Finding the active species: The conversion of methanol to aromatics over Zn-ZSM-5/alumina shaped catalysts

Propane Dehydrogenation on PtxZny Active Sites in Silicalite-1

The improvement of Pt-based catalysts for propane dehydrogenation (PDH) has progressed by recent investigations that have identified Zn as a promising promoter for Pt subnanometer catalysts. It is desirable to gain insights into the structure, stability, and activity of such active sites and the factors that influence them, such as Zn : Pt ratio, Pt coordination and nuclearity. Here, we employ density functional theory and microkinetic simulations to investigate the stability of PtxZny (x=1-3, y=0-3) active sites grafted on silanols of Silicalite-1 and the PDH activity of Pt. We find that the coordination of a Pt atom to a nest of grafted Zn(II) atoms increases the stability of the Pt1Zny sites, whose activity is similar for y=0-2 and drops dramatically for y>2. We further demonstrate, via linear scaling relations and microkinetic simulations, that the turnover frequency obeys a volcano law as a function of propylene binding strength. The Pt2Zn1 and Pt3Zn1 sites are stable and exhibit activity similar to Pt1Zn2, but only Pt1Zn2 manifests reaction kinetics consistent with experimental data, strongly suggesting the active site composition in the synthesized catalyst samples. The methodology presented here suggests a general strategy for deducing active site information such as composition through simple kinetic experiments.

The synergistic interplay of hierarchy, crystal size, and Ga-promotion in the methanol-to-aromatics process over ZSM-5 zeolites

In the context of advancing social modernization, the projected shortfall in the demand for renewable aromatic hydrocarbons is expected to widen, influenced by industries like high-end materials, pharmaceuticals, and consumer goods. Sustainable methods for aromatic production from alternative sources, particularly the methanol-to-aromatics (MTA) process using zeolite ZSM-5 and associated with the "methanol economy", have garnered widespread attention. To facilitate this transition, our project consolidates conventional strategies that impact aromatics selectivity-such as using hierarchical zeolites, metallic promoters, or altering zeolite physicochemical properties-into a unified study. Our findings demonstrate the beneficial impact of elongated crystal size and heightened zeolite hierarchy on preferential aromatics selectivity, albeit through distinct mechanisms involving the consumption of shorter olefins. While metallic promoters enhance MTA performance, crystal size, and hierarchy remain pivotal in achieving the maximized aromatics selectivity. This study contributes to a deeper understanding of achieving superior aromatics selectivity through physicochemical modifications in zeolite ZSM-5 during MTA catalysis, thereby advancing the field's comprehension of structure-reactivity relationships.

Unraveling the Structure-Activity-Stability Relationship over Gallium-Promoted HZSM-5 Nanocrystalline Aggregates for Propane Aromatization

The aromatization of light alkane is an important process for increasing the aromatic production and utilization efficiency of light alkane resources simultaneously. Herein, Ga-modified HZSM-5 catalysts were prepared and investigated by a series of characterization techniques such as X-ray diffraction, nuclear magnetic resonance spectroscopy, transmission electron microscopy, N2 adsorption-desorption, and NH3 temperature-programmed desorption to study their physicochemical properties. The catalytic performance in propane aromatization was also tested. Importantly, the structure-activity relationship, reaction pathway, and coke formation mechanism in propane aromatization were systematically explored. It was found that different Ga introduction methods would affect the amounts of Brønsted and Lewis acid sites, and Ga-HZSM-5 prepared by the hydrothermal method exhibited higher amounts of Brønsted and Lewis acid sites but a lower B/L ratio. As a result, Ga-HZSM-5 showed higher propane conversion and benzene, toluene, and xylene yield compared with that of Ga2O3/HZSM-5. The propane aromatization reaction pathway indicated that propane dehydrogenation to propene was a crucial step for aromatic formation. The increase of the Lewis acid density in Ga-HZSM-5 can effectively improve the dehydrogenation rate and promote the aromatization reaction. Furthermore, the formation of coke species was studied by thermogravimetry-mass spectrometry and Raman approaches, the results of which indicated that the graphitization degree of coke formed over spent Ga-HZSM-5 is lower, resulting in enhanced anticoking stability.

