Aqueous-Phase Methane Oxidation over Fe-MFI Zeolites; Promotion through Isomorphous Framework Substitution

Solvent-Free Synthesis Enables Encapsulation of Subnanometric FeOx Clusters in Pure Siliceous Zeolites for Efficient Catalytic Oxidation Reactions

Metal/metal oxide clusters possess a higher count of unsaturated coordination sites than nanoparticles, providing multiatomic sites that single atoms do not. Encapsulating metal/metal oxide clusters within zeolites is a promising approach for synthesizing and stabilizing these clusters. The unique feature endows the metal clusters with an exceptional catalytic performance in a broad range of catalytic reactions. However, the encapsulation of stable FeOx clusters in zeolite is still challenging, which limits the application of zeolite-encapsulated FeOx clusters in catalysis. Herein, we design a modified solvent-free method to encapsulate FeOx clusters in pure siliceous MFI zeolites (Fe@MFI). It is revealed that the 0.3-0.4 nm subnanometric FeOx clusters are stably encapsulated in the 5/6-membered rings intersectional voids of the pure siliceous MFI zeolites. The encapsulated Fe@MFI catalyst with a Fe loading of 1.4 wt % demonstrates remarkable catalytic activity and recycle stability in the direct oxidation of methane, while also promoting the direct oxidation of cyclohexane, surpassing the performance of conventional zeolite-supported Fe catalysts.

Fundamental Limitation in Electrochemical Methane Oxidation to Alcohol: A Review and Theoretical Perspective on Overcoming It

The direct conversion of gaseous methane to energy-dense liquid derivatives such as methanol and ethanol is of profound importance for the more efficient utilization of natural gas. However, the thermo-catalytic partial oxidation of this simple alkane has been a significant challenge due to the high C-H bond energy. Exploiting electrocatalysis for methane activation via active oxygen species generated on the catalyst surface through electrochemical water oxidation is generally considered as economically viable and environmentally benign compared to energy-intensive thermo-catalysis. Despite recent progress in electrochemical methane oxidation to alcohol, the competing oxygen evolution reaction (OER) still impedes achieving high faradaic efficiency and product selectivity. In this review, an overview of current progress in electrochemical methane oxidation, focusing on mechanistic insights on methane activation, catalyst design principles based on descriptors, and the effect of reaction conditions on catalytic performance are provided. Mechanistic requirements for high methanol selectivity, and limitations of using water as the oxidant are discussed, and present the perspective on how to overcome these limitations by employing carbonate ions as the oxidant.

Recent Advances in the Catalytic Conversion of Methane to Methanol: From the Challenges of Traditional Catalysts to the Use of Nanomaterials and Metal-Organic Frameworks

Methane and carbon dioxide are the main contributors to global warming, with the methane effect being 25 times more powerful than carbon dioxide. Although the sources of methane are diverse, it is a very volatile and explosive gas. One way to store the energy content of methane is through its conversion to methanol. Methanol is a liquid under ambient conditions, easy to transport, and, apart from its use as an energy source, it is a chemical platform that can serve as a starting material for the production of various higher-value products. Accordingly, the transformation of methane to methanol has been extensively studied in the literature, using traditional catalysts as different types of zeolites. However, in the last few years, a new generation of catalysts has emerged to carry out this transformation with higher conversion and selectivity, and more importantly, under mild temperature and pressure conditions. These new catalysts typically involve the use of a highly porous supporting material such as zeolite, or more recently, metal-organic frameworks (MOFs) and graphene, and metallic nanoparticles or a combination of different types of nanoparticles that are the core of the catalytic process. In this review, recent advances in the porous supports for nanoparticles used for methane oxidation to methanol under mild conditions are discussed.

Maximizing Active Fe Species in ZSM-5 Zeolite Using Organic-Template-Free Synthesis for Efficient Selective Methane Oxidation

