Cavity Controls the Selectivity: Insights of Confinement Effects on MTO Reaction

Controlling product selectivity and catalyst lifetime by altering acid strength, cavity size of SAPO, and diffusion rate of methanol in the MTO reaction: DFT and MD calculations

The initiation mechanisms of the MTO process over silicoaluminophosphate (SAPO) catalysts with zeolite-like structures using first-principles calculations have been investigated. The supramolecular system of silicoaluminophosphates consisting of inorganic cages with Brønsted acid sites and trapped organic compounds was used as a catalyst in the MTO reaction. To study the structure-property relationship in more detail, the effect of acidity and cage size of different types of SAPOs (SAPO-18, SAPO-34, and SAPO-17 with CHA, AEI, and ERI structures, respectively) in the aromatic cycle of hydrocarbon pool mechanism was investigated. The differences in reaction barriers can be explained by the cage size, pore topology, and environment of framework protons of materials. Product selectivity was controlled by using cavity-type zeolite, the steric constraint of the cavity for the formation of critical intermediates, and acidic strength. The results show that ethylene selectivity increases as the cavity size decreases, and the elliptical pore size of the structures decreases, thereby decreasing the acidity of the zeolite structure, leading to an increase in propylene selectivity. SAPO-18 exhibits the longest reaction lifetime and has the highest amount of carbonaceous material after reaction completion. SAPO-17 with small pore and cavity size is selective to ethylene, although it shows a rapid catalyst deactivation rate.

Promoting Syngas to Olefins with Isolated Internal Silanols-Enriched Al-IDM-1 Aluminosilicate Nanosheets

Selective conversion of syngas to value-added olefins has attracted considerable research interest. Regulating product distribution remains challenging, such as achieving higher olefin selectivity, propylene/ethylene (P/E) and olefin/paraffin (O/P) ratios. A new pentasil zeolite Al-IDM-1 with recently approved -ION structure, composed of 17-membered-ring (MR) extra-large lobed pores and intersected 10-MR medium pores, shows a C2-6 = selectivity up to 85 % and a high O/P value of 14 in the conversion of syngas when being combined with Zna Alb Ox oxide. Moreover, for the high-silica Al-IDM-1 with Si/Al ratio of 400, the selectivity of propylene and butene accounts for 88 % in C2-4 = , resulting in high P/E (>4) and butene/ethylene (B/E >3) ratios. The high C3-4 = selectivity is contributed by two main reasons, that is, the relatively weak acidity of Al-IDM-1 zeolite enhances the olefin-based cycle revealed by the probe reactions of methanol-to-propylene (MTP) and 1-hexene cracking, and the rich isolated internal SiOH groups in Al-IDM-1 promote the desorption of C3-4 = , once they are formed inside zeolite pores.

Cavity-controlled methanol conversion over zeolite catalysts

The successful development and application in industry of methanol-to-olefins (MTO) process brought about an innovative and efficient route for olefin production via non-petrochemical resources and also attracted attention of C1 chemistry and zeolite catalysis. Molecular sieve catalysts with diversified microenvironments embedding unique channel/cavity structure and acid properties, exhibit demonstrable features and advantages in the shape-selective catalysis of MTO. Especially, shape-selective catalysis over 8-MR and cavity-type zeolites with acidic supercage environment and narrow pore opening manifested special host-guest interaction between the zeolite catalyst and guest reactants, intermediates and products. This caused great differences in product distribution, catalyst deactivation and molecular diffusion, revealing the cavity-controlled methanol conversion over 8-MR and cavity-type zeolite catalyst. Furthermore, the dynamic and complicated cross-talk behaviors of catalyst material (coke)-reaction-diffusion over these types of zeolites determines the catalytic performance of the methanol conversion. In this review, we shed light on the cavity-controlled principle in the MTO reaction including cavity-controlled active intermediates formation, cavity-controlled reaction routes with the involvement of these intermediates in the complex reaction network, cavity-controlled catalyst deactivation and cavity-controlled diffusion. All these were exhibited by the MTO reaction performances and product selectivity over 8-MR and cavity-type zeolite catalysts. Advanced strategies inspired by the cavity-controlled principle were developed, providing great promise for the optimization and precise control of MTO process.

