First-Principles Analysis of Site- and Condition-Dependent Fe Speciation in SSZ-13 and Implications for Catalyst Optimization

A Computational Mechanistic Study on Copper Autoreduction in Cu-CHA Zeolite Catalysts

The activation of Cu-zeolite catalysts is accompanied by an autoreduction reaction, in which a part of Cu(II) species is spontaneously reduced to Cu(I) species. The stoichiometry of autoreduction in which the release of one O2 is accompanied by the reduction of four Cu(II) to Cu(I) has been proposed, but the detailed mechanism of this autoreduction remains unclear. In this work, we used DFT calculations to study the autoreduction mechanism in Cu-CHA zeolites. The two reduction mechanisms of [CuOH]+ to Cu+ in CHA-type zeolite were systematically studied. In Mechanism I, two [CuOH]+ react via dehydration to form [Cu-O-Cu]2+, and the further reaction of two [Cu-O-Cu]2+ to produce O2 is the most critical step, which requires four charge-compensating framework Al in close proximity. In Mechanism II, the production of O2 occurs via [CuO]+ intermediates, and the generation of possible [CuO]+ is the most critical step. The exploration of autoreduction reactions in a variety of Cu-CHA models with different Al sittings shows that the O-O distances between two intermediate precursors, i. e., two [Cu-O-Cu]2+ in Mechanism I, or two [CuO]+ in Mechanism II, are key factors determining the activation barriers of O2 production during autoreduction.

Understanding deNOx mechanisms in transition metal exchanged zeolites

Transition-metal-containing zeolites have wide-ranging applications in several catalytic processes including the selective catalytic reduction (SCR) of NOx species. To understand how transition metal ions (TMIs) can effect NOx reduction chemistry, both structural and mechanistic aspects at the atomic level are needed. In this review, we discuss the coordination chemistry of TMIs and their mobility within the zeolite framework, the reactivity of active sites, and the mechanisms and intermediates in the NH3-SCR reaction. We emphasise the key relationship between TMI coordination and structure and mechanism and discuss approaches to enhancing catalytic activity via structural modifications.

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.

Methane Oxidation over the Zeolites-Based Catalysts

Zeolites have ordered pore structures, good spatial constraints, and superior hydrothermal stability. In addition, the active metal elements inside and outside the zeolite framework provide the porous material with adjustable acid–base property and good redox performance. Thus, zeolites-based catalysts are more and more widely used in chemical industries. Combining the advantages of zeolites and active metal components, the zeolites-based materials are used to catalyze the oxidation of methane to produce various products, such as carbon dioxide, methanol, formaldehyde, formic acid, acetic acid, and etc. This multifunction, high selectivity, and good activity are the key factors that enable the zeolites-based catalysts to be used for methane activation and conversion. In this review article, we briefly introduce and discuss the effect of zeolite materials on the activation of C–H bonds in methane and the reaction mechanisms of complete methane oxidation and selective methane oxidation. Pd/zeolite is used for the complete oxidation of methane to carbon dioxide and water, and Fe- and Cu-zeolite catalysts are used for the partial oxidation of methane to methanol, formaldehyde, formic acid, and etc. The prospects and challenges of zeolite-based catalysts in the future research work and practical applications are also envisioned. We hope that the outcome of this review can stimulate more researchers to develop more effective zeolite-based catalysts for the complete or selective oxidation of methane.