The selective oxidation of CH₄ in the aqueous phase to produce valuable chemicals has attracted considerable attention due to its mild reaction conditions and simple process. As the most widely studied catalyst for this reaction, Fe-ZSM-5 demonstrates high intrinsic activity and selectivity; however, Fe-ZSM-5 prepared using conventional methods has a limited number of active Fe sites, resulting in low CH₄ conversion per unit mass of the catalyst. This study reports a facile organic-template-free synthesis strategy that enables the incorporation of more Fe into the zeolite framework with a higher dispersion degree compared to conventional synthesis methods. Because framework Fe incorporated in this way is more readily transformed into isolated extra-framework Fe species under thermal treatment, the overall effect is that Fe-ZSM-5 prepared using this method (Fe-HZ5-TF) has 3 times as many catalytically active sites as conventional Fe-ZSM-5. When used for the selective oxidation of CH₄ with 0.5 M H₂O₂ at 75 °C, Fe-HZ5-TF produced a high C₁ oxygenate yield of 109.4 mmol g_cat^-1 h^-1 (a HCOOH selectivity of 91.1%), surpassing other catalysts reported to date. Spectroscopic characterization and density functional theory calculations revealed that the active sites in Fe-HZ5-TF are mononuclear Fe species in the form of [(H₂O)₃Fe(IV)═O]²⁺ bound to Al pairs in the zeolite framework. This differs from conventional Fe-ZSM-5, where binuclear Fe acts as the active site. Analysis of the catalyst and product evolution during the reaction suggests a radical-driven pathway to explain CH₄ activation at the mononuclear Fe site and subsequent conversion to C₁ oxygenates.

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.

Effects of Cu Species on Liquid-Phase Partial Oxidation of Methane with H2O2 over Cu-Fe/ZSM-5 Catalysts

In this study, a Cu-promoted Fe/ZSM-5 catalyst was examined to reveal the effects of Cu species in selective oxidation of methane into methane oxygenates using H2O2 in water. Cu/ZSM-5, Cu-Fe/ZSM-5, and Fe/ZSM-5 catalysts were prepared using wet impregnation, solid-state ion exchange, and ion-exchange methods. Various techniques, including nitrogen physisorption, temperature-programmed reduction with H2, UV-vis spectroscopy, and FT-IR spectroscopy after NO adsorption, were utilized to characterize the catalysts. The promotional effect of Cu on the Cu-Fe/ZSM-5 catalyst in terms of methanol selectivity was confirmed. The preparation method has a considerable influence on the catalyst performance, and the ion-exchange method is the most effective. However, leaching of the Cu species was observed during this reaction, which can affect the quantification of formic acid by 1H-NMR. The homogeneous Cu species increase hydrogen peroxide decomposition and CO2 selectivity, which is undesirable for this reaction.

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.

Activation and conversion of alkanes in the confined space of zeolite-type materials

Microporous zeolite-type materials, with crystalline porous structures formed by well-defined channels and cages of molecular dimensions, have been widely employed as heterogeneous catalysts since the early 1960s, due to their wide variety of framework topologies, compositional flexibility and hydrothermal stability. The possible selection of the microporous structure and of the elements located in framework and extraframework positions enables the design of highly selective catalysts with well-defined active sites of acidic, basic or redox character, opening the path to their application in a wide range of catalytic processes. This versatility and high catalytic efficiency is the key factor enabling their use in the activation and conversion of different alkanes, ranging from methane to long chain n-paraffins. Alkanes are highly stable molecules, but their abundance and low cost have been two main driving forces for the development of processes directed to their upgrading over the last 50 years. However, the availability of advanced characterization tools combined with molecular modelling has enabled a more fundamental approach to the activation and conversion of alkanes, with most of the recent research being focused on the functionalization of methane and light alkanes, where their selective transformation at reasonable conversions remains, even nowadays, an important challenge. In this review, we will cover the use of microporous zeolite-type materials as components of mono- and bifunctional catalysts in the catalytic activation and conversion of C₁⁺ alkanes under non-oxidative or oxidative conditions. In each case, the alkane activation will be approached from a fundamental perspective, with the aim of understanding, at the molecular level, the role of the active sites involved in the activation and transformation of the different molecules and the contribution of shape-selective or confinement effects imposed by the microporous structure.

Acidity as Descriptor for Methanol Desorption in B-, Ga- and Ti-MFI Zeotypes

The isomorphous substitution of Si with metals other than Al in zeotype frameworks allows for tuning the acidity of the zeotype and, therefore, to tailor the catalyst’s properties as a function of the desired catalytic reaction. In this study, B, Ga, and Ti are incorporated in the MFI framework of silicalite samples and the following series of increasing acidity is observed: Ti-silicalite < B-silicalite < Ga-silicalite. It is also observed that the lower the acidity of the sample, the easier the methanol desorption from the zeotype surface. In the target reaction, namely the direct conversion of methane to methanol, methanol extraction is affected by the zeotype acidity. Therefore, the results shown in this study contribute to a more enriched knowledge of this reaction.

