Solid-State Ion-Exchanged Cu/Mordenite Catalysts for the Direct Conversion of Methane to Methanol

A thorough mechanistic study of ethanol, acetaldehyde, and ethylene adsorption on Cu-MOR via DFT analysis

A comprehensive study combining the density functional theory (DFT) and ab initio thermodynamic analysis was conducted to unravel the active sites and adsorption mechanisms of ethanol, acetaldehyde, and ethylene on various copper-modified mordenite (Cu-MOR) configurations, including Cu3/MOR, Cu3O3/MOR, and Cu6/MOR. This research involved an exhaustive exploration of structural and formation energies, revealing that the formation energies of these structures are temperature-dependent. Despite all three structures thermodynamically accommodating ethanol adsorption, their respective adsorption mechanisms differ significantly. In Cu3/MOR, weak van der Waals interactions predominate, while strong Cu-OOH interactions in Cu6/MOR facilitate ethanol dehydration. Conversely, Cu3O3/MOR exhibits pronounced Cu3O3-HOH interactions that favor ethanol dehydrogenation. Notably, Cu3O3/MOR displays robust ethylene adsorption, which enhances the potential for further ethylene activation. In-depth Bader charge and density of states analyses underscore the varying strengths and electronic characteristics of these interactions. This research provides a theoretical foundation for the design of highly efficient Cu-MOR catalysts tailored for the selective conversion of ethanol.

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.

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.

Cu and Zn Bimetallic Co-Modified H-MOR Catalyst for Direct Oxidation of Low-Concentration Methane to Methanol

The direct oxidation of low-concentration methane to value-added chemicals can not only reduce carbon emission but also provide an alternative production route for fossil fuels. Herein, we proposed a novel catalyst for the direct oxidation of low-concentration methane to methanol via the impregnation method, which selected copper and zinc as co-modifiers to modify the MOR catalyst. The highest methanol yield of 71.35 μmol·gcat-1·h-1 was obtained over a bimetallic Cu0.5Zn0.35-MOR catalyst. The catalyst retained good activity after three cycles of testing experiments, indicating good recyclability. Based on the results of performance tests and characterization studies, it was confirmed that Cu species bound to the zeolite framework were the main active sites for methane oxidation. The introduction of Zn decreased the generation of the octahedrally coordinated extra-framework aluminum, which promoted the dispersion of Cu within the zeolite framework. In other words, more tetrahedrally coordinated FAl-stabilized Cu species were presented in our CuZn-MOR catalyst system in comparison to the monometallic Cu-MOR catalyst. Benefiting from the aforementioned modification, the agglomerative sintering of the metal during the reaction was effectively prevented. This work may provide a feasible guide for the future optimization of Cu-based catalysts designed for the selective oxidation of methane.

Methane Oxidation to Methanol

The direct transformation of methane to methanol remains a significant challenge for operation at a larger scale. Central to this challenge is the low reactivity of methane at conditions that can facilitate product recovery. This review discusses the issue through examination of several promising routes to methanol and an evaluation of performance targets that are required to develop the process at scale. We explore the methods currently used, the emergence of active heterogeneous catalysts and their design and reaction mechanisms and provide a critical perspective on future operation. Initial experiments are discussed where identification of gas phase radical chemistry limited further development by this approach. Subsequently, a new class of catalytic materials based on natural systems such as iron or copper containing zeolites were explored at milder conditions. The key issues of these technologies are low methane conversion and often significant overoxidation of products. Despite this, interest remains high in this reaction and the wider appeal of an effective route to key products from C-H activation, particularly with the need to transition to net carbon zero with new routes from renewable methane sources is exciting.

Copper-zeolites Prepared by Solid-state Ion Exchange - Characterization and Evaluation for the Direct Conversion of Methane to Methanol

Direct conversion of methane to methanol (MTM) over Cu-zeolites is a so-called “dream reaction” for the chemical industry. There is still a lot that can be done in order to optimize the reaction by e.g. achieving a deeper understanding of the reaction mechanism and the nature of the Cu-sites. In this study, we investigated a solid-state ion exchange method to incorporate CuI ions into zeolites (MOR, BEA, ZSM-5 and FAU), as a more scalable technique. The solid-state ion exchange led to a Cu/Al ration of about 0.8, however with a heterogeneous distribution of Cu. Regardless, Fourier transform-infrared spectroscopy still revealed that most Brønsted acid sites were exchanged in all four samples. Further, CH4-temperature programmed reaction experiments showed that some Cu-sites formed were reactive towards CH4, with CuI-MOR and CuI-FAU having the largest CH4 consumption. Ultimately, the CuI-zeolites were tested in the MTM reaction and proved capable of producing methanol, even without the presence of Brønsted sites. A MOR with lower Cu/Al ratio (0.30) was also tested for comparison, and as this sample obtained a much higher productivity than the CuI-MOR with high Cu-loading (0.10 vs. 0.03 molMeOH/molCu), it was demonstrated that some fine-tuning is necessary to obtain the active Cu sites for methane activation.

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.