Enhanced SO2 Resistance of Cs-Modified Fe-HZSM-5 for NO Decomposition

Direct decomposition of NO into N2 and O2 is an ideal technology for NOx removal. Catalyst deactivation by sulfur poisoning is the major obstacle for practical application. This paper focuses on strengthening the SO2 resistance of metal-exchanged HZSM-5 catalysts, by investigating the metals, promoters, preparation methods, metal-to-promoter molar ratios, Si/Al ratios and metal loadings. The results show that in the presence of SO2 (500 ppm), Fe is the best compared with Co, Ni and Cu. Cs, Ba and K modification enhanced the low-temperature activity of the Fe-HZSM-5 catalyst for NO decomposition, which can be further improved by increasing the exchanged-solution concentration and Fe/Cs molar ratio or decreasing the Si/Al molar ratio. Interestingly, Cs-doped Fe-HZSM-5 exhibited a high NO conversion and low NO2 selectivity but a high SO2 conversion within 10 h of continuous operation. This indicates that Cs-Fe-HZSM-5 has a relatively high SO2 resistance. Combining the characterization results, including N2 physisorption, XRD, ICP, XRF, UV–Vis, XPS, NO/SO2-TPD, H2-TPR and HAADF-STEM, SO42− was found to be the major sulfur species deposited on the catalyst’s surface. Cs doping inhibited the SO2 adsorption on Fe-HZSM-5, enhanced the Fe dispersion and increased the isolated Fe and Fe-O-Fe species. These findings could be the primary reasons for the high activity and SO2 resistance of Cs-Fe-HZSM-5.

Single Atom Catalysts for Selective Methane Oxidation to Oxygenates

Direct conversion of methane (CH₄) to C_1-2 liquid oxygenates is a captivating approach to lock carbons in transportable value-added chemicals, while reducing global warming. Existing approaches utilizing the transformation of CH₄ to liquid fuel via tandemized steam methane reforming and the Fischer-Tropsch synthesis are energy and capital intensive. Chemocatalytic partial oxidation of methane remains challenging due to the negligible electron affinity, poor C-H bond polarizability, and high activation energy barrier. Transition-metal and stoichiometric catalysts utilizing harsh oxidants and reaction conditions perform poorly with randomized product distribution. Paradoxically, the catalysts which are active enough to break C-H also promote overoxidation, resulting in CO₂ generation and reduced carbon balance. Developing catalysts which can break C-H bonds of methane to selectively make useful chemicals at mild conditions is vital to commercialization. Single atom catalysts (SACs) with specifically coordinated metal centers on active support have displayed intrigued reactivity and selectivity for methane oxidation. SACs can significantly reduce the activation energy due to induced electrostatic polarization of the C-H bond to facilitate the accelerated reaction rate at the low reaction temperature. The distinct metal-support interaction can stabilize the intermediate and prevent the overoxidation of the reaction products. The present review accounts for recent progress in the field of SACs for the selective oxidation of CH₄ to C_1-2 oxygenates. The chemical nature of catalytic sites, effects of metal-support interaction, and stabilization of intermediate species on catalysts to minimize overoxidation are thoroughly discussed with a forward-looking perspective to improve the catalytic performance.

Rational design of ZSM-5 zeolite containing a high concentration of single Fe sites capable of catalyzing the partial oxidation of methane with high turnover frequency

We successfully synthesized a Fe/ZSM-5 catalyst enabling conversion of methane to C1 oxygenates in record yields, and demonstrated that the fraction of the single Fe cation, as well as the Al distribution, are the powerful activity descriptors.

The Operating Cycle of NO Adsorption and Desorption in Pd-Chabazite for Passive NOx Adsorbers

Pd-doped chabazite (Pd/CHA) offers unique opportunities to adsorb and desorb NO_x in the target temperature range for application as a passive NO_x adsorber (PNA). The ability of Pd/CHA to trap NO_x emissions at low temperatures (<200 °C) is facilitated by the binding of NO_x species at various Pd sites available in the CHA framework. Density functional theory (DFT) simulations are performed to understand Pd speciation in CHA and the interaction of NO with Pd/CHA to explain the mechanisms of NO adsorption, oxidation, and desorption processes. The calculations are used to elucidate the important role of Pd¹⁺ cationic species, anchored at 6MR-3NN, in providing a strong (E_b = -272 kJ/mol) NO adsorption site in Pd/CHA. For NO release, the redox transformation of Pd species comes into play and Pd¹⁺ species are suggested to transform into cationic Pd²⁺, [PdOH]⁺, or [Pd-O-Pd]²⁺ species, all of which show significantly reduced NO binding (-116, -153, and -117 kJ/mol, respectively) as compared to Pd¹⁺. This enables NO desorption at the operating temperature of a downstream catalyst for subsequent catalytic reduction.

