Crystal-plane effects of MFI zeolite in catalytic conversion of methanol to hydrocarbons

Interplay Between Particle Size and Hierarchy of Zeolite ZSM-5 During the CO2 -to-aromatics Process

The CO2 -to-aromatics process is a chemical reaction that converts carbon dioxide (CO2 ) into valuable petrochemical, i. e., aromatics (especially, benzene, toluene, and xylene) over the metal/zeolite bifunctional catalytic systems. These aromatics are used in producing plastics, fibers, and other industrial products, which are currently exclusively sourced from fossil-derived feedstocks. The significance of this process lies in its potential to mitigate climate change by reducing greenhouse gas emissions and simultaneously producing valuable chemicals. Consequently, these CO2 -derived aromatics can reduce the reliance on fossil fuels as a source of feedstocks, which can help to promote a more sustainable and circular economy. Owing to the existence of a wider straight channel favoring the aromatization process, zeolite ZSM-5 is extensively used to yield aromatics during CO2 hydrogenation over bifunctional (metal/zeolite) catalytic systems. To provide a better understanding of this unique property of zeolite ZSM-5, this work investigates the impact of particle size and hierarchy of the zeolite and how these govern the reaction performance and the overall selectivity. As a result, an improved understanding of the zeolite-catalyzed hydrocarbon conversion process has been obtained.

Molecular Diffusion in Nanoreactors' Pore Channel System: Measurement Techniques, Structural Regulation, and Catalytic Effects

Nanoreactors, as a new class of materials with highly enriched and ordered pore channel structures, can achieve special catalytic effects by precisely identifying and controlling the molecular diffusion behavior within the ordered pore channel system. Nanoreactors-driven molecular diffusion within the ordered pore channels can be highly dependent on the local microenvironment in the nanoreactors' pore channel system. Although the diffusion process of molecules within the ordered pore channels of nanoreactors is crucial for the regulation of catalytic behaviors, it has not yet been as clearly elucidated as it deserves to be in this study. In this review, fundamental theory and measurement techniques for molecular diffusion in the pore channel system of nanoreactors are presented, structural regulation strategies of pore channel parameters for controlling molecular diffusion are discussed, and the effects of molecular diffusion in the pore channel system on catalytic reactivity and selectivity are further analyzed. This article attempts to further develop the underlying theory of molecular diffusion within the theoretical framework of nanoreactor-driven catalysis, and the proposed perspectives may contribute to the rational design of advanced catalytic materials and the precise control of complex catalytic kinetics.

Molecular transport in zeolite catalysts: depicting an integrated picture from macroscopic to microscopic scales

Increasing social sustainability triggers the persistent progress of industrial catalysis in energy transformation and chemical production. Zeolites have been demonstrated to be pivotal catalysts in chemical industries due to their moderate acidity and versatile well-defined pore structures. However, in the context of enhancing the performances of zeolite catalysts, the perspectives on the diffusion regulations within the pores and channels in the bulk phases or external surfaces of the zeolites are often overlooked. Establishing the structure-transport-reactivity relationships in heterogeneous catalysis can provide rational guidelines to design high-performance catalysts. Herein, this tutorial review attempts to systematically depict an integrated picture of molecular transport behaviors in zeolite catalysts from macroscopic to microscopic perspectives. The advances in the accurate diffusion measurements employing both macroscopic and microscopic techniques are briefly introduced. The diffusion characteristics in zeolite catalysts under working conditions (e.g., high temperature, multi-components, and reaction coupling) are then addressed. The macroscopic internal diffusion and the microscopic diffusion occurring in the micro-zones of zeolite crystals (e.g., surface diffusion, diffusion anisotropy, and confined diffusion) are reviewed and discussed in more detail. These diffusion behaviors highly impact the underlying reaction mechanism, catalytic performances, and catalyst optimization strategies. Finally, the multi-type pore systems of practical zeolite catalysts in industrial reactors and their transport behaviors are analyzed. The fully-crystalline monolithic zeolites in the absence of binders are highlighted as rising-star catalytic materials for industrial applications. The research challenges in this field and the potential future development directions are summarized.