Liquid metals for boosting stability of zeolite catalysts in the conversion of methanol to hydrocarbons

Methanol-to-hydrocarbons (MTH) process has been considered one of the most practical approaches for producing value-added products from methanol. However, the commonly used zeolite catalysts suffer from rapid deactivation due to coke deposition and require regular regeneration treatments. We demonstrate that low-melting-point metals, such as Ga, can effectively promote more stable methanol conversion in the MTH process by slowing coke deposition and facilitating the desorption of carbonaceous species from the zeolite. The ZSM-5 zeolite physically mixed with liquid gallium exhibited an enhanced lifetime in the MTH reaction, which increased by a factor of up to ~14 as compared to the parent ZSM-5. These results suggest an alternative route to the design and preparation of deactivation-resistant zeolite catalysts.

From Lab to Technical CO2 Hydrogenation Catalysts: Understanding PdZn Decomposition

The valorization of CO₂ to produce high-value chemicals, such as methanol and hydrocarbons, represents key technology in the future net-zero society. Herein, we report further investigation of a PdZn/ZrO₂ + SAPO-34 catalyst for conversion of CO₂ and H₂ into propane, already presented in a previous work. The focus of this contribution is on the scale up of this catalyst. In particular, we explored the effect of mixing (1:1 mass ratio) and shaping the two catalyst functions into tablets and extrudates using an alumina binder. Their catalytic performance was correlated with structural and spectroscopic characteristics using methods such as FT-IR and X-ray absorption spectroscopy. The two scaled-up bifunctional catalysts demonstrated worse performance than a 1:1 mass physical mixture of the two individual components. Indeed, we demonstrated that the preparation negatively affects the element distribution. The physical mixture is featured by the presence of a PdZn alloy, as demonstrated by our previous work on this sample and high hydrocarbon selectivity among products. For both tablets and extrudates, the characterization showed Zn migration to produce Zn aluminates from the alumina binder phase upon reduction. Moreover, the extrudates showed a remarkable higher amount of Zn aluminates before the activation rather than the tablets. Comparing tablets and extrudates with the physical mixture, no PdZn alloy was observed after activation and only the extrudates showed the presence of metallic Pd. Due to the Zn migration, SAPO-34 poisoning and subsequent deactivation of the catalyst could not be excluded. These findings corroborated the catalytic results: Zn aluminate formation and Pd⁰ separation could be responsible for the decrease of the catalytic activity of the extrudates, featured by high methane selectivity and unconverted methanol, while tablets displayed reduced methanol conversion to hydrocarbons mainly attributed to the partial deactivation of the SAPO-34.

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.

Effect of H-ZSM-5 zeolite content on the intrinsic kinetics of methanol dehydration to dimethyl ether over H-ZSM-5/Al2O3 molded catalyst

The catalyst composition affects the activation energy and methanol absorption heat, whereas the mechanism of methanol absorption (associative or dissociative) and pre-exponential factor exhibit no sensitivity to catalyst composition.

Multifunctional Catalyst Combination for the Direct Conversion of CO2 to Propane

The production of carbon-rich hydrocarbons via CO₂ valorization is essential for the transition to renewable, non-fossil-fuel-based energy sources. However, most of the recent works in the state of the art are devoted to the formation of olefins and aromatics, ignoring the rest of the hydrocarbon commodities that, like propane, are essential to our economy. Hence, in this work, we have developed a highly active and selective PdZn/ZrO₂+SAPO-34 multifunctional catalyst for the direct conversion of CO₂ to propane. Our multifunctional system displays a total selectivity to propane higher than 50% (with 20% CO, 6% C₁, 13% C₂, 10% C₄, and 1% C₅) and a CO₂ conversion close to 40% at 350 °C, 50 bar, and 1500 mL g^-1 h^-1. We attribute these results to the synergy between the intimately mixed PdZn/ZrO₂ and SAPO-34 components that shifts the overall reaction equilibrium, boosting CO₂ conversion and minimizing CO selectivity. Comparison to a PdZn/ZrO₂+ZSM-5 system showed that propane selectivity is further boosted by the topology of SAPO-34. The presence of Pd in the catalyst drives paraffin production via hydrogenation, with more than 99.9% of the products being saturated hydrocarbons, offering very important advantages for the purification of the products.

Synthesis of hierarchical GaZSM-5 zeolites by the HCl treatment method and their catalytic performance in methanol aromatization

A series of ZSM-5 samples exhibiting isomorphic substitution with Ga and containing both micropores and mesopores were synthesized by a posttreatment method involving different concentrations of hydrochloric acid.