Methanol-to-Olefins Catalysis on HSSZ-13 and HSAPO-34 and Its Relationship to Acid Strength

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Ketenes in the Induction of the Methanol-to-Olefins Process

Ketene (CH₂ =C=O) has been postulated as a key intermediate for the first olefin production in the zeolite-catalyzed chemistry of methanol-to-olefins (MTO) and syngas-to-olefins (STO) processes. The reaction mechanism remains elusive, because the short-lived ethenone ketene and its derivatives are difficult to detect, which is further complicated by the low expected ketene concentration. We report on the experimental detection of methylketene (CH₃ -CH=C=O) formed by the methylation of ketene on HZSM-5 via operando synchrotron photoelectron photoion coincidence (PEPICO) spectroscopy. Ketene is produced in situ from methyl acetate. The observation of methylketene as the ethylene precursor evidences a computationally predicted ketene-to-ethylene route proceeding via a methylketene intermediate followed by decarbonylation.

Operando PEPICO unveils the catalytic fast pyrolysis mechanism of the three methoxyphenol isomers

The development of lignin valorization processes such as catalytic fast pyrolysis (CFP) to produce fine chemicals and fuels leads to a more sustainable future. The implementation of CFP is enabled by understanding the chemistry of lignin constituents, which, however, requires thorough mechanistic investigations by detecting reactive species. In this contribution, we investigate the CFP of the three methoxyphenol (MP) isomers over H-ZSM-5 utilizing vacuum ultraviolet synchrotron radiation and operando photoelectron photoion coincidence (PEPICO) spectroscopy. All isomers demethylate at first to yield benzenediols, from which dehydroxylation reactions proceed to produce phenol and benzene. Additional pathways to form benzene proceed over cyclopentadiene, methylcyclopentadiene, and fulvene intermediates. The detection of trace amounts of methanol in the product stream suggests a demethoxylation reaction to yield phenol. Guaiacol (2- or ortho-MP) exhibits slightly higher reactivity compared to 3-MP and 4-MP, due to the formation of the fulvenone ketene, which opens additional routes to benzene and phenol. When compared to benzenediol catalytic pyrolysis, the additional methyl group in MP leads to high conversion at lower reactor temperatures, which is mostly owed to the lower H₃C–O vs. H–O bond energy and the possibility to demethoxylate to produce phenol.

Demethylation, demethoxylation and fulvenone ketene formation determine the reactivity of methoxyphenols over H-ZSM-5 to yield phenols, benzene and toluene. Intermediates are isomer-selectively detected utilizing threshold photoelectron spectroscopy.

Synthesis of Hierarchical Porous SAPO-34 and Its Catalytic Activity for 4,6-Dimethyldibenzothiophene

Zeolite SAPO-34 has been widely used in the industry because of its special pore structure and wide distribution of acid sites in the pore channel. However, traditional SAPO-34 with a small pore size suffers from carbon deposition and deactivation in catalytic reactions, and its inability to catalytically convert bulky organic molecules limits its industrial application. Meanwhile, impurities of SAPO-5, which have weak acidity leading to rapid catalyst deactivation, appear in SAPO-34 zeolite. Therefore, it is of great significance to synthesize SAPO-34 zeolite with a mesoporous pore structure, which can significantly improve the transfer of molecules in zeolites. In this paper, SAPO-34 zeolite with a hierarchical pore structure was synthesized, and its hydrodesulfurization performance for 4,6-dimethyldibenzothiophene (4,6-DMDBT) was studied in a fixed bed reactor. The characteristic results show that BET-specific surface area, micropore volume, and mesoporous volume of synthesized SAPO-34 are 754 m² g⁻¹, 0.25, and 0.23 cm³ g⁻¹ respectively, and the pore size is mainly concentrated at 4 nm. The catalytic conversion of 4,6-DMDMT with Co- and Mo-supported SAPO-34 is about 83%, which is much higher than the catalytic performance of Al₂O₃.