Controllable Orientation Growth of ZSM-5 for Methanol to Hydrocarbon Conversion: Cooperative Effects of Seed Induction and Medium pH Control

The growth orientation of ZSM-5 zeolites strongly affects product selectivity in methanol conversion reaction. Here, we proposed a versatile synthetic strategy by introducing seeds and controlling medium pH to achieve controllable orientation growth of ZSM-5. The systematic analysis of the crystallization process indicated that the introduction of seeds ensured successful crystallization in a quasi-neutral solution and the dissolution rate of seeds and aluminosilicate determined the growth orientation of ZSM-5. In the quasi-neutral solution, the slow dissolution of seeds and aluminosilicate enhanced growth advantages along the c axis. The ratio between the length of the c axis and b axis (L_c/L_b) of the obtained ZSM-5 at pH of 7 could reach 8.1, much higher than 1.8 obtained at pH of 11. No obvious impact of seed added amount on growth orientation was found, while with increasing seed crystal size, the obtained ZSM-5 showed preferred growth along the c axis. The L_c/L_b of the sample adding seeds with a size of 355 nm reached 7.9, much higher than 2.1 of the sample adding seeds with a size of 70 nm. The obtained ZSM-5 with specific growth orientation exhibited potential shape selectivity in methanol to aromatics and olefin reaction. This work opens new possibilities to tailor the orientation growth of ZSM-5 based on the seed-induced strategy under mild conditions.

Electron Diffraction Enables the Mapping of Coke in ZSM-5 Micropores Formed during Methanol-to-Hydrocarbons Conversion

Unveiling the coke formation in zeolites is an essential prerequisite for tackling the deactivation of these catalysts in the transformations of hydrocarbons. Herein, we present the direct mapping of coke in the micropores of ZSM-5 catalysts used in methanol-to-hydrocarbons conversion by single-crystal electron diffraction analysis. The latter technique revealed a polycyclic aromatic structure along the straight channel, wherein the high-quality data permit refinement of its occupancy to about 40 %. These findings were exploited to analyze the evolution of micropore coke during the reaction. Herein, coke-associated signals, which correlate with the activity loss, indicate that the nucleation of coke commences in the intersections of sinusoidal and straight channels, while the formation of coke in the straight pores occurs in the late stages of deactivation. The findings uncover an attractive method for analyzing coke deposition in the micropore domain.

ZSM-5 Catalysts for MTO: Effect and Optimization of the Tetrapropylammonium Hydroxide Concentration on Synthesis and Performance

Light olefin production from methanol using various zeolite catalysts has industrial and economic importance considering the growth of the petrochemical market. Zeolites are generally synthesized using various organic templates as structure-directing agents (SDAs). In this study, synthesis of a series of ZSM-5 zeolites was performed systematically using the microwave-assisted crystallization method, and these samples were analyzed in detail to understand the effect of the SDA concentration. Powder diffraction, N₂ adsorption, scanning electron microscopy, ammonia adsorption desorption, and ²⁷Al and ²⁹Si NMR spectroscopies were used for the characterization. The organic SDA tetrapropyl ammonium hydroxide (TPAOH/SiO₂ mole ratio = 0.0500) is found to have an optimum concentration against the silica precursor for achieving the highest crystallinity, suitable morphology, ideal pore size, effective pore volume, and tuned microporous/mesoporous area. For samples with a template concentration ratio of 0.050 or higher, ²⁹Si and ²⁷Al NMR data revealed the presence of an intact ZSM-5 structure. Using a fixed bed reactor at 500 °C and atmospheric pressure, the catalytic performance of the selected catalysts from the series is investigated for the methanol-to-olefin conversion reaction. The sample with the highest crystallinity showed the best conversion, selectivity toward light olefins, and time on stream stability. It is also worth noting that the highest crystallinity, micropore area, and micropore volume are reached for the optimum value rather than the highest template concentration. This allows for a reduction in the template concentration and a move closer to a synthesis pathway benign to environment and economics.

