Molecular shape-selectivity of MFI zeolite nanosheets in n-decane isomerization and hydrocracking

Synthesis, Characterization, and Application of Amorphous Silica-Aluminas Support for Fischer-Tropsch Wax Hydrocracking Catalysts

High-performance amorphous silica-aluminas (ASAs) were prepared prior to the formation of the 10-membered ring (10-MR) ZSM-5 zeolite by regulating the hydrothermal processing time. Their structures, morphologies, acidity properties, and Si-Al coordination were well studied. Particularly, a facile FTIR method of in-situ adsorbing bulky 2,6-dimethlypyridine followed by pyridine adsorption was innovatively utilized to quantify the Brønsted acid sites in micropores. All the ASAs samples were transformed into catalysts by loading with 0.5 wt % Pt. The structure-activity relationship, especially from the strength, density, and location of Brønsted acid sites, was investigated by Fischer-Tropsch synthesis (FTS) wax hydrocracking. The evaluation results showed that the medium strong Brønsted acid sites located on the external surface played a crucial role in the activity. Contrary to the general belief that larger pores favor the production of heavy cracking fractions, the ASAs with a 10-MR microporous structure proved to be more effective for diesel production than those with a 12-membered ring (12-MR). Strong Brønsted acid sites in micropores were less conducive to diesel production mainly due to stronger adsorption at these sites and steric hindrance from the microporous system. Furthermore, the Pt/AS-20 catalyst with few intramicropore Brønsted acid sites exhibited high diesel selectivity (83.3%) at 50.5% conversion under industrially relevant reaction conditions, which provides a significant opportunity to develop FTS wax hydrocracking catalysts more rationally.

Effect of the nickel impregnation method on clay supports in the hydroconversion reaction of n-decane

Ni bifunctional catalysts supported on vermiculite, halloysite and bentonite previously modified by means of delamination or acid treatment were synthesized.

Hierarchical COK-X Materials for Applications in Catalysis and Adsorptive Separation and Controlled Release

Over the years, COK has developed a family of silicate materials and metal–organic framework hybrids with hierarchical porosity and functionality, coined zeogrids, zeotiles, and COK-x (stemming from the Flemish name of the laboratory “Centrum voor Oppervlaktechemie en Katalyse”). Several of these materials have unique features relevant to heterogeneous catalysis, molecular separation, and controlled release and found applications in the field of green chemistry, environmental protection, and pharmaceutical formulation. Discovery of a new material typically occurs by serendipity, but the research was always guided by hypothesis. This review provides insight in the process of tuning initial research hypotheses to match material properties to specific applications. This review describes the synthesis, structure, properties, and applications of 12 different materials. Some have simple synthesis protocols, facilitating upscaling and reproduction and rendering them attractive also in this respect.

Designing Sites in Heterogeneous Catalysis: Are We Reaching Selectivities Competitive With Those of Homogeneous Catalysts?

A critical review of different prominent nanotechnologies adapted to catalysis is provided, with focus on how they contribute to the improvement of selectivity in heterogeneous catalysis. Ways to modify catalytic sites range from the use of the reversible or irreversible adsorption of molecular modifiers to the immobilization or tethering of homogeneous catalysts and the development of well-defined catalytic sites on solid surfaces. The latter covers methods for the dispersion of single-atom sites within solid supports as well as the use of complex nanostructures, and it includes the post-modification of materials via processes such as silylation and atomic layer deposition. All these methodologies exhibit both advantages and limitations, but all offer new avenues for the design of catalysts for specific applications. Because of the high cost of most nanotechnologies and the fact that the resulting materials may exhibit limited thermal or chemical stability, they may be best aimed at improving the selective synthesis of high value-added chemicals, to be incorporated in organic synthesis schemes, but other applications are being explored as well to address problems in energy production, for instance, and to design greener chemical processes. The details of each of these approaches are discussed, and representative examples are provided. We conclude with some general remarks on the future of this field.