Local structure and NO adsorption/desorption property of Pd2+ cations at different paired Al sites in CHA zeolite

Recently, Pd-exchanged CHA zeolites (Pd-CHA) have attracted attention as promising passive NOx adsorbers (PNAs) for reducing NOx emissions during the cold start period of a vehicle engine. In this work, the relationship between the local structures and the NO adsorption/desorption properties of the Pd cations in CHA zeolites was investigated. Pd cation formation and NO adsorption were theoretically explored by density functional theory (DFT) calculations for different paired Al sites in six-/eight-membered rings (6MR/8MR). Furthermore, we prepared a series of Pd-CHAs with different Pd loadings (0.5-5.4 wt%) and evaluated their NO adsorption/desorption properties by in situ infrared (IR) spectroscopy and temperature-programmed desorption (TPD) measurements. The increase in the Pd loading resulted in a shift in the NO desorption temperature toward a higher temperature regime. This phenomenon was ascribed to the increase in the proportion of less stable Pd cations, resulting in improved NO adsorption. Furthermore, the effect of Al distribution on the NO adsorption property of Pd-CHA was examined using CHA zeolites containing different proportions of paired Al sites in 6MR while maintaining similar Si/Al ratios (Si/Al = 12.0-16.5). The present study, based on a combination of theoretical and experimental techniques, shows that the NO adsorption/desorption properties over Pd-CHA can be tuned by controlling the Pd loading amount and the type of paired Al sites.

Dynamic Interconversion of Metal Active Site Ensembles in Zeolite Catalysis

Catalysis science is founded on understanding the structure, number, and reactivity of active sites. Kinetic models that consider active sites to be static and noninteracting entities are routinely successful in describing the behavior of heterogeneous catalysts. Yet, active site ensembles often restructure in response to their external environment and even during steady-state catalytic turnover, sometimes requiring non-mean-field kinetic treatments to describe distance-dependent interactions among sites. Such behavior is being recognized more frequently in modern catalysis research, with the advent of experimental methods to quantify turnover rates with increasing precision, an expanding arsenal of operando characterization tools, and computational descriptions of atomic structure and motion at chemical potentials and timescales increasingly relevant to reaction conditions. This review focuses on dynamic changes to metal active site ensembles on zeolite supports, which are silica-based crystalline materials substituted with Al that generate binding sites for isolated and low-nuclearity metal site ensembles. Metal sites can become solvated and mobilized during reaction, facilitating interactions among sites that change their nuclearity and function. Such intersite communication can be regulated by the zeolite support, resulting in non-single-site and potentially non-mean-field kinetic behavior arising from mechanisms of catalytic action that combine elements of those canonically associated with homogeneous and heterogeneous catalysis.We discuss recent literature examples that document dynamic active site behavior in metal-zeolites and outline methodologies to identify and interpret such behavior. We conclude with our outlook on future research directions to develop this evolving branch of catalysis science and harness it for practical applications.

Selective catalytic reduction of NO over Cu-AFX zeolites: mechanistic insights from in situ/operando spectroscopic and DFT studies

In situ/operando spectroscopic experiments and DFT calculations unravel the redox mechanism of NH₃-SCR over Cu-AFX zeolites.