Size controllable synthesis of ZSM-5 zeolite and its catalytic performance in the reaction of methanol conversion to aromatics

ZSM-5 zeolites were hydrothermally synthesized with commercial silica sol, and the crystal size was controlled by adding silicalite-1 seed in the synthetic system. The crystal size of ZSM-5 was affected by the crystallization time of seed, seed content and seed size. ZSM-5 zeolites with controllable particle size in the range of 200-2200 nm could be obtained. The prepared samples with different particle sizes were used for the reaction of methanol conversion to aromatics (MTA). The results suggested that the HZSM-5 catalyst with small crystal size showed much longer catalyst lifetime and higher selectivity for C5 + hydrocarbons and aromatics, especially C9 + aromatics in the MTA reaction. Moreover, the introduction of zinc (Zn) into the HZSM-5 zeolites can considerably promote the selectivity to aromatics in the products. Zn modified HZSM-5 zeolites with different Zn loading amounts were prepared by the incipient wetness impregnation method, and the highest aromatics selectivity was obtained when the Zn loading was 1.0%. The improvement of methanol aromatization was ascribed to the synergistic effect of Brønsted acid sites and the newly formed Zn-Lewis acid sites.

Synthesis of Mesoporous Zeolites and Their Opportunities in Heterogeneous Catalysis

Currently, zeolites are one of the most important classes of heterogeneous catalysts in chemical industries owing to their unique structural characteristics such as molecular-scale size/shape-selectivity, heterogenized single catalytic sites in the framework, and excellent stability in harsh industrial processes. However, the microporous structure of conventional zeolite materials limits their applications to small-molecule reactions. To alleviate this problem, mesoporous zeolitic frameworks were developed. In the last few decades, several methods have been developed for the synthesis of mesoporous zeolites; these zeolites have demonstrated greater lifetime and better performance than their bulk microporous counterparts in many catalytic processes, which can be explained by the rapid diffusion of reactant species into the zeolite framework and facile accessibility to bulky molecules through the mesopores. Mesoporous zeolites provide versatile opportunities not only in conventional chemical industries but also in emerging catalysis fields. This review presents many state-of-the-art mesoporous zeolites, discusses various strategies for their synthesis, and details their contributions to catalytic reactions including catalytic cracking, isomerization, alkylation and acylation, alternative fuel synthesis via methanol-to-hydrocarbon (MTH) and Fischer–Tropsch synthesis (FTS) routes, and different fine-chemical syntheses.

A diffusion anisotropy descriptor links morphology effects of H-ZSM-5 zeolites to their catalytic cracking performance

Zeolite morphology is crucial in determining their catalytic activity, selectivity and stability, but quantitative descriptors of such a morphology effect are challenging to define. Here we introduce a descriptor that accounts for the morphology effect in the catalytic performances of H-ZSM-5 zeolite for C₄ olefin catalytic cracking. A series of H-ZSM-5 zeolites with similar sheet-like morphology but different c-axis lengths were synthesized. We found that the catalytic activity and stability is improved in samples with longer c-axis. Combining time-resolved in-situ FT-IR spectroscopy with molecular dynamics simulations, we show that the difference in catalytic performance can be attributed to the anisotropy of the intracrystalline diffusive propensity of the olefins in different channels. Our descriptor offers mechanistic insight for the design of highly effective zeolite catalysts for olefin cracking.

Hierarchical zeolites comprising orthogonally stacked bundles of zeolite nanosheets for catalytic and adsorption applications

The synthesis of hierarchical MFI zeolites comprising orthogonally stacked bundles of zeolite nanosheets using a new type of triblock structure-directing agents (SDAs) was reported. The textural properties, including the degree of nanosheet branching and the spacing between adjacent nanosheets, could be controlled by changing the length of the linkers in the triblock SDAs. The hierarchical pure-silica silicalite-1 materials exhibited high and stable catalytic activity for the vapor-phase Beckmann rearrangement of cyclohexanone oxime with high selectivity of ε-caprolactam. On the other hand, the hierarchical ZSM-5 materials showed high adsorption capacity of Pb²⁺ ion following a Langmuir-type adsorption behavior. After being deposited with Pd nanoparticles, the hierarchical Pd/ZSM-5 nanocomposites exhibited high activity in the aqueous-phase hydrogenation of phenol to cyclohexanone at room temperature. The results show promise of the disclosed hierarchical zeolites for catalytic and adsorption applications.