Dynamic Catalytic Mechanism of the Methanol-to-Hydrocarbons Reaction over Zeolites

ConspectusThe methanol-to-hydrocarbons (MTH) process has provided a new route to obtaining basic chemicals without relying on an oil resource. Acidity and shape selectivity endow the zeolite with a decisive role in MTH catalysis. However, the inherent reaction characteristics of the MTH reaction over zeolites, such as the complexity of catalytic reaction kinetics, the diversity of catalytic reaction modes, and even the limitations of catalytic and diffusive decoupling, have all confused people with respect to obtaining a comprehensive mechanistic understanding. By examining the zeolite-catalyzed MTH reaction from the perspective of chemical bonding, one would realize that this reaction reflects the dynamic assembly process of C-C bonds from C1 components to multicarbon products. The key to understanding the MTH reaction lies in the mechanism by which C-C bonds are formed and rearranged in the confined microenvironment of the channel or cage structures of zeolite catalysts to achieve shape-selective production.The applications of advanced in situ spectroscopy as well as computational chemistry provide tremendous opportunities for capturing and identifying the details of the structure and properties of reactants, intermediates, and products in the confined reaction space of zeolite channels or cages, observing the real-time dynamic evolution of the catalytic surface, and modeling the elementary reaction steps at the molecular and atomic levels.In this Account, the dynamic catalytic mechanism of the zeolite-catalyzed MTH reaction will be outlined based on decades of continuous research and in-depth understanding. The combination of advanced in situ spectroscopy and theoretical methods allowed us to observe and simulate the formation, growth, and aging process on the working catalyst surface and thus map the dynamical evolution of active sites from a Brønsted acid site (BAS) to an organic-inorganic hybrid supramolecule (OIHS) in the MTH reaction. Moreover, the ever-evolving dynamic succession of the OIHS from surface methoxy species (SMS) to active ion-pair complexes (AIPC) to inert complexes (IC) guided the dynamic autocatalytic process from initiation to sustaining and then to termination, resulting in a complex interlaced hypercycle reaction network. The concept of dynamic catalysis will provide deep insight into the complex catalytic mechanisms as well as the structure-activity relationships in MTH chemistry. More importantly, we are now getting closer to the nature of zeolite catalysis beyond the traditional view of BAS catalysis.

Ethane Ammoxidation over Sn/H-Zeolite Catalysts: Toward the Factors Contributing to the Yield of Acetonitrile

Different Sn/H-zeolite (β, MOR, SSZ-13, FER, and Y zeolite) catalysts are prepared with the improved impregnation method. The effects of reaction temperature and the composition of the reaction gas (ammonia, oxygen, and ethane) on the catalytic reaction are investigated. Adjusting the fraction of ammonia and/or ethane in the reaction gas can effectively strengthen the ethane dehydrogenation (ED) route and ethylamine dehydrogenation (EA) route and inhibit the ethylene peroxidation (EO) route, whereas the adjustment of oxygen cannot effectively promote acetonitrile formation because it cannot avoid enhancing the EO route. By comparing the acetonitrile yields on different Sn/H-zeolite catalysts at 600 °C, it is revealed that the ammonia pool effect, the residual Brönsted acid in the zeolite, and the Sn-Lewis acid synergistically catalyze ethane ammoxidation. Moreover, a higher L/B ratio of the Sn/H zeolite is beneficial to the improvement of acetonitrile yield. With a certain application potential, the Sn/H-FER-zeolite catalyst shows an ethane conversion of 35.2% and an acetonitrile yield of 22.9% at 600 °C; although a similar catalytic performance was observed on the best Co-zeolite catalyst in literature, the Sn/H-FER-zeolite catalyst is more selective to ethene and CO than the Co catalyst. In addition, the selectivity to CO₂ is less than 2% of that on the Sn-zeolite catalyst. This may be attributed to the special 2D topology and pore/channel system of the FER zeolite, which guarantee an ideal synergistic effect of the ammonia pool, the residual Brönsted acid in the zeolite, and the Sn-Lewis acid for the Sn/H-FER-catalyzed ethane ammoxidation reaction.

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.

Investigating the Interaction between Methanol and the Heulandite-type Zeolite using First Principle Molecular Dynamic

The interaction between methanol and the Heulandite-type zeolite has been unveiled to give an atomic scale detail regarding the catalytic activity of this zeolite for methanol conversion. The study was carried out by first principle molecular dynamics to get an insight into the structure and electronic behaviour of methanol inside the zeolite structure at different temperatures. The behaviour of methanol was studied when the location of the proton of Bronsted acid sites was varied to give both possible direct and less interaction with methanol. The results show that methanol interacts with the proton from zeolite to give a cationic species of [CH3OH2]+ both in 300K and 573K conditions. However, when the proton is located at different location far from possible interaction with methanol, the formation of a cationic species is hindered. This study provides an insight into the design of Heulandite type zeolite to give a catalytic activity toward methanol transformation.

