Effect of Location and Distribution of Al Sites in ZSM-5 on the Formation of Cu-Oxo Clusters Active for Direct Conversion of Methane to Methanol

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.

Continuous selective conversion of methane to methanol over a Cu-KFI zeolite catalyst using a water-O2 mixture as the oxygen source

The continuous catalytic oxidation of methane to methanol on a Cu-KFI zeolite using water-O2 mixture as the oxidant is reported. A high methanol space-time yield of 880.3 mmol molCu-1 h-1 with 83% selectivity is achieved at 450 °C. Isotopic labelling experiments show that both H2O and O2 provide the oxygen source in this catalytic methane-to-methanol conversion reaction.

Speciation and Reactivity Control of Cu-Oxo Clusters via Extraframework Al in Mordenite for Methane Oxidation

The stoichiometric conversion of methane to methanol by Cu-exchanged zeolites can be brought to highest yields by the presence of extraframework Al and high CH4 chemical potentials. Combining theory and experiments, the differences in chemical reactivity of monometallic Cu-oxo and bimetallic Cu-Al-oxo nanoclusters stabilized in zeolite mordenite (MOR) are investigated. Cu-L3 edge X-ray absorption near-edge structure (XANES), infrared (IR), and ultraviolet-visible (UV-vis) spectroscopies, in combination with CH4 oxidation activity tests, support the presence of two types of active clusters in MOR and allow quantification of the relative proportions of each type in dependence of the Cu concentration. Ab initio molecular dynamics (MD) calculations and thermodynamic analyses indicate that the superior performance of materials enriched in Cu-Al-oxo clusters is related to the activity of two μ-oxo bridges in the cluster. Replacing H2O with ethanol in the product extraction step led to the formation of ethyl methyl ether, expanding this way the applicability of these materials for the activation and functionalization of CH4. We show that competition between different ion-exchanged metal-oxo structures during the synthesis of Cu-exchanged zeolites determines the formation of active species, and this provides guidelines for the synthesis of highly active materials for CH4 activation and functionalization.

Gas-Phase Selective Oxidation of Methane into Methane Oxygenates

Methane is an abundant resource and its direct conversion into value-added chemicals has been an attractive subject for its efficient utilization. This method can be more efficient than the present energy-intensive indirect conversion of methane via syngas, a mixture of CO and H2. Among the various approaches for direct methane conversion, the selective oxidation of methane into methane oxygenates (e.g., methanol and formaldehyde) is particularly promising because it can proceed at low temperatures. Nevertheless, due to low product yields this method is challenging. Compared with the liquid-phase partial oxidation of methane, which frequently demands for strong oxidizing agents in protic solvents, gas-phase selective methane oxidation has some merits, such as the possibility of using oxygen as an oxidant and the ease of scale-up owing to the use of heterogeneous catalysts. Herein, we summarize recent advances in the gas-phase partial oxidation of methane into methane oxygenates, focusing mainly on its conversion into formaldehyde and methanol.

Light alkane oxidation over well-defined active sites in metal–organic framework materials

We review structure–catalytic property relationships for MOF materials used in the direct oxidation of light alkanes, focusing specifically on the elucidation of active site structures and probes for reaction mechanisms.

Activity of Cu-Al-Oxo Extra-Framework Clusters for Selective Methane Oxidation on Cu-Exchanged Zeolites

Cu-zeolites are able to directly convert methane to methanol via a three-step process using O₂ as oxidant. Among the different zeolite topologies, Cu-exchanged mordenite (MOR) shows the highest methanol yields, attributed to a preferential formation of active Cu-oxo species in its 8-MR pores. The presence of extra-framework or partially detached Al species entrained in the micropores of MOR leads to the formation of nearly homotopic redox active Cu-Al-oxo nanoclusters with the ability to activate CH₄. Studies of the activity of these sites together with characterization by ²⁷Al NMR and IR spectroscopy leads to the conclusion that the active species are located in the 8-MR side pockets of MOR, and it consists of two Cu ions and one Al linked by O. This Cu-Al-oxo cluster shows an activity per Cu in methane oxidation significantly higher than of any previously reported active Cu-oxo species. In order to determine unambiguously the structure of the active Cu-Al-oxo cluster, we combine experimental XANES of Cu K- and L-edges, Cu K-edge HERFD-XANES, and Cu K-edge EXAFS with TDDFT and AIMD-assisted simulations. Our results provide evidence of a [Cu₂AlO₃]²⁺ cluster exchanged on MOR Al pairs that is able to oxidize up to two methane molecules per cluster at ambient pressure.

