inside zeolites with diverse frameworks and varying acidic properties.

Probing coke formation during the methanol-to-hydrocarbon reaction on zeolite ZSM-5 catalyst at the nanoscale using tip-enhanced fluorescence microscopy

The deactivation mechanism of the widely used zeolite ZSM-5 catalysts remains unclear to date due to the lack of analytical techniques with sufficient sensitivity and/or spatial resolution. Herein, a combination of hyperspectral confocal fluorescence microscopy (CFM) and tip-enhanced fluorescence (TEFL) microscopy is used to study the formation of different coke (precursor) species involved in the deactivation of zeolite ZSM-5 during the methanol-to-hydrocarbon (MTH) reaction. CFM submicron-scale imaging shows a preferential formation of graphite-like coke species at the edges of zeolite ZSM-5 crystals within 10 min of the MTH reaction (i.e., working catalyst), whilst the amount of graphite-like coke species uniformly increased over the entire zeolite ZSM-5 surface after 90 min (i.e., deactivated catalyst). Furthermore, TEFL nanoscale imaging with ∼35 nm spatial resolution revealed that formation of coke species on the zeolite ZSM-5 surface is non-uniform and a relatively larger amount of coke is formed at the crystal steps, indicating a higher initial catalytic activity.

Inhomogeneities in coke formation during methanol-to-hydrocarbon reaction on the zeolite ZSM-5 catalyst are imaged with ∼35 nm spatial resolution using tip-enhanced fluorescence microscopy.

Conversion of methanol to hydrocarbons over H-MCM-22 zeolite: deactivation behaviours related to acid density and distribution

The deactivation of H-MCM-22 zeolites with different Si/Al ratios can be roughly divided into three stages: first the rapid deactivation of the supercages, the second reaction with slow coking and the deactivation stage with rapid coking mainly on the external pockets.

Dehydroaromatization of methane over noble metal loaded Mo/H-ZSM-5 zeolite catalysts

Dehydroaromatization of methane (MDA) reaction was investigated over platinum modified Mo/H-ZSM-5 catalysts which were pre-carbided at 750 °C. The influence of platinum on the catalytic performance and product selectivity of Mo/H-ZSM-5 catalysts for the MDA reaction at 700 °C were studied. The presence of platinum led to a slight decrease in methane conversion from 7.5 to 4.2%. Aromatic selectivities above 90% were obtained with catalysts containing low platinum loadings (0.5 and 1.0 wt.%), with benzene being the most prominent product. A decrease in coke selectivity and coke deposits was noted with the platinum modified Mo/H-ZSM-5 zeolite catalysts. A comparative study was performed to compare platinum, palladium and ruthenium promoted Mo/H-ZSM-5 zeolite catalysts with un-promoted Mo/H-ZSM-5. The ruthenium promoted catalyst proved to be superior in catalytic performance, with a higher methane conversion obtained than that found for platinum promoted and palladium promoted Mo/H-ZSM-5 catalysts. Benzene selectivity of about 60% was obtained for ruthenium and palladium promoted Mo/H- ZSM-5 catalysts and the total aromatic selectivity was maintained at 90%. TGA results showed a total reduction of 50% by weight of carbon deposited on the promoted Mo/H-ZSM-5 catalyst.

Graphic abstract

Finned zeolite catalysts

There is growing evidence for the advantages of synthesizing nanosized zeolites with markedly reduced internal diffusion limitations for enhanced performances in catalysis and adsorption. Producing zeolite crystals with sizes less than 100 nm, however, is non-trivial, often requires the use of complex organics and typically results in a small product yield. Here we present an alternative, facile approach to enhance the mass-transport properties of zeolites by the epitaxial growth of fin-like protrusions on seed crystals. We validate this generalizable methodology on two common zeolites and confirm that fins are in crystallographic registry with the underlying seeds, and that secondary growth does not impede access to the micropores. Molecular modelling and time-resolved titration experiments of finned zeolites probe internal diffusion and reveal substantial improvements in mass transport, consistent with catalytic tests of a model reaction, which show that these structures behave as pseudo-nanocrystals with sizes commensurate to that of the fin. This approach could be extended to the rational synthesis of other zeolite and aluminosilicate materials.