Identifying key mononuclear Fe species for low-temperature methane oxidation

The direct functionalization of methane into platform chemicals is arguably one of the holy grails in chemistry. The actual active sites for methane activation are intensively debated. By correlating a wide variety of characterization results with catalytic performance data we have been able to identify mononuclear Fe species as the active site in the Fe/ZSM-5 zeolites for the mild oxidation of methane with H₂O₂ at 50 °C. The 0.1% Fe/ZSM-5 catalyst with dominant mononuclear Fe species possess an excellent turnover rate (TOR) of 66 mol_MeOH mol_Fe⁻¹ h⁻¹, approximately 4 times higher compared to the state-of-the-art dimer-containing Fe/ZSM-5 catalysts. Based on a series of advanced in situ spectroscopic studies and ¹H- and ¹³C- nuclear magnetic resonance (NMR), we found that methane activation initially proceeds on the Fe site of mononuclear Fe species. With the aid of adjacent Brønsted acid sites (BAS), methane can be first oxidized to CH₃OOH and CH₃OH, and then subsequently converted into HOCH₂OOH and consecutively into HCOOH. These findings will facilitate the search towards new metal-zeolite combinations for the activation of C–H bonds in various hydrocarbons, for light alkanes and beyond.

The monomeric Fe species in Fe/ZSM-5 have been identified as the intrinsic active sites for the low-temperature methane oxidation.

Lanthanum modified Fe-ZSM-5 zeolites for selective methane oxidation with H2O2

Lanthanum modified Fe-ZSM-5 catalyst can both increase selective methane oxidation performance and decrease H2O2 consumption.

Selective Oxidation of Methane over Fe-Zeolites by In Situ Generated H2O2

Liquid-phase selective oxidation of methane into methane oxygenates, including methanol and formic acid, with molecular oxygen was investigated using Fe-zeolites and Pd/activated carbon in the presence of molecular hydrogen as a reducing agent. Various Fe-zeolites such as Fe-ZSM-5, Fe-mordenite, Fe-β, Fe-Y, and Fe-ferrierite were prepared by ion-exchange and compared for this reaction. Among them, Fe-ZSM-5 was selected for further study because this catalyst showed high activity in the selective oxidation of methane with relatively less leaching. Further, the effect of reaction temperature, pH, and the amount of catalyst was examined, and detailed investigations revealed that the leached Fe species, which were facilitated in the presence of acid, were mainly responsible for methane oxidation under the given reaction conditions.

Approaches for Selective Oxidation of Methane to Methanol

Methane activation chemistry, despite being widely reported in literature, remains to date a subject of debate. The challenges in this reaction are not limited to methane activation but extend to stabilization of the intermediate species. The low C-H dissociation energy of intermediates vs. reactants leads to CO2 formation. For selective oxidation, nature presents methane monooxygenase as a benchmark. This enzyme selectively consumes methane by breaking it down into methanol. To assemble an active site similar to monooxygenase, the literature reports Cu-ZSM-5, Fe-ZSM-5, and Cu-MOR, using zeolites and systems like CeO2/Cu2O/Cu. However, the trade-off between methane activation and methanol selectivity remains a challenge. Density functional theory (DFT) calculations and spectroscopic studies indicate catalyst reducibility, oxygen mobility, and water as co-feed as primary factors that can assist in enabling higher selectivity. The use of chemical looping can further improve selectivity. However, in all systems, improvements in productivity per cycle are required in order to meet the economical/industrial standards.

Precise control of density and strength of acid sites of MFI-type zeolite nanoparticles via simultaneous isomorphous substitution by Al and Fe

The co-incorporation of Al and Fe at various relative ratios into the MFI-type zeolite framework enabled linear control of the density and strength of acid sites, and such well-tuned acidity led to a better catalyst lifetime.

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.

Selective oxidation of methane to methanol with H2O2 over an Fe-MFI zeolite catalyst using sulfolane solvent

The effect of reaction conditions for direct oxidation of methane to methanol over Fe-MFI zeolite with H2O2 has been investigated. Sulfolane has been proved to be an efficient solvent for liquid-phase methane oxidation. A sulfolane/water mixture with an appropriate proportion led to an extremely high methanol production with a high selectivity.

Direct conversion of methane to methanol with zeolites: towards understanding the role of extra-framework d-block metal and zeolite framework type

This Perspective article highlights the latest advances in the field of direct methane to methanol conversion by zeolites containing first row, extra-framework d-block metals (Mn, Fe, Co, Ni, Cu and Zn).

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.