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.

Catalytic cycle of the partial oxidation of methane to methanol over Cu-ZSM-5 revealed using DFT calculations

Density functional theory (DFT) calculations were performed to investigate the catalytic cycle of methane conversion to methanol over both [Cu2(O2)]2+ and [Cu2(μ-O)]2+ active sites in the Cu-ZSM-5 catalyst. The [Cu2(O2)]2+ site is found to be active for the partial oxidation of methane to methanol, and although it has a higher energy barrier in the methane activation step, it involves a very low energy barrier in the methanol formation step (36.3 kJ mol-1) as well as a lower methanol desorption energy (52.5 kJ mol-1). As the [Cu2(O2)]2+ active site is also thermodynamically stable, it may play an important role during methane conversion to methanol. Furthermore, the methane activation step follows the homolytic route and the heterolytic route for the [Cu2(O2)]2+ and [Cu2(μ-O)]2+ active sites, respectively, whereas the methanol formation step follows the direct radical rebound mechanism and the indirect rebound mechanism, respectively. Our calculations further indicate that the electronic properties of the reactive O atoms in the active site influence their reactivity toward methane oxidation. More specifically, the higher the spin density and the more negative the charge of the reactive O atom at the active site are, the lower the energy barrier for methane activation will be; and the more negative the charge of the hydroxyl group in the reaction intermediate during the partial oxidation of methane to methanol is, the higher energy barrier of the methanol formation step will be in the triplet state. Furthermore, we used a larger cluster model to predict the mechanism of the methane activation step and the effect of atomic charge of the O atom at the [Cu2(μ-O)]2+ and [Cu2(O2)]2+ active sites on the energy barriers of partial oxidation of methane to methanol, and the conclusions drawn employing the larger cluster model are consistent with those drawn using the smaller double-5T-ring cluster model. In addition, different from the traditional mechanism for methane activation at [Cu2(O2)]2+, which consists of two transition states, we find that the partial oxidation of methane at [Cu2(O2)]2+ can also occur via a single step by direct insertion of one of the O atoms at the active site into the C-H bond of methane.

Effect of copper ion-exchange on catalytic wet peroxide oxidation of phenol over ZSM-5 membrane

Cu-ZSM-5 zeolite membrane catalysts prepared by ion exchange method were synthesized on paper-like sintered stainless fibers (PSSFs) with three-dimensional net structure for the catalytic wet peroxide oxidation (CWPO) of phenol in structured fixed bed reactor. The experimental results exhibited that the BET of optimal catalyst was 165 m²/g with the ion exchange concentration of 0.1 M and time of 24 h, respectively, at temperature of 40 °C and one time ion exchange. The FT-IR results illustrated that band intensity was the lowest, and original Cu⁺ species and lattice oxygen were predominant in optimal catalyst according to the XPS results. Then, the effects of ion exchange concentration, time, temperature and times on catalytic performance of phenol were also investigated in structured fixed bed. It was found that the phenol was completely removed, TOC conversion (around 76.6%), high CO₂ selectivity (about 78%) and low copper leaching rate (about 30%) were achieved with only 1.91 wt% copper loading over the optimal catalyst. Finally, a reasonable reaction mechanism occurring in the presence of H₂O₂ for CWPO of phenol was proposed by analyzing the HPLC results, which indicated Fenton-like reactions were mainly based on the HO· production by catalytic decomposition of hydrogen peroxide with Cu⁺ species.

Desorption products during linear heating of copper zeolites with pre-adsorbed methanol

Study of desorption products from Cu-zeolites (MFI and CHA) during methanol-TPD using a chemical flow reactor with a gas phase FTIR spectrometer.

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.