Insights on a Hierarchical MFI Zeolite: A Combined Spectroscopic and Catalytic Approach for Exploring the Multilevel Porous System Down to the Active Sites

The hierarchization of zeolites to overcome the major drawbacks related to molecular diffusion limitation in micropores is a popular concept in heterogeneous catalysis. Despite the constant increase of new synthesis strategies to produce such hierarchical systems, the deep knowledge of their structural arrangement and how the zeolitic lattice is organized in a multilevel porous system is often missing. This information is essential to design a structure, tuning the porosity and the distribution of easily accessible active sites, and successively controlling the catalytic properties. In the present work, the synthesis of one of the most sophisticated forms of the hierarchical ZSM-5 zeolite has been reproduced, obtaining two multilevel porous materials with different crystallinity degrees, with the final aim of investigating and clarifying the finest features of their active sites. For this purpose, an extended characterization step by means of a unique multitechnique approach has been performed, thus revealing the active site nature, abundance, and distribution. IR spectroscopy with different molecular probes and a targeted catalytic test based on the hydroconversion reaction of n-decane were the toolbox for disclosing how the MFI lattice takes part in the hierarchical structure and how it, working in synergy with the mesoporous system, confers to this material a totally new shape-size selectivity. Merging the information obtained for the synthesized hierarchical zeolite with the characterization results of two reference materials (a mesoporous aluminum-containing MCM-41 and a microporous commercial ZSM-5), it was possible to define an internal and external map of the pore network of this complex and unique molecular sieve, where strong Brønsted acidic sites are located at the mouth of the MFI micropores and, at the same time, exposed at the surface of the mesoporous channels. Hence, the possibility of easily releasing bulky products is ensured and the application possibilities of the MFI lattice are expanded beyond cracking reactions.

Seed-sol-assisted construction of a coffin-shaped multilamellar ZSM-5 single crystal using CTAB

A coffin-shaped multilamellar ZSM-5 single crystal (CMZS) composed of orderly stacked 2D nanosheets (70-100 nm) was synthesized via the use of cetyltrimethylammonium bromide (CTAB) in the presence of silicalite-1 seed sol. This crystallization strategy opens a facile approach for industrial applications using CMZS in the catalytic conversion of bulky molecules.

Two-Dimensional MFI Zeolite Nanosheets Exfoliated by Surfactant Assisted Solution Process

Two-dimensional (2D) zeolite nanosheets are important for the synthesis of high flux zeolite membranes due to their lateral size in a preferred orientation. A way to obtain 2D zeolite nanosheets is to exfoliate interlocked structures generated during the hydrothermal synthesis. The mechanical and polymer assisted exfoliation process leads to mechanical damage in nanosheets and short lateral size. In the present study, polyvinylpyrrolidone (PVP) was introduced as an exfoliation agent and dispersant, so that multilamellar interlocked silicalite-1 zeolite nanosheets successfully exfoliated into a large lateral size (individual nanosheets 500~1200 nm). The good exfoliation behavior was due to the strong penetration of PVP into multilamellar nanosheets. Sonication assisted by mild milling helps PVP molecules to penetrate through the lamellar structure, contributing to the expansion of the distance between adjacent layers and thus decreasing the interactions between each layer. In addition, the stability of exfoliated nanosheets was evaluated with a series of organic solvents. The exfoliated nanosheets were well dispersed in n-butanol and stable for 30 days. Therefore, the PVP-assisted solution-based exfoliation process provides high aspect ratio MFI zeolite nanosheets in organic solvents for a long period.

Impregnating Subnanometer Metallic Nanocatalysts into Self-Pillared Zeolite Nanosheets

Impregnation is the most commonly used approach to prepare supported metal catalysts in industry. However, this method suffers from the formation of large metal particles with uneven dispersion, poor thermal stability, and thus unsatisfied catalytic performance. Here, we demonstrate that the self-pillared MFI zeolite (silicalite-1 and ZSM-5) nanosheets with larger surface area and abundant Si-OH groups are ideal supports to immobilize ultrasmall monometallic (e.g., Rh and Ru) and various bimetallic clusters via simple incipient wetness impregnation method. The loaded subnanometric metal clusters are uniformly dispersed within sinusoidal five-membered rings of MFI and remain stable at high temperatures. The Rh/SP-S-1 is highly efficient in ammonia borane (AB) hydrolysis, showing a TOF value of 430 mol_H2 mol_Rh^-1 min^-1 at 298 K, which is more than 6-fold improvement over that of nanosized zeolite-supported Rh catalyst and even comparable with that of zeolite-supported Rh single-atom catalyst. Because of the synergistic effect between bimetallic Rh-Ru clusters and zeolite acidity, the H₂ generation rate from AB hydrolysis over Rh_0.8Ru_0.2/SP-ZSM-5-100 reaches up to 1006 mol_H2 mol_metal^-1 min^-1 at 298 K, and also shows record activities in cascade hydrogenation of various nitroarenes by coupling with the hydrolysis of AB. This work demonstrates that zeolite nanosheets are excellent supports to anchor diverse ultrasmall metallic species via the simple impregnation method, and the obtained nanocatalysts can be applied in various industrially important catalytic reactions.