Lower olefins from methane: recent advances

Modern methods for methane conversion to lower olefins having from 2 to 4 carbon atoms per molecule are generalized. Multistage processing of methane into ethylene and propylene via syngas or methyl chloride and methods for direct conversion of CH4 to ethylene are described. Direct conversion of syngas to olefins as well as indirect routes of the process via methanol or dimethyl ether are considered. Particular attention is paid to innovative methods of olefin synthesis. Recent achievements in the design of catalysts and development of new techniques for efficient implementation of oxidative coupling of methane and methanol conversion to olefins are analyzed and systematized. Advances in commercializing these processes are pointed out. Novel catalysts for Fischer – Tropsch synthesis of lower olefins from syngas and for innovative technique using oxide – zeolite hybrid catalytic systems are described. The promise of a new route to lower olefins by methane conversion via dimethyl ether is shown. Prospects for the synthesis of lower olefins via methyl chloride and using non-oxidative coupling of methane are discussed. The most efficient processes used for processing of methane to lower olefins are compared on the basis of degree of conversion of carbonaceous feed, possibility to integrate with available full-scale production, number of reaction stages and thermal load distribution.

The bibliography includes 346 references.

Atom Probe Tomography for Catalysis Applications: A Review

Atom probe tomography is a well-established analytical instrument for imaging the 3D structure and composition of materials with high mass resolution, sub-nanometer spatial resolution and ppm elemental sensitivity. Thanks to recent hardware developments in Atom Probe Tomography (APT), combined with progress on site-specific focused ion beam (FIB)-based sample preparation methods and improved data treatment software, complex materials can now be routinely investigated. From model samples to complex, usable porous structures, there is currently a growing interest in the analysis of catalytic materials. APT is able to probe the end state of atomic-scale processes, providing information needed to improve the synthesis of catalysts and to unravel structure/composition/reactivity relationships. This review focuses on the study of catalytic materials with increasing complexity (tip-sample, unsupported and supported nanoparticles, powders, self-supported catalysts and zeolites), as well as sample preparation methods developed to obtain suitable specimens for APT experiments.

Methane-to-methanol conversion over zeolite Cu-SSZ-13, and its comparison with the selective catalytic reduction of NOx with NH3

Using in situ FT-IR and operando UV-vis-NIR DRS, performed on a series of different Cu–ion-exchanged SSZ-13 zeolites, both a mono-nuclear site or a dimeric copper active site are consistent for methane-to-methanol activation.

Influence of the Reaction Temperature on the Nature of the Active and Deactivating Species During Methanol-to-Olefins Conversion over H-SAPO-34

The selectivity toward lower olefins during the methanol-to-olefins conversion over H-SAPO-34 at reaction temperatures between 573 and 773 K has been studied with a combination of operando UV-vis diffuse reflectance spectroscopy and online gas chromatography. It was found that the selectivity toward propylene increases in the temperature range of 573-623 K, while it decreases in the temperature range of 623-773 K. The high degree of incorporation of olefins, mainly propylene, into the hydrocarbon pool affects the product selectivity at lower reaction temperatures. The nature and dynamics of the active and deactivating hydrocarbon species with increasing reaction temperature were revealed by a non-negative matrix factorization of the time-resolved operando UV-vis diffuse reflectance spectra. The active hydrocarbon pool species consist of mainly highly methylated benzene carbocations at temperatures between 573 and 598 K, of both highly methylated benzene carbocations and methylated naphthalene carbocations at 623 K, and of only methylated naphthalene carbocations at temperatures between 673 and 773 K. The operando spectroscopy results suggest that the nature of the active species also influences the olefin selectivity. In fact, monoenylic and highly methylated benzene carbocations are more selective to the formation of propylene, whereas the formation of the group of low methylated benzene carbocations and methylated naphthalene carbocations at higher reaction temperatures (i.e., 673 and 773 K) favors the formation of ethylene. At reaction temperatures between 573 and 623 K, catalyst deactivation is caused by the gradual filling of the micropores with methylated naphthalene carbocations, while between 623 and 773 K the formation of neutral poly aromatics and phenanthrene/anthracene carbocations are mainly responsible for catalyst deactivation, their respective contribution increasing with increasing reaction temperature. Methanol pulse experiments at different temperatures demonstrate the dynamics between methylated benzene and methylated naphthalene carbocations. It was found that methylated naphthalene carbocations species are deactivating and block the micropores at low reaction temperatures, while acting as the active species at higher reaction temperatures, although they give rise to the formation of extended hydrocarbon deposits.