Influence of zeolite confinement effects on cation-π interactions in methanol-to-hydrocarbon conversion

By using 2D ¹³C-¹³C correlation MAS NMR spectroscopy and DFT calculations, the nature of cation-π interactions between cyclopentenyl cations and benzene was clarified over H-ZSM-5, H-β and H-SSZ-13 zeolites. The cation-π interactions are favored over H-β and H-SSZ-13 with large channels or cages. The zeolite structure is identified to affect the arrangements of cyclopentenyl cations and benzene in the confined environment, leading to different extents of overlapping of positive-negative charge centers and cation-π interaction strength. The stronger cation-π interactions facilitate the bimolecular reactions between cyclopentenyl cations and benzene and the formation of coke species.

Carbocation chemistry confined in zeolites: spectroscopic and theoretical characterizations

Acid-catalyzed reactions inside zeolites are one type of broadly applied industrial reactions, where carbocations are the most common intermediates of these reaction processes, including methanol to olefins, alkene/aromatic alkylation, and hydrocarbon cracking/isomerization. The fundamental research on these acid-catalyzed reactions is focused on the stability, evolution, and lifetime of carbocations under the zeolite confinement effect, which greatly affects the efficiency, selectivity and deactivation of zeolite catalysts. Therefore, a profound understanding of the carbocations confined in zeolites is not only beneficial to explain the reaction mechanism but also drive the design of new zeolite catalysts with ideal acidity and cages/channels. In this review, we provide both an in-depth understanding of the stabilization of carbocations by the pore confinement effect and summary of the advanced characterization methods to capture carbocations in zeolites, including UV-vis spectroscopy, solid-state NMR, fluorescence microscopy, IR spectroscopy and Raman spectroscopy. Also, we clarify the relationship between the activity and stability of carbocations in zeolite-catalyzed reactions, and further highlight the role of carbocations in various hydrocarbon conversion reactions inside zeolites with diverse frameworks and varying acidic properties.

Selective oxidation conversion of methanol/dimethyl ether

As important platform compounds, methanol and dimethyl ether (DME) are vital bridges between the coal chemical, petrochemical and fine chemical industries. At present, the synthesis of methanol/DME has been industrialized, and the production capacity is much larger than the market demand. Therefore, the conversion of methanol/DME into more valuable chemicals is an important and significant topic. The synthesis of high value-added oxygenated chemicals and diesel oil additives from methanol/DME by an oxidation method has attracted substantial attention due to it being green and environmentally friendly and having good atom economy. In this feature article, we have summarized the recent advances in the synthesis of formaldehyde, methyl formate, dimethoxymethane, and polyoxymethylene dimethyl ethers, from the selective oxidation of methanol/DME, and further discussed the adsorption and activation of reactant molecules, selective cleavage of C-O, C-H or O-H bonds in methanol/DME molecules and the C-O chain growth in the target products. In the end, major challenges and future prospects are proposed from the viewpoint of catalyst design and application. It is expected that this feature article will provide theoretical guidance for the activation and cleavage of C-O, C-H, or O-H bonds in other small molecules of alcohol/ether as well as low-carbon alkanes, so as to synthesize high value-added chemicals.

Direct assessment of confinement effect in zeolite-encapsulated subnanometric metal species

Subnanometric metal species confined inside the microporous channels/cavities of zeolites have been demonstrated as stable and efficient catalysts. The confinement interaction between the metal species and zeolite framework has been proposed to play the key role for stabilization, though the confinement interaction is elusive to be identified and measured. By combining theoretical calculations, imaging simulation and experimental measurements based on the scanning transmission electron microscopy-integrated differential phase contrast imaging technique, we have studied the location and coordination environment of isolated iridium atoms and clusters confined in zeolite. The image analysis results indicate that the local strain is intimately related to the strength of metal-zeolite interaction and a good correlation is found between the zeolite deformation energy, the charge state of the iridium species and the local absolute strain. The direct observation of confinement with subnanometric metal species encapsulated in zeolites provides insights to understand their structural features and catalytic consequences.

Zeolite-encapsulated metal nanoparticles have important catalytic properties, but their effect on the zeolite local structure has been difficult to characterize. Here the authors, using DFT calculations and scanning transmission electron microscopy, characterize the local strain due to confinement effects in metal-zeolite catalysts.