Combustion-Synthesized Porous CuO-CeO2-SiO2 Composites as Solid Catalysts for the Alkenylation of C(sp3)-H Bonds Adjacent to a Heteroatom via Cross-Dehydrogenative Coupling

A series of mixed oxides of CuO, CeO2, and SiO2 were prepared by gel combustion and employed for the first time as efficient solid catalysts in a solvent-less liquid-phase cross-dehydrogenative coupling. The facile one-pot catalyst synthesis resulted in highly porous materials presenting large specific surface areas and strong metal–support interactions. The interaction with highly dispersed CeO2 enhanced the redox properties of the CuO species. The CuO-CeO2-SiO2 composites exhibited excellent catalytic performance for the selective coupling between 1,1-diphenylethylene and tetrahydrofuran with a yield up to 85% of 2-(2,2-diphenylvinyl)-tetrahydrofuran in the presence of di-tert-butyl peroxide (DTPB) and KI. Albeit both CuO and CeO2 species are proved to be responsible for the catalytic conversion, a great synergistic improvement in the catalytic activity was obtained by extended contact between the oxide phases by high porosity in comparison with the reactions using individual Cu or Ce catalysts. The activity of the composite catalyst was shown to be highly stable after five successive reaction cycles. Furthermore, the study scope was extended to the synthesis of different derivatives via composite-catalyzed coupling of C(sp2)-H with C(sp3-H) adjacent to a heteroatom. The good yields recorded proved the general validity of this composite for the cross-dehydrogenative coupling reaction rarely performed on solid catalysts.

Recent Advances in Catalysis Based on Transition Metals Supported on Zeolites

This article reviews the current state and development of thermal catalytic processes using transition metals (TM) supported on zeolites (TM/Z), as well as the contribution of theoretical studies to understand the details of the catalytic processes. Structural features inherent to zeolites, and their corresponding properties such as ion exchange capacity, stable and very regular microporosity, the ability to create additional mesoporosity, as well as the potential chemical modification of their properties by isomorphic substitution of tetrahedral atoms in the crystal framework, make them unique catalyst carriers. New methods that modify zeolites, including sequential ion exchange, multiple isomorphic substitution, and the creation of hierarchically porous structures both during synthesis and in subsequent stages of post-synthetic processing, continue to be discovered. TM/Z catalysts can be applied to new processes such as CO₂ capture/conversion, methane activation/conversion, selective catalytic NO_x reduction (SCR-deNO_x), catalytic depolymerization, biomass conversion and H₂ production/storage.

Harnessing of Diluted Methane Emissions by Direct Partial Oxidation of Methane to Methanol over Cu/Mordenite

The upgrading of diluted methane emissions into valuable products can be accomplished at low temperatures (200 °C) by the direct partial oxidation of methanol over copper-exchanged zeolite catalysts. The reaction has been studied in a continuous fixed-bed reactor loaded with a Cu–mordenite catalyst, according to a three-step cyclic process: adsorption of methane, desorption of methanol, and reactivation of the catalyst. The purpose of the work is the use of methane emissions as feedstocks, which is challenging due to their low methane concentration and the presence of oxygen. Methane concentration had a marked influence on methane adsorption and methanol production (decreased from 164 μmol/g Cu for pure methane to 19 μmol/g Cu for 5% methane). The presence of oxygen, even in low concentrations (2.5%), reduced methane adsorption drastically. However, methanol production was only affected slightly (average decrease of 9%), concluding that methane adsorbed on the active centers yielding methanol is not influenced by oxygen.

Steric and Electrostatic Effects on the Diffusion of CH4/CH3OH in Copper-Exchanged Zeolites: Insights from Enhanced Sampling Molecular Dynamics and Free Energy Calculations

Copper-exchanged zeolites have demonstrated high selectivity in methane-to-methanol conversion carried out on copper-oxo centers. Nevertheless, the reaction can only occur if the methane molecules reach the active site while the methanol molecules must leave the material without high energetic cost for the migration. In this context, we have used force field-based molecular dynamics simulations with the potential of mean force method to estimate the energy barrier in cage to cage diffusion of methane and methanol molecules in the chabazite framework type zeolite. The results show considerably higher energy barrier for methanol diffusion. The steric effect of the active site and the electrostatic environment favors the CH₃OH diffusion toward nonactive cages where it tends to accumulate due to the strong interactions with the zeolite. The same behavior is observed in the water molecules distribution, which emphasizes the control of the electrostatic potential over the polar molecules migration. For high concentration of polar molecules, the electrostatic effect is shielded and the driving force is reduced for CH₃OH diffusion. The results show that if the electrostatic environment can be controlled, the product migration may be facilitated, which can improve the catalytic process.