Spherical core-shell alumina support particles for model platinum catalysts

γ- and δ-alumina are popular catalyst support materials. Using a hydrothermal synthesis method starting from aluminum nitrate and urea in diluted solution, spherical core-shell particles with a uniform particle size of about 1 μm were synthesized. Upon calcination at 1000 °C, the particles adopted a core-shell structure with a γ-alumina core and δ-alumina shell as evidenced by 2D and 3D electron microscopy and 27Al magic angle spinning nuclear magnetic resonance spectroscopy. The spherical alumina particles were loaded with Pt nanoparticles with an average size below 1 nm using the strong electrostatic adsorption method. Electron microscopy and energy dispersive X-ray spectroscopy revealed a homogeneous platinum dispersion over the alumina surface. These platinum loaded alumina spheres were used as a model catalyst for bifunctional catalysis. Physical mixtures of Pt/alumina spheres and spherical zeolite particles are equivalent to catalysts with platinum deposited on the zeolite itself facilitating the investigation of the catalyst components individually. The spherical alumina particles are very convenient supports for obtaining a homogeneous distribution of highly dispersed platinum nanoparticles. Obtaining such a small Pt particle size is challenging on other support materials such as zeolites. The here reported and well-characterized Pt/alumina spheres can be combined with any zeolite and used as a bifunctional model catalyst. This is an interesting strategy for the examination of the acid catalytic function without the interference of the supported platinum metal on the investigated acid material.

Selective regulation of n-dodecane isomerization and cracking performance in Pt/beta catalysts via orientation control of Brønsted acid site distribution

The isomerization and cracking performance of n-dodecane have been successfully regulated by the orientation control of Brønsted acid site distribution in Beta zeolites.

Efficient Conversion of Pine Wood Lignin to Phenol

Obtaining chemical building blocks from biomass is attractive for meeting sustainability targets. Herein, an effective approach was developed to convert the lignin part of woody biomass into phenol, which is a valuable base chemical. Monomeric alkylmethoxyphenols were obtained from pinewood, rich in guaiacol-type lignin, through Pt/C-catalyzed reductive depolymerization. In a second step, an optimized MoP/SiO2 catalyst was used to selectively remove methoxy groups in these lignin monomers to generate 4-alkylphenols, which were then dealkylated by zeolite-catalyzed transalkylation to a benzene stream. The overall yield of phenol based on the initial lignin content in pinewood was 9.6 mol %.

The diquaternary ammonium surfactant-directed synthesis of single-unit-cell nanowires of ZSM-5 zeolite

Hierarchical ultrathin ZSM-5 zeolite samples with controllable crystal growth directions were realized by designing bifunctional soft templates with different hydrophobic alkyl chain groups. MFI-type crystal growth along the a-c plane and stacking along the b-axis could be controlled to form nanowires of ZSM-5, which exhibited better catalytic activity for phenol hydroxylation than nanosheets of ZSM-5.

Function of well-established mesoporous layers of recrystallized ZSM-22 zeolites in the catalytic performance of n-alkane isomerization

The effect of mesoporous layers of recrystallized ZSM-22/MCM-41 material on isomerization performance was systemically investigated using several probe molecules.

Mo or W catalysts promoted with Ni or Co supported on modified bentonite for decane hydroconversion

A clay mineral-type modified bentonite, produced via delamination and subsequent incorporation of AlZr and AlCe species to modulate their acid properties, was used to obtain bifunctional catalysts with the incorporation of NiMo, CoMo, NiW and CoW.