Investigation into the crystallization of molecular sieve DNL-6

Crystallization of DNL-6, a silicoaluminophosphate (SAPO) based molecular sieve with the RHO topology, was investigated under both the hydrothermal synthesis (HTS) and dry-gel conversion (DGC) conditions. Crystallization of DNL-6 under the HTS conditions is rather fast. But a combination of crystallization under the DGC conditions and reducing reaction temperature slow down the reactions, allowing for intermediates to be captured. Under the DGC conditions, DNL-6 crystallizes through a semi-crystalline layered phase. The nature of this intermediate is aluminophosphate (AlPO) rather than SAPO with most P atoms having a local environment of P(–O–Al)3(OH). The surfactant (cetyltrimethylammonium chloride) used for synthesis appears to be part of the layered intermediate. Si is directly incorporated in the DNL-6 framework via SM II mechanism when the semi-crystalline AlPO phase is transforming to DNL-6 with the assistance of a very small amount of water. Both the structure directing agent and the surfactant play a role in the formation of DNL-6, as they were found within the final synthesized products. SEM data show that hydrothermal synthesis produces a much more crystalline product. The facts that the semi-crystalline layered phase was also observed in the powder X-ray diffraction patterns of the solid samples obtained under the HTS conditions and that the evolution of the local structure around P and Al in the intermediate phases are similar imply that under the reaction conditions employed in the present study, the formation pathways of DNL-6 under the HTS and DGC conditions appear to have some similarities.

Tuning product selectivity in the MTO reaction over Zn-modified SSZ-13 catalysts

In this work, Zn-modified SSZ-13 catalysts with different spatial distributions of zinc species were prepared by ion exchange (IE), wet impregnation (WI) and in situ synthesis (IS) methods employed for the methanol-to-olefin (MTO) reaction.

Small pore SAPO-14-based zeolites with improved propylene selectivity in methanol to olefins

Methanol to olefins (MTO) is an important non petroleum route to prepare light olefins, however, it still remains a challenge to improve the one-pass propylene selectivity towards the industrial SAPO-34...

Directed transforming of coke to active intermediates in methanol-to-olefins catalyst to boost light olefins selectivity

Methanol-to-olefins (MTO), the most important catalytic process producing ethylene and propylene from non-oil feedstocks (coal, natural gas, biomass, CO₂, etc.), is hindered by rapid catalyst deactivation due to coke deposition. Common practice to recover catalyst activity, i.e. removing coke via air combustion or steam gasification, unavoidably eliminates the active hydrocarbon pool species (HCPs) favoring light olefins formation. Density functional theory calculations and structured illumination microscopy reveal that naphthalenic cations, active HCPs enhancing ethylene production, are highly stable within SAPO-34 zeolites at high temperature. Here, we demonstrate a strategy of directly transforming coke to naphthalenic species in SAPO-34 zeolites via steam cracking. Fluidized bed reactor-regenerator pilot experiments show that an unexpectedly high light olefins selectivity of 85% is achieved in MTO reaction with 88% valuable CO and H₂ and negligible CO₂ as byproducts from regeneration under industrial-alike continuous operations. This strategy significantly boosts the economics and sustainability of MTO process.

Methanol-to-olefins is hindered by rapid catalyst deactivation due to coke deposition. Here the authors demonstrate an approach of directly transforming coke to active intermediates to simultaneously recover catalyst activity and boost light olefins selectivity.

Elucidating Zeolite Channel Geometry-Reaction Intermediate Relationships for the Methanol-to-Hydrocarbon Process

The chemical industry has exploited zeolite shape selectivity for more than 50 years, yet our fundamental understanding remains incomplete. Herein, the zeolite channel geometry-reactive intermediate relationships are studied in detail using anisotropic zeolite ZSM-5 crystals for the methanol-to-hydrocarbon (MTH) process, and advanced magic-angle spinning solid-state NMR (ssNMR) spectroscopy. The utilization of anisotropic ZSM-5 crystals enabled the preferential formation of reaction intermediates in single-orientation zeolite channels, as revealed by molecular dynamics simulations and in situ UV/Vis diffuse-reflectance spectroscopy. The ssNMR results show that the slightly more constrained sinusoidal zeolite channels favor the olefin cycle by promoting the homologation of alkanes, whereas the more extended straight zeolite channels facilitate the aromatic cycle with a higher degree of alkylation of aromatics. Dynamic nuclear polarization experiments further indicate the preferential formation of heavy aromatics at the zeolite surface dominated by the sinusoidal channels, providing further insight into catalyst deactivation.