Recent Progress in Direct Conversion of Methane to Methanol Over Copper-Exchanged Zeolites

The conversion of methane into an easily transportable liquid fuel or chemicals has become a highly sought-after goal spurred by the increasing availability of cheap and abundant natural gas. While utilization of methane for the production of syngas and its subsequent conversion via an indirect route is typical, it is cost-intensive, and alternative direct conversion routes have been investigated actively. One of the most promising directions among these is the low-temperature partial oxidation of methane to methanol over a metal-loaded zeolite, which mimics facile enzymatic chemistry of methane oxidation. Thus mono-, bi-, and trinuclear oxide compounds of iron and copper stabilized on ZSM-5 or mordenite, which are structurally analogous to those found in methane monooxygenases, have demonstrated promising catalytic performances. The two major problems of theses metal-loaded zeolites are low yield to methanol and batch-like non-catalytic reaction systems challenging to extend to an industrial scale. In this mini-review, attention was given to the direct methane oxidation to methanol over copper-loaded zeolite systems. A brief introduction on the catalytic methane direct oxidation routes and current status of the applied metal-containing zeolites including the ones with copper ions are given. Next, by analyzing the extensive experimental and theoretical data available, the consensus among the researchers to achieve the target of high methanol yield is discussed in terms of zeolite topology, active species, and reaction parameters. Finally, the recent efforts on continuous methanol production from the direct methane oxidation aiming for an industrial process are summarized.

Cu(i)-O2 oxidation reactions in a fluorinated all-O-donor ligand environment

Investigation of Cu-O2 oxidation reactivity is important in biological and anthropogenic chemistry. Zeolites are one of the most promising Cu/O based oxidation catalysts for development of industrial-scale CH4 to CH3OH conversion. Their oxidation mechanisms are not well understood, however, highlighting the importance of the investigation of molecular Cu(i)-O2 reactivity with O-donor complexes. Herein, we give an overview of the synthesis, structural properties, and O2 reactivity of three different series of O-donor fluorinated Cu(i) alkoxides: K[Cu(OR)2], [(Ph3P)Cu(μ-OR)2Cu(PPh3)], and K[(R3P)Cu(pinF)], in which OR = fluorinated monodentate alkoxide ligands and pinF = perfluoropinacolate. This breadth allowed for the exploration of the influence of the denticity of the ligand, coordination number, the presence of phosphine, and KF/O interactions on their O2 reactivity. KF/O interactions were required to activate O2 in the monodentate-ligand-only family, whereas these connections did not affect O2 activation in the bidentate complexes, potentially due to the presence of phosphine. Both families formed trisanionic, trinuclear cores of the form {Cu3(μ3-O)2}3-. Intramolecular and intermolecular substrate oxidation were also explored and found to be influenced by the fluorinated ligand. Namely, {Cu3(μ3-O)2}3- from K[Cu(OR)2] could perform both monooxygenase reactivity and oxidase catalysis, whereas those from K[(R3P)Cu(pinF)] could only perform oxidase catalysis.

The influence of zeolite morphology on the conversion of methane to methanol on copper-exchanged omega zeolite (MAZ)

The synthesis conditions and morphology of the zeolite play an enormous role in the direct conversion of methane to methanol.

Direct conversion of methane to methanol with zeolites: towards understanding the role of extra-framework d-block metal and zeolite framework type

This Perspective article highlights the latest advances in the field of direct methane to methanol conversion by zeolites containing first row, extra-framework d-block metals (Mn, Fe, Co, Ni, Cu and Zn).

Cation pair formation in copper and palladium exchanged MFI zeolite frameworks – a theoretical study

[Pd–O–Pd]²⁺ as a mediator in proton transfer from Brønsted acid sites to reactants; [Cu–OH–Cu]²⁺ stabilized by hydrogen bonds to framework oxygen.

Dual oxidase/oxygenase reactivity and resonance Raman spectra of {Cu3O2} moiety with perfluoro-t-butoxide ligands

A mechanism for the formation of O-donor trinuclear {Cu₃O₂} moiety is reported.

Effect of Brønsted acid sites on the direct conversion of methane into methanol over copper-exchanged mordenite

The direct conversion of methane into methanol was studied in a stepwise process over copper-exchanged mordenite.

Cation-exchanged zeolites for the selective oxidation of methane to methanol

Development of an ideal methane activation catalyst presents a trade-off between stability and reactivity of the active site that can be achieved by tuning the transition metal cation, active site motif and the zeolite topology.

Cu-CHA – a model system for applied selective redox catalysis

We review the structural chemistry and reactivity of copper-exchanged molecular sieves with chabazite (CHA) topology, as an industrially applied catalyst in ammonia mediated reduction of harmful nitrogen oxides (NH₃-SCR) and as a general model system for red-ox active materials (also the recent results in the direct conversion of methane to methanol are considered).