MAPO-18 Catalysts for the Methanol to Olefins Process: Influence of Catalyst Acidity in a High-Pressure Syngas (CO and H2) Environment

The transition from integrated petrochemical complexes toward decentralized chemical plants utilizing distributed feedstocks calls for simpler downstream unit operations. Less separation steps are attractive for future scenarios and provide an opportunity to design the next-generation catalysts, which function efficiently with effluent reactant mixtures. The methanol to olefins (MTO) reaction constitutes the second step in the conversion of CO2, CO, and H2 to light olefins. We present a series of isomorphically substituted zeotype catalysts with the AEI topology (MAPO-18s, M = Si, Mg, Co, or Zn) and demonstrate the superior performance of the M(II)-substituted MAPO-18s in the conversion of MTO when tested at 350 °C and 20 bar with reactive feed mixtures consisting of CH3OH/CO/CO2/H2. Co-feeding high pressure H2 with methanol improved the catalyst activity over time, but simultaneously led to the hydrogenation of olefins (olefin/paraffin ratio < 0.5). Co-feeding H2/CO/CO2/N2 mixtures with methanol revealed an important, hitherto undisclosed effect of CO in hindering the hydrogenation of olefins over the Brønsted acid sites (BAS). This effect was confirmed by dedicated ethene hydrogenation studies in the absence and presence of CO co-feed. Assisted by spectroscopic investigations, we ascribe the favorable performance of M(II)APO-18 under co-feed conditions to the importance of the M(II) heteroatom in altering the polarity of the M-O bond, leading to stronger BAS. Comparing SAPO-18 and MgAPO-18 with BAS concentrations ranging between 0.2 and 0.4 mmol/gcat, the strength of the acidic site and not the density was found to be the main activity descriptor. MgAPO-18 yielded the highest activity and stability upon syngas co-feeding with methanol, demonstrating its potential to be a next-generation MTO catalyst.

Surface Fingerprinting of Faceted Metal Oxides and Porous Zeolite Catalysts by Probe-Assisted Solid-State NMR Approaches

Acid catalysis in heterogeneous systems such as metal oxides and porous zeolites has been widely involved in various catalytic processes for chemical and petrochemical industries. In acid-catalyzed reactions, the performance (e.g., activity and selectivity) is closely associated with the acidic features of the catalysts, viz., type (Lewis vs Brønsted acidity), distribution (external vs internal surface), strength (strong vs weak), concentration (amount), and spatial interactions of acidic sites. The characterization of local structure and acidic properties of these active sites has important implications for understanding the reaction mechanism and the practical catalytic applications of acidic catalysts. Among diverse acidity characterization approaches, the solid-state nuclear magnetic resonance (SSNMR) technique with suitable probe molecules has been recognized as a reliable and versatile tool. Such a probe-assisted SSNMR approach could provide qualitative (type, distribution, and spatial interactions) and quantitative (strength and concentration) information on each acidic site. This Account aims to integrate our recent important findings in determining the structures and acidic characteristics of some typical metal oxide and zeolite catalysts by using the probe-assisted SSNMR technique, as well as clarifying the continuously evolving process of each discrete acidic site under hydrothermal or chemical treatments even at the molecular level with multiscale theoretical simulations.More specifically, we will describe herein the development and applications of the probe-assisted SSNMR methods, such as trimethylphosphine (TMP) and acetonitrile-d₃ (CD₃CN) in conjunction with advanced two-dimensional (2D) homo- and heteronuclear correlation spectroscopy, for characterizing the structures and properties of acidic sites in varied solid catalysts. Moreover, relevant information regarding the surface fingerprinting of various facets on crystalline metal oxide nanoparticles and active centers inside porous zeolites, the mapping of relevant spatial interactions, and the verification of structure-activity correlation were investigated as well. Relevant discussions are mainly based on the recent NMR experiments of our collaborating research groups, including (i) determining the acidic characterization with probe-assisted SSNMR approaches, (ii) mapping various active centers (or crystalline facets), and (iii) revealing their influence on catalytic performance of solid acid catalyst systems. It is anticipated that this information may provide more in-depth insights toward our fundamental understanding of solid acid catalysis.