Carbonylation of Dimethyl Ether to Methyl Acetate over SSZ-13

Boron-incorporated nanosized SUZ-4 zeolite for DME carbonylation

Boron-incorporated nanosized HB-SUZ-4 showcased a noteworthy 24% boost in dimethyl ether carbonylation, with an elevation in methyl acetate selectivity from 91.8% to 96.0%. The improved performance is attributed to shortened diffusion lengths along the 8-member ring channels, decreased Brønsted acidity in the 10-member ring channels, and Lewis acid sites stabilizing CO.

Improved catalytic performance in gas-phase dimethyl ether carbonylation over facile NH4F etched ferrierite

Gas-phase dimethyl ether (DME) carbonylation to methyl acetate (MA) initiates a promising route for producing ethanol from syngas. Ferrierite (FER, ZSM-35) has received considerable attention as it displays excellent stability in the carbonylation reaction and its modification strategy is to improve its catalytic activity on the premise of maintaining its stability as much as possible. However, conventional post-treatment methods such as dealumination and desilication usually selectively remove framework Al or Si atoms, ultimately altering the intrinsic composition, crystallinity, and acidity of zeolites inevitably. In this study, we successfully prepared a series of hierarchical ZSM-35 materials through post-treatment with NH4F etching, which dissolved framework Al and Si at similar rates and preferentially attacked the defective sites. Interestingly, the produced pore systems effectively penetrated the [100] plane, offering elevated access to both the 8-membered ring (8-MR) and 10-membered ring (10-MR) channels. The physicochemical and acid properties of the pristine and NH4F etched ZSM-35 samples were comprehensively characterized using various techniques, including XRD, XRF, FESEM, HRTEM, Nitrogen adsorption-desorption, NH3-TPD, Py-IR, 27Al MAS NMR, and 29Si MAS NMR. Under moderate treatment conditions, the intrinsic microporous structure, acid properties, and crystallinity of zeolite were retained, leading to superior catalytic activity and stability with respect to the pristine sample. Nonetheless, severe NH4F etching disrupted the crystalline framework and created additional defective sites, bringing about faster deposition of coke precursors on the interior Brønsted acid sites (BAS) and decreased catalytic performance. This technique provides a novel and efficient method to slightly enhance the micropore and mesopore volume of industrially pertinent zeolites through a straightforward post-treatment, thus elevating the catalytic performance of these zeolites.

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.

Enhancement of the dimethyl ether carbonylation activation via regulating acid sites distribution in FER zeolite framework

The carbonylation of dimethyl ether (DME) with CO is a key step for ethanol synthesis from syngas, but traditional mordenite (MOR) zeolite shows low catalytic stability. Herein, various FER zeolite nanosheets were prepared with four types of organic templates. The catalytic performance of FER in DME carbonylation is strongly dependent on the location of strong acid site in framework, which can be effectively regulated by altering organic template. FER-MORP sample synthesized with morpholine shows the highest DME conversion of 53%, thus, giving a methyl acetate space-time yield (STYMA) of 0.889 mmol g-1 h-1. DFT calculation, NH3-IR, 1H/27Al/29Si MAS NMR, and in situ DRIFTS results indicate that morpholine directs more Al species, or strong Brønsted acid sites (BAS), to locate in 8-membered ring (8-MR) channels, which not only enhances carbonylation activity but also suppresses formation of coke species. The catalytic performance is well maintained within 4 repeated recycles (∼460 h).

Activity Enhancement of Ferrierite in Dimethyl Ether Carbonylation Reactions through Recrystallization with Sodium Oleate

Methyl acetate (MA) has a wide range of applications as an important industrial chemical. Traditional MOR zeolite for carbonylation of DME to MA accumulated carbon easily because of a 12-membered ring (12 MR) channel. In this work, we innovatively developed the method of recrystallization ferrierite (FER) zeolite using special chelating ligand sodium oleate which can affect ions other than alkali metals. The characterization results of N₂ adsorption, transmission electron microscopy (TEM), and Fourier transform infrared spectroscopy (FT-IR) show that hydrothermal recrystallization of ferrierite using sodium oleate resulted in a higher Si/Al ratio, a bigger specific surface area and a larger number of Brønsted acid sites in the eight MR channels, which was more efficient in the reaction of carbonylation of dimethyl ether than ordinary alkali treatment.