Water-Induced Structural Dynamic Process in Molecular Sieves under Mild Hydrothermal Conditions: Ship-in-a-Bottle Strategy for Acidity Identification and Catalyst Modification

Water is the most important substance in nature. Imitating the formation of natural materials, molecular sieves have been synthesized under hydrothermal conditions and applied in industry. Herein, we reveal an unforeseen observation on a very special water-induced structural dynamic process of these materials. Dynamic and reversible breaking and forming of T-O-T bonds in silicoaluminophosphate (SAPO) occurs through interactions between gaseous water and the molecular-sieve framework under mild hydrothermal conditions and is confirmed by detection of the incorporation of ¹⁷ O from H₂ ¹⁷ O into molecular-sieve framework. Encapsulation of the bulky molecules trimethylphosphine and pyridine (kinetic diameters much larger than the pore size of SAPO-34) into CHA cavities consolidated the water-induced dynamic process. Consequently, new insights into the dynamic features of molecular sieves in water are provided. The ship-in-a-bottle strategy based on these findings also open new fields for fine acidity identification and gives extra boost in shape-selective catalysis.

Impact of Zeolite Framework Composition and Flexibility on Methanol-To-Olefins Selectivity: Confinement or Diffusion?

The methanol-to-olefins reaction catalyzed by small-pore cage-based acid zeolites and zeotypes produces a mixture of short chain olefins, whose selectivity to ethene, propene and butene varies with the cavity architecture and with the framework composition. The product distribution of aluminosilicates and silicoaluminophosphates with the CHA and AEI structures (H-SSZ-13, H-SAPO-34, H-SSZ-39 and H-SAPO-18) has been experimentally determined, and the impact of acidity and framework flexibility on the stability of the key cationic intermediates involved in the mechanism and on the diffusion of the olefin products through the 8r windows of the catalysts has been evaluated by means of periodic DFT calculations and ab initio molecular dynamics simulations. The preferential stabilization by confinement of fully methylated hydrocarbon pool intermediates favoring the paring pathway is the main factor controlling the final olefin product distribution.

Opportunities for less-explored zeolitic materials in the syngas-to-olefins pathway over nanoarchitectured catalysts: a mini review

The continuous demand for olefins has stimulated recent research to develop appropriate technology to produce olefins from alternative resources.

Direct synthesis of [B,H]ZSM-5 by a solid-phase method: AlF siting and catalytic performance in the MTP reaction

[B,H]ZSM-5 directly synthesized by a solid-phase method with tuned Al_F siting and acidity exhibited a longer lifetime in the MTP reaction.

Recent Progress in Methanol-to-Olefins (MTO) Catalysts

Methanol conversion to olefins, as an important reaction in C1 chemistry, provides an alternative platform for producing basic chemicals from nonpetroleum resources such as natural gas and coal. Methanol-to-olefin (MTO) catalysis is one of the critical constraints for the process development, determining the reactor design, and the profitability of the process. After the construction and commissioning of the world's first MTO plant by Dalian Institute of Chemical Physics, based on high-efficiency catalyst and fluidization technology in 2010, more attention has been attracted for a deep understanding of the reaction mechanism and catalysis principle, which has led to the continuous development of catalysts and processes. Herein, the recent progress in MTO catalyst development is summarized, focusing on the advances in the optimization of SAPO-34 catalysts, together with the development efforts on catalysts with preferential ethylene or propylene selectivity.

Thermal Degradation of Polystyrene under Extreme Nanoconfinement

Extreme nanoconfinement has been shown to significantly affect the properties of materials. Here we demonstrate that extreme nanoconfinement can significantly improve the thermal stability of polystyrene (PS) and reduce its flammability. Capillary rise infiltration (CaRI) is used to infiltrate PS into films of randomly packed silica nanoparticles (NPs) to produce highly confined states. We demonstrate that as the NP size is decreased, increasing the degree of confinement, the isothermal degradation time is dramatically increased, by up to a factor of 30 at 543 K for PS confined in ∼3 nm pores. The activation energy of PS degradation is also increased, by 50 kJ/mol in the most confined state (∼3 nm pores). We demonstrate that the degradation proceeds through the film surface and from the center of large holes toward NP surfaces, indirect evidence that the process is diffusion limited. The surface-driven process dramatically reduces char formation even in large NP packings that show no significant changes in their dynamics and glass transition temperature (T_g) compared to the bulk.