Critical Role of Al Pair Sites in Methane Oxidation to Methanol on Cu-Exchanged Mordenite Zeolites

Cu-exchanged aluminosilicate zeolites have been intensively studied for the selective oxidation of methane to methanol via a chemical looping manner, while the nature of active Cu-oxo species for these catalysts is still under debate. This study inquired into the effects of Al distribution on methane oxidation over Cu-exchanged aluminosilicate zeolites, which provided an effective way to discern the activity difference between mononuclear and polynuclear Cu-oxo species. Specifically, conventional Na+/Co2+ ion-exchange methods were applied to quantify isolated Al and Al pair (i.e., Al−OH−(Si−O)1–3−Al−OH) sites for three mordenite (MOR) zeolites, and a correlation was established between the reactivity of the resultant Cu-MOR catalysts and the portions of the accessible framework Al sites. These results indicated that the Cu-oxo clusters derived from the Al pair sites were more reactive than the CuOH species grafted at the isolated Al sites, which is consistent with in situ ultraviolet-visible spectroscopic characterization and density functional theory calculations. Further theoretical analysis of the first C–H bond cleavage in methane on these Cu-oxo species unveiled that stabilization of the formed methyl group was the predominant factor in determining the reactivity of methane oxidation.

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 C-H Activation by [Cu2O]2+ and [Cu3O3]2+ in Copper-Exchanged Zeolites: Computational Analysis of Redox Chemistry and X-ray Absorption Spectroscopy

There is an ongoing debate regarding the role of [Cu₃O₃]²⁺ in methane-to-methanol conversion by copper-exchanged zeolites. Here, we perform electronic structure analysis and localized orbital bonding analysis to probe the redox chemistry of its Cu and μ-oxo sites. Also, the X-ray absorption near-edge structure, XANES, of methane activation in [Cu₃O₃]²⁺ is compared to that of the more ubiquitous [Cu₂O]²⁺. Methane C-H activation is associated with only the Cu²⁺/Cu⁺ redox couple in [Cu₂O]²⁺. For [Cu₃O₃]²⁺, there is no basis for the Cu³⁺/Cu²⁺ couple's participation at the density functional theory ground state. In [Cu₃O₃]²⁺, there are many possible intrazeolite intermediates for methane activation. In the nine possibilities that we examined, methane activation is driven by a combination of the Cu²⁺/Cu⁺ and oxyl/O^2- redox couples. Based on this, the Cu 1s-edge XANES spectra of [Cu₂O]²⁺ and [Cu₃O₃]²⁺ should both have energy signatures of Cu²⁺ → Cu⁺ reduction during methane activation. This is indeed what we obtained from the calculated XANES spectra. [Cu₂O]²⁺ and [Cu₃O₃]²⁺ intermediates with one Cu⁺ site are shifted by 0.9-1.7 eV, while those with two Cu⁺ sites are shifted by 3.0-4.2 eV. These are near a range of 2.5-3.2 eV observed experimentally after contacting methane with activated copper-exchanged zeolites. Thus, activation of methane by [Cu₃O₃]²⁺ will lead to formation of Cu⁺ sites. Importantly, for future quantitative XANES studies, involvement of O^- + e^- → O^2- in [Cu₃O₃]²⁺ implies a disconnect between the overall reactivity and the number of electrons used in the Cu²⁺/Cu⁺ redox couple.

A potential catalyst for continuous methane partial oxidation to methanol using N2O: Cu-SSZ-39

Continuous catalytic methanol production from methane is reported on Cu-SSZ-39 using N₂O as an oxidant. Through optimization of CH₄, N₂O and H₂O partial pressures, a methanol formation rate of 499 μmol_CH3OH g^-1 h^-1 and a methanol selectivity of 34% is achieved.

Speciation of Manganese in a Synthetic Recycling Slag Relevant for Lithium Recycling from Lithium-Ion Batteries

Lithium aluminum oxide has previously been identified to be a suitable compound to recover lithium (Li) from Li-ion battery recycling slags. Its formation is hampered in the presence of high concentrations of manganese (9 wt.% MnO2). In this study, mock-up slags of the system Li2O-CaO-SiO2-Al2O3-MgO-MnOx with up to 17 mol% MnO2-content were prepared. The manganese (Mn)-bearing phases were characterized with inductively coupled plasma optical emission spectrometry (ICP-OES), X-ray diffraction (XRD), electron probe microanalysis (EPMA), and X-ray absorption near edge structure analysis (XANES). The XRD results confirm the decrease of LiAlO2 phases from Mn-poor slags (7 mol% MnO2) to Mn-rich slags (17 mol% MnO2). The Mn-rich grains are predominantly present as idiomorphic and relatively large (>50 µm) crystals. XRD, EPMA and XANES suggest that manganese is present in the form of a spinel solid solution. The absence of light elements besides Li and O allowed to estimate the Li content in the Mn-rich grain, and to determine a generic stoichiometry of the spinel solid solution, i.e., (Li(2x)Mn2+(1−x))1+x(Al(2−z),Mn3+z)O4. The coefficients x and z were determined at several locations of the grain. It is shown that the aluminum concentration decreases, while the manganese concentration increases from the start (x: 0.27; z: 0.54) to the end (x: 0.34; z: 1.55) of the crystallization.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Active sites and mechanisms in the direct conversion of methane to methanol using Cu in zeolitic hosts: a critical examination

In this critical review we examine the current state of our knowledge in respect of the nature of the active sites in copper containing zeolites for the selective conversion of methane to methanol.

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.