Fe-Exchanged Small-Pore Zeolites as Ammonia Selective Catalytic Reduction (NH3-SCR) Catalysts

Cu-exchanged small-pore zeolites have been extensively studied in the past decade as state-of-the-art selective catalytic reduction (SCR) catalysts for diesel engine exhaust NOx abatement for the transportation industry. During this time, Fe-exchanged small-pore zeolites, e.g., Fe/SSZ-13, Fe/SAPO-34, Fe/SSZ-39 and high-silica Fe/LTA, have also been investigated but much less extensively. In comparison to their Cu-exchanged counterparts, such Fe/zeolite catalysts display inferior low-temperature activities, but improved stability and high-temperature SCR selectivities. Such characteristics entitle these catalysts to be considered as key components of highly efficient emission control systems to improve the overall catalyst performance. In this short review, recent studies on Fe-exchanged small-pore zeolite SCR catalysts are summarized, including (1) the synthesis of small-pore Fe/zeolites; (2) nature of the SCR active Fe species in these catalysts as determined by experimental and theoretical approaches, including Fe species transformation during hydrothermal aging; (3) SCR reactions and structure-function correlations; and (4) a few aspects on industrial applications.

Solvation and Mobilization of Copper Active Sites in Zeolites by Ammonia: Consequences for the Catalytic Reduction of Nitrogen Oxides

ConspectusCopper-exchanged chabazite (Cu-CHA) zeolites are catalysts used in diesel emissions control for the abatement of nitrogen oxides (NO_x) via selective catalytic reduction (SCR) reactions with ammonia as the reductant. The discovery of these materials in the early 2010s enabled a step-change improvement in diesel emissions aftertreatment technology. Key advantages of Cu-CHA zeolites over prior materials include their effectiveness at the lower temperatures characteristic of diesel exhaust, their durability under high-temperature hydrothermal conditions, and their resistance to poisoning from residual hydrocarbons present in exhaust. Fundamental catalysis research has since uncovered mechanistic and kinetic features that underpin the ability of Cu-CHA to selectively reduce NO_x under strongly oxidizing conditions and to achieve improved NO_x conversion relative to other zeolite frameworks, particularly at low exhaust temperatures and with ammonia instead of other reductants.One critical mechanistic feature is the NH₃ solvation of exchanged Cu ions at low temperatures (<523 K) to create cationic Cu-amine coordination complexes that are ionically tethered to anionic Al framework sites. This ionic tethering confers regulated mobility that facilitates interconversion between mononuclear and binuclear Cu complexes, which is necessary to propagate SCR through a Cu²⁺/Cu⁺ redox cycle during catalytic turnover. This dynamic catalytic mechanism, wherein single and dual metal sites interconvert to mediate different half-reactions of the redox cycle, combines features canonically associated with homogeneous and heterogeneous reaction mechanisms.In this Account, we describe how a unified experimental and theoretical interrogation of Cu-CHA catalysts in operando provided quantitative evidence of regulated Cu ion mobility and its role in the SCR mechanism. This approach relied on new synthetic methods to prepare model Cu-CHA zeolites with varied active-site structures and spatial densities in order to verify that the kinetic and mechanistic models describe the catalytic behavior of a family of materials of diverse composition, and on new computational approaches to capture the active-site structure and dynamics under conditions representative of catalysis. Ex situ interrogation revealed that the Cu structure depends on the conditions for the zeolite synthesis, which influence the framework Al substitution patterns, and that statistical and electronic structure models can enumerate Cu site populations for a known Al distribution. This recognition unifies seemingly disparate spectroscopic observations and inferences regarding Cu ion structure and responses to different external conditions. SCR rates depend strongly on the Cu spatial density and zeolite composition in kinetic regimes where Cu⁺ oxidation with O₂ becomes rate-limiting, as occurs at lower temperatures and under fuel-rich conditions. Transient experiments, ab initio molecular dynamics simulations, and statistical models relate these sensitivities to the mobility constraints imposed by the CHA framework on NH₃-solvated Cu ions, which regulate the pore volume accessible to these ions and their ability to pair and complete the catalytic cycle. This highlights the key characteristics of the CHA framework that enable superior performance under low-temperature SCR reaction conditions.This work illustrates the power of precise control over a catalytic material, simultaneous kinetic and spectroscopic interrogation over a wide range of reaction conditions, and computational strategies tailored to capture those reaction conditions to reveal in microscopic detail the mechanistic features of a complex and widely practiced catalysis. In doing so, it highlights the key role of ion mobility in catalysis and thus potentially a more general phenomenon of reactant solvation and active site mobilization in reactions catalyzed by exchanged metal ions in zeolites.