Designing a Mesoporous Zeolite Catalyst for Products Optimizing in n-Decane Hydrocraking

Mesoporous ZSM-5 zeolite is developed to enhance the catalytic performance in a hydrocracking reaction. The generated mesopores and mesoporous channels in the new catalyst supply more opportunities for reactant accessing the active sites according to the better mass transfer and diffusion. Meanwhile, the acidity of the mesoporous catalyst is also weakened because of the removal of Si and Al species from its MFI structure, which makes the products distribution drift to more valued chemicals such as olefins. In the modified mesoporous ZSM-5 zeolites via different metallic promoters, the olefins’ selectivity increases as the alkalinity of the catalyst increases. The reason for this is that the formed olefins will be further hydrogenated into corresponding alkanes immediately over the extremely acidic zeolite catalyst. Hence, the moderate alkalinity will limit this process, while at the same time the remaining olefins products will too. Furthermore, the Pd-based mesoporous ZSM-5 zeolite shows an excellent n-decane conversion and high propane selectivity due to the occurrence of hydrogen spillover via the Pd promoter. The phenomenon of hydrogen spillover supplies more chemisorbed sites of hydrogen atoms for hydrocracking and hydrogenating in this reaction. In short, this study explores the important effect factors in n-decane hydrocracking reaction activity and products distribution. It also shows a potential for the further industrial application of petroleum-derived fuel hydrocracking according to the optimized products distribution under metallic promoted mesoporous zeolite.

Incorporation of Brazilian Diatomite in the Synthesis of An MFI Zeolite

The need for greener procedures is a fact to reduce residues, to decrease industrial costs, and to accomplish the environmental agreements. In an attempt to address this question, we propose the addition of a natural resource, Brazilian diatomite, to an MFI zeolite traditional synthesis. We have characterized the resulting product with different techniques, such as X-ray diffraction, microscopy, and gas sorption, and, afterwards, we evaluate the greenness of the process by the Green Star method. The results were promising: We obtained the desired topology in the form of small crystallites aggregated and a pore diameter of 0.8 nm. In conclusion, the product has the necessary characteristics for an adsorption or catalytic future tests and escalation to industrial production.

Recent advances in preparation methods for catalytic thin films and coatings

Advancements in the preparation methods and applications of catalytic thin films and coatings are briefly summarized.

2D Oxide Nanomaterials to Address the Energy Transition and Catalysis

2D oxide nanomaterials constitute a broad range of materials, with a wide array of current and potential applications, particularly in the fields of energy storage and catalysis for sustainable energy production. Despite the many similarities in structure, composition, and synthetic methods and uses, the current literature on layered oxides is diverse and disconnected. A number of reviews can be found in the literature, but they are mostly focused on one of the particular subclasses of 2D oxides. This review attempts to bridge the knowledge gap between individual layered oxide types by summarizing recent developments in all important 2D oxide systems including supported ultrathin oxide films, layered clays and double hydroxides, layered perovskites, and novel 2D-zeolite-based materials. Particular attention is paid to the underlying similarities and differences between the various materials, and the subsequent challenges faced by each research community. The potential of layered oxides toward future applications is critically evaluated, especially in the areas of electrocatalysis and photocatalysis, biomass conversion, and fine chemical synthesis. Attention is also paid to corresponding novel 3D materials that can be obtained via sophisticated engineering of 2D oxides.

Catalytic Hydroisomerization of Long-Chain Hydrocarbons for the Production of Fuels

Hydroisomerization of long chain paraffins for the production of branched alkanes has recently been intensively studied due to a large availability of these compounds. The most interesting research topics have been the development of novel bifunctional catalysts to maximize the yield of isomers and to suppress the cracking reactions. Since both of these reactions are catalyzed by Brønsted acid sites, the optimum catalyst exhibits equal amounts of metal and acid sites, and it facilitates rapid mass transfer. Thus, several hierarchical and nano-shaped zeolites have been developed, in addition to composite catalysts containing both micro- and mesoporous phases. In addition to catalyst development, the effect of the reactant structure, optimal reaction conditions, catalyst stability and comparison of batch vs continuous operations have been made.

Cooperative structure direction of organosilanes and tetrapropylammonium hydroxide to generate hierarchical ZSM-5 zeolite with controlled porous structure

Hierarchical ZSM-5 zeolites of controlled porous structure were realized by the cooperative direction of organosilanes and tetrapropylammonium hydroxide.