Unraveling reaction networks behind the catalytic oxidation of methane with H2O2 over a mixed-metal MIL-53(Al,Fe) MOF catalyst

Reaction paths underlying the catalytic oxidation of methane with H2O2 over an Fe containing MIL-53(Al) metal-organic framework were studied by periodic DFT calculations. Not only the activation of methane, but the full reaction network was considered, which includes the formation of the active site, the overoxidation of methane to CO2 and the decomposition of H2O2 to H2O and O2. Calculations indicate that the activation barrier for the initial activation of the Fe sites upon reaction with H2O2 is comparable to that of the subsequent C-H activation and also of the reaction steps involved in the undesirable overoxidation processes. The pronounced selectivity of the oxidation reaction over MIL-53(Al,Fe) towards the target mono-oxygenated CH3OH and CH3OOH products is attributed to the limited coordination freedom of the Fe species encapsulated in the extended octahedral [AlO6] structure-forming chains, which effectively prevents the direct overoxidation paths prior to product desorption from the active sites. Importantly, our computational analysis reveals that the active sites for the desired methane oxidation are able to much more efficiently promote the direct catalytic H2O2 decomposition reaction, rendering thus the current combination of the active site and the reactants undesirable for the prospective methane valorization process.

Mechanistic Complexity of Methane Oxidation with H2O2 by Single-Site Fe/ZSM-5 Catalyst

Periodic density functional theory (DFT) calculations were carried out to investigate the mechanism of methane oxidation with H2O2 over the defined Fe sites in Fe/ZSM-5 zeolite. The initial Fe site is modeled as a [(H2O)2-Fe(III)-(μO)2-Fe(III)-(H2O)2]2+ extraframework cluster deposited in the zeolite pore and charge-compensated by two anionic lattice sites. The activation of this cluster with H2O2 gives rise to the formation of a variety of Fe(III)-oxo and Fe(IV)-oxo complexes potentially reactive toward methane dissociation. These sites are all able to promote the first C-H bond cleavage in methane by following three possible reaction mechanisms: namely, (a) heterolytic and (b) homolytic methane dissociation as well as (c) Fenton-type reaction involving free OH radicals as the catalytic species. The C-H activation step is followed by formation of MeOH and MeOOH and regeneration of the active site. The Fenton-type path is found to proceed with the lowest activation barrier. Although the barriers for the alternative heterolytic and homolytic pathways are found to be somewhat higher, they are still quite favorable and are expected to be feasible under reaction conditions, resulting ultimately in MeOH and MeOOH products. H2O2 oxidant competes with CH4 substrate for the same sites. Since the oxidation of H2O2 to O2 and two [H+] is energetically more favorable than the C-H oxofunctionalization, the overall efficiency of the latter target process remains low.

Porous metallosilicates for heterogeneous, liquid-phase catalysis: perspectives and pertaining challenges

Porous silicates containing dilute amounts of tri-, tetra- and penta-valent metal sites, such as TS-1, Sn-β and Fe-ZSM-5, have recently emerged as state of the art catalysts for a variety of sustainable chemical transformations. In contrast with their aluminosilicate cousins, which are widely employed throughout the refinery industry for gas-phase catalytic transformations, such metallosilicates have exhibited unprecedented levels of performance for a variety of liquid-phase catalytic processes, including the conversion of biomass to chemicals, and sustainable oxidation technologies with H2O2. However, despite their unique levels of performance for these new types of chemical transformations, increased utilization of these promising materials is complicated by several factors. For example, their utilization in a liquid, and often polar, medium hinders process intensification (scale-up, catalyst deactivation). Moreover, such materials do not generally exhibit the active-site homogeneity of conventional aluminosilicates, and they typically possess a wide variety of active-site ensembles, only some of which may be directly involved in the catalytic chemistry of interest. Consequently, mechanistic understanding of these catalysts remains relatively low, and competitive reactions are commonly observed. Accordingly, unified approaches towards developing more active, selective and stable porous metallosilicates have not yet been achieved. Drawing on some of the most recent literature in the field, the purpose of this mini review is both to highlight the breakthroughs made with regard to the use of porous metallosilicates as heterogeneous catalysts for liquid-phase processing, and to highlight the pertaining challenges that we, and others, aim to overcome during the forthcoming years.

Oxidative functionalization of C–H compounds induced by the extremely efficient osmium catalysts (a review)

In recent years, osmium complexes have found applications not only in thecis-hydroxylation of olefins but also very efficient in the oxygenation of C–H compounds (saturated and aromatic hydrocarbons and alcohols) by hydrogen peroxide as well as organic peroxides.