The mechanism and ligand effects of single atom rhodium supported on ZSM-5 for the selective oxidation of methane to methanol

The mechanism for the partial oxidation of methane to methanol on single atom rhodium supported on ZSM-5 is investigated by DFT. The most favoured mechanism for methane activation is shown to be via oxidative addition at an undercoordinated rhodium metal centre and not through a typical metal oxo intermediate. The formation of a C-OH bond, and not methane activation, is found to be the rate determining step. CO coordinated to the rhodium centre is observed to strongly promote this bond formation. Water is required in the system to help prevent catalyst poisoning by CO, which greatly hinders the methane activation step, and to protonate an intermediate RhOOH species. These results suggest that more focus is required on methyl-oxygen bond formation and that exclusive consideration of methane activation will not completely explain some methane partial oxidation systems.

Cooperative and Competitive Occlusion of Organic and Inorganic Structure-Directing Agents within Chabazite Zeolites Influences Their Aluminum Arrangement

We combine experiment and theory to investigate the cooperation or competition between organic and inorganic structure-directing agents (SDAs) for occupancy within microporous voids of chabazite (CHA) zeolites and to rationalize the effects of SDA siting on biasing the framework Al arrangement (Al-O(-Si-O)_x-Al, x = 1-3) among CHA zeolites of essentially fixed composition (Si/Al = 15). CHA zeolites crystallized using mixtures of TMAda⁺ and Na⁺ contain one TMAda⁺ occluded per cage and Na⁺ co-occluded in an amount linearly proportional to the number of 6-MR paired Al sites, quantified by Co²⁺ titration. In contrast, CHA zeolites crystallized using mixtures of TMAda⁺ and K⁺ provide evidence that three K⁺ cations, on average, displace one TMAda⁺ from occupying a cage and contain predominantly 6-MR isolated Al sites. Moreover, CHA crystallizes from synthesis media containing more than 10-fold higher inorganic-to-organic ratios with K⁺ than with Na⁺ before competing crystalline phases form, providing a route to decrease the amount of organic SDA needed to crystallize high-silica CHA. Density functional theory calculations show that differences in the ionic radii of Na⁺ and K⁺ determine their preferences for siting in different CHA rings, which influences their energy to co-occlude with TMAda⁺ and stabilize different Al configurations. Monte Carlo models confirm that energy differences resulting from Na⁺ or K⁺ co-occlusion promote the formation of 6-MR and 8-MR paired Al arrangements, respectively. These results highlight opportunities to exploit using mixtures of organic and inorganic SDAs during zeolite crystallization in order to more efficiently use organic SDAs and influence framework Al arrangements.

Advances in the synthesis, characterisation, and mechanistic understanding of active sites in Fe-zeolites for redox catalysts

The recent research developments on the active sites in Fe-zeolites for redox catalysis are discussed. Building on the characterisation of the α-Fe/α-O active sites in the beta and chabazite zeolites, we demonstrate a bottom-up approach to successfully understand and develop Fe-zeolite catalysts. We use the room temperature benzene to phenol reaction as a relevant example. We then suggest how the spectroscopic identification of other monomeric and dimeric iron sites could be tackled. The challenges in the characterisation of active sites and intermediates in NOX selective catalytic reduction catalysts and further development of catalysts for mild partial methane oxidation are briefly discussed.

Experimental and theoretical study of multinuclear indium–oxo clusters in CHA zeolite for CH4 activation at room temperature

The local structure of CHA-zeolite supported indium–oxo clusters and CH₄ activation at room temperature were experimentally and theoretically studied.

Methane selective oxidation to methanol by metal-exchanged zeolites: a review of active sites and their reactivity

A review of the recent progress in revealing the structures, formation, and reactivity of the active sites in Fe-, Co-, Ni- and Cu-exchanged zeolites as well as outlooks on future research challenges and opportunities is presented.