Disentangling Reaction Processes of Zeolites within Single-Oriented Channels

Establishing structure-reactivity relationships for specific channel orientations of zeolites is vital to developing new, superior materials for various applications, including oil and gas conversion processes. Herein, a well-defined model system was developed to build structure-reactivity relationships for specific zeolite-channel orientations during various catalytic reaction processes, for example, the methanol- and ethanol-to-hydrocarbons (MTH and ETH) process as well as oligomerization reactions. The entrapped and effluent hydrocarbons from single-oriented zeolite ZSM-5 channels during the MTH process were monitored by using operando UV/Vis diffuse reflectance spectroscopy (DRS) and on-line mass spectrometry (MS), respectively. The results reveal that the straight channels favor the formation of internal coke, promoting the aromatic cycle. Furthermore, the sinusoidal channels produce aromatics, (e.g., toluene) that further grow into larger polyaromatics (e.g., graphitic coke) leading to deactivation of the zeolites. This underscores the importance of careful engineering of materials to suppress coke formation and tune product distribution by rational control of the location of zeolite acid sites and crystallographic orientations.

Highly selective conversion of methanol to propylene: design of an MFI zeolite with selective blockage of (010) surfaces

As an important catalyst of methanol-to-propylene (MTP) conversion, the ZSM-5 zeolite has an anisotropic diffusion path and a large pore size, resulting in the formation of undesirable heavy aromatic by-products. Herein, we developed a surface-specific silica deposition method to block straight channels of nanosized ZSM-5 crystals selectively. By such a coating method, we can selectively suppress the yield of aromatics from the original 13% to 2.4% at 100% conversion of methanol. Trapped hydrocarbon pool species are directly confirmed by aberration-corrected S/TEM for the first time. Such a method of trapping and restricting hydrocarbon pool species in a multiscale zeolite with 10-membered rings would significantly increase its catalytic efficiency and olefin diffusion. Moreover, this provides new methodologies for zeolite structure construction and will be greatly beneficial for the industrial MTP process.

Overview of Current and Future Perspectives of Saudi Arabian Natural Clinoptilolite Zeolite: A Case Review

After a thorough review of existing studies of clinoptilolite zeolites, three areas for potential investigation of the Saudi Arabian zeolites were found. They are the characterizations, the catalytic activity, active sites, and uses of natural clinoptilolite zeolites. First, no analysis is available worldwide to compare the percentage weight of local zeolites with those sourced from other countries, nor does one exist for the establishment on the zeolite conversion of MBOH with water on acidic catalysts at lower temperatures. Secondly, a review of current literature on the topic revealed that basic and active sites of Saudi Arabian zeolites have yet to be examined. Future investigation of zeolite catalytic activity can be achieved by methyl butynol test reaction (MBOH) and absorption-desorption of ammonia. In the characterization of a range of international materials, the methyl butynol test reaction was utilized, including on natural zeolites, natural clays, and synthesized hydrotalcites. However, the catalytic performance of natural Saudi Arabian clinoptilolite zeolites by test reaction of MBOH conversion has not been yet investigated. Therefore, this article also includes an outline of the general testing conditions and parameters required to execute the accurate characterization of local Saudi clinoptilolite under optimal test conditions. Likewise, knowledge of the important active acidic centers of local materials is prescribed. This can be ascertained by determining the conditions together with the test parameters for the application of the “temperature-programmed desorption of ammonia” method in order to obtain an accurate determination of local Saudi clinoptilolite acidic centers. Additionally, an outline of the catalytic activity of worldwide clinoptilolite is given in this article together with kinetic investigations of other sources for the clinoptilolite zeolite in order to form the basis for the testing of local Saudi clinoptilolite. The percentage average of chemical composition (Wt.%) of natural clinoptilolite from various countries is also included. Finally, a future research plan is proposed here. This will form the basis for a complete study or survey to be compiled detailing the modifications needed to increase the surface areas for Saudi natural clinoptilolite zeolites using different methods of modifications. This could enhance its application as acid catalysts for use in the retardation of coke formation and for membrane separation on cationic exchange.