Facile synthesis of aluminosilicate zeolites with STT, CHA and MWW topology structures

Efficient synthesis of zeolites with different topologies is of great significance for both fundamental research and industrial application. Herein, the SSZ-23 zeolite, an odd zeolite containing 7-membered ring (7-MR) and 9-MR channels, has been synthesized under fluorine-free conditions via the route of pre-aging and pH regulation. By this novel synthesis route, the crystallization time can be significantly shortened to 3 days, nearly half as that by the conventional route in fluoride media. The pH value of the aging gel, i.e., the basicity, is found to play a key role in the synthesis, as SSZ-13 and SSZ-25 zeolites can be synthesized simply by changing the basicity of the same aging gel. Characterization results indicate that decreasing the basicity can promote the condensation between Si and Si/Al species and thus increase the framework density of the resulting zeolites. Finally, the dimethyl ether (DME) carbonylation reaction is employed to evaluate the catalytic properties of the above three zeolites with an identical chemical composition, and to reveal the unique confinement effect in various zeolite topologies.

Molecular Views on Mechanisms of Brønsted Acid-Catalyzed Reactions in Zeolites

The Brønsted acidity of proton-exchanged zeolites has historically led to the most impactful applications of these materials in heterogeneous catalysis, mainly in the fields of transformations of hydrocarbons and oxygenates. Unravelling the mechanisms at the atomic scale of these transformations has been the object of tremendous efforts in the last decades. Such investigations have extended our fundamental knowledge about the respective roles of acidity and confinement in the catalytic properties of proton exchanged zeolites. The emerging concepts are of general relevance at the crossroad of heterogeneous catalysis and molecular chemistry. In the present review, emphasis is given to molecular views on the mechanism of generic transformations catalyzed by Brønsted acid sites of zeolites, combining the information gained from advanced kinetic analysis, in situ, and operando spectroscopies, and quantum chemistry calculations. After reviewing the current knowledge on the nature of the Brønsted acid sites themselves, and the key parameters in catalysis by zeolites, a focus is made on reactions undergone by alkenes, alkanes, aromatic molecules, alcohols, and polyhydroxy molecules. Elementary events of C-C, C-H, and C-O bond breaking and formation are at the core of these reactions. Outlooks are given to take up the future challenges in the field, aiming at getting ever more accurate views on these mechanisms, and as the ultimate goal, to provide rational tools for the design of improved zeolite-based Brønsted acid catalysts.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

Recent advances in the routes and catalysts for ethanol synthesis from syngas

Ethanol, as one of the important bulk chemicals, is widely used in modern society. It can be produced by fermentation of sugar, petroleum refining, or conversion of syngas (CO/H₂). Among these approaches, conversion of syngas to ethanol (STE) is the most environmentally friendly and economical process. Although considerable progress has been made in STE conversion, control of CO activation and C-C growth remains a great challenge. This review highlights recent advances in the routes and catalysts employed in STE technology. The catalyst designs and pathway designs are summarized and analysed for the direct and indirect STE routes, respectively. In the direct STE routes (i.e., one-step synthesis of ethanol from syngas), modified catalysts of methanol synthesis, modified catalysts of Fischer-Tropsch synthesis, Mo-based catalysts, noble metal catalysts and multifunctional catalysts are systematically reviewed based on their catalyst designs. Further, in the indirect STE routes (i.e., multi-step processes for ethanol synthesis from syngas via methanol/dimethyl ether as intermediates), carbonylation of methanol/dimethyl ether followed by hydrogenation, and coupling of methanol with CO to form dimethyl oxalate followed by hydrogenation, are outlined according to their pathway designs. The goal of this review is to provide a comprehensive perspective on STE technology and inspire the invention of new catalysts and pathway designs in the near future.

Catalyst sites and active species in the early stages of MTO conversion over cobalt AlPO-18 followed by IR spectroscopy

Reaction-time resolved IR spectroscopy highlights the role of CO and surface –OCH3 in the MTO conversion catalysed by CoAPO-18 with maximised concentration of acidic sites.

Dynamic evolution of Al species in the hydrothermal dealumination process of CHA zeolite

The hydrothermal stability of zeolites is an important factor being considered which could restrict their scope of industrial application. Revealing the water-induced dealumination mechanism is crucial for improving the hydrothermal...

A Carbonylation Zeolite with Specific Nanosheet Structure for Efficient Catalysis

Up to now, the member of zeolite family has expanded to more than 230. However, only little part of them have been reported as catalysts used in reactions. Discovering potential zeolites for reactions is significantly important, especially in industrial applications. A carbonylation zeolite catalyst Al-RUB-41 has special morphology and channel orientation. The 8-MR channel of Al-RUB-41 is just perpendicular to its thin sheet, making a very short mass-transfer distance along 8-MR. This specific nature endows Al-RUB-41 with efficient catalytic ability to dimethyl ether carbonylation reaction with beyond 95% methyl acetate selectivity. Compared with the most widely accepted carbonylation zeolite catalysts, Al-RUB-41 behaves a much better catalytic stability than H-MOR and a greatly enhanced catalytic activity than H-ZSM-35. A space-confined deactivation mechanism over Al-RUB-41 is proposed. By erasing the acid sites on outer surface, Al-RUB-41@SiO₂ catalyst achieves a long-time and high-efficiency activity without any deactivation trend.

Promoting Effect of Copper Loading and Mesoporosity on Cu-MOR in the Carbonylation of Dimethyl Ether to Methyl Acetate

Cu-mordenite (Cu-MOR) catalysts with different copper loadings were prepared, characterized and examined in continuous, gas-flow synthesis of methyl acetate (MA) by dimethyl ether (DME) carbonylation. Improved activity and selectivity were observed for Cu-MOR catalysts with up to 1 wt% Cu and X-ray photoelectron spectroscopy (XPS), electron paramagnetic resonance (EPR) spectroscopy and temperature-programmed reduction with hydrogen (H2-TPR) were used to elucidate the state of copper in the catalysts. Moreover, mesoporous MOR catalysts (RHMs) were prepared by mild stepwise recrystallization with X-ray powder diffraction (XRPD) and ammonia temperature-programmed desorption (NH3-TPD) demonstrating the retained MOR structure and the acid property of the catalysts, respectively. The RHM catalysts showed improved lifetime compared to pristine MOR giving a yield up to 78% MA with 93% selectivity after 5 h on stream (GHSV = 6711 h−1). Under identical reaction conditions, 1 wt% Cu-RHM catalysts had an even higher catalytic activity and durability resulting in a MA yield of 90% with 97% selectivity for 7–8 h of operation as well as a lower coke formation.

Silver-Modified Nano Mordenite for Carbonylation of Dimethyl Ether

Mordenite (H-MOR) catalysts were synthesized by a hydrothermal method, and silver-modified mordenite (Ag-MOR) catalysts were prepared by ion exchange with AgNO3 at different concentrations. The performance of these catalysts in the carbonylation of dimethyl ether (DME) to methyl acetate (MA) was also evaluated. The catalysts were characterized by Ar adsorption/desorption, XRD, ICP-AES, SEM, HRTEM, 27Al NMR, H2-TPR, NH3-TPD, Py-IR, and CO-TPD. According to the characterization results, Ag ion exchange sites were mainly located in the 8-membered ring (8-MR) channels of Ag-MOR; evenly dispersed Ag2O particles were also present. The acid site distribution was changed by the modification of Ag, and the amount of Brønsted acid sites increased in 8-MR and decreased in 12-MR. The CO adsorption performance of the catalyst significantly increased with the modification of Ag. These changes improved the conversion and selectivity of the carbonylation of DME. Over 4Ag-MOR in particular, DME conversion and MA selectivity reached 94% and 100%, respectively.

K+ located in 6-membered rings of low-silica CHA enhancing the lifetime and propene selectivity in MTO

Methanol-to-olefins (MTO) technology presently serves as a key to convert coal or natural gas to valuable hydrocarbons, in particular lower olefins.

In-Exchanged CHA Zeolites for Selective Dehydrogenation of Ethane: Characterization and Effect of Zeolite Framework Type

In this study, the characterization of In-exchanged CHA zeolite (In-CHA (SiO2/Al2O3 = 22.3)) was conducted by in-situ X-ray diffraction (XRD) and ammonia temperature-programmed desorption (NH3-TPD). We also prepared other In-exchanged zeolites with different zeolite structures (In-MFI (SiO2/Al2O3 = 22.3), In-MOR (SiO2/Al2O3 = 20), and In-BEA (SiO2/Al2O3 = 25)) and different SiO2/Al2O3 ratios (In-CHA(Al-rich) (SiO2/Al2O3 = 13.7)). Their catalytic activities in nonoxidative ethane dehydrogenation were compared. Among the tested catalysts, In-CHA(Al-rich) provided the highest conversion. From kinetic experiments and in-situ Fourier transform infrared (FTIR) spectroscopy, [InH2]+ ions are formed regardless of SiO2/Al2O3 ratio, serving as the active sites.