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

Revealing Active Sites and Reaction Pathways in Direct Oxidation of Methane over Fe-Containing CHA Zeolites Affected by the Al Arrangement

Fe-containing zeolites are effective catalysts in converting the greenhouse gases CH4 and N2O into valuable chemicals. However, the activities of Fe-containing zeolites in methane conversion and N2O decomposition are frequently conflated, and the activities of different Fe species are still controversial. Herein, Fe-containing aluminosilicate CHA zeolites with Fe species at different spatial distances affected by the arrangement of framework Al atoms were synthesized in a one-pot manner in the presence or absence of Na. The arrangement of framework Al atoms was identified by 27Al and 29Si MAS NMR spectra and thermogravimetry-differential thermal analysis (TG-DTA) curves. Ultraviolet (UV)-vis, X-ray absorption spectroscopy (XAS), and NO adsorption fourier transform infrared spectroscopy (FTIR) spectra were adopted to analyze Fe speciation. The higher proportion of Fe species in the 6 MR of Fe-CHA zeolites in the presence of Na was confirmed by the NO adsorption FTIR spectrum. The activities of proximal and distant Fe sites in reactions including direct oxidation of methane to methanol, methanol to hydrocarbon, and N2O decomposition were compared at different temperatures to provide the corresponding active sites and reaction pathways. The distant, isolated Fe and isolated proton were more active in the direct oxidation of methane to methanol and tandem conversion of methanol to hydrocarbon reactions than the proximal, isolated Fe and paired protons, respectively. Additionally, proximal, isolated Fe sites afforded higher activity in N2O decomposition. These findings guide the design of highly active catalysts in methane oxidation, methanol to hydrocarbon, and N2O decomposition reactions, addressing energy and environmental concerns.

Optimizing the reaction pathway of methane photo-oxidation over single copper sites

Direct photocatalytic conversion of methane to value-added C1 oxygenate with O2 is of great interest but presents a significant challenge in achieving highly selective product formation. Herein, a general strategy for the construction of copper single-atom catalysts with a well-defined coordination microenvironment is developed on the basis of metal-organic framework for selective photo-oxidation of CH4 to HCHO. We propose the directional activation of O2 on the mono-copper site breaks the original equilibrium and tilts the balance of radical formation almost completely toward •OOH. The synchronously generated •OOH and •CH3 radicals rapidly combine to form HCHO while inhibiting competing reactions, thus resulting in ultra-highly selective HCHO production (nearly 100%) with a time yield of 2.75 mmol gcat-1 h-1. This work highlights the potential of rationally designing reaction sites to manipulate reaction pathways and achieve selective CH4 photo-oxidation, and could guide the further design of high-performance single-atom catalysts to meet future demand.

Atomically Dispersed Iron-Copper Dual-Metal Sites Synergistically Boost Carbonylation of Methane

The direct liquid-phase oxidative carbonylation of methane, utilizing abundant natural gas, offers a mild and straightforward alternative. However, most catalysts proposed for this process suffer from low acetic acid yields due to few active sites and rapid C1 oxygenate generation, impeding their industrial feasibility. Herein, we report a highly efficient 0.1Cu/Fe-HZSM-5-TF (TF denotes template-free synthesis) catalyst featuring exclusively mononuclear Fe and Cu anchored in the ZSM-5 channels. Under optimized conditions, the catalyst achieved an unprecedented acetic acid yield of 40.5 mmol gcat -1 h-1 at 50 °C, tripling the previous records of 12.0 mmol gcat -1 h-1. Comprehensive characterization, isotope-labeled experiments and density functional theory (DFT) calculations reveal that the homogeneous mononuclear Fe sites are responsible for the activation and oxidation of methane, while the neighboring Cu sites play a key role in retarding the oxidation process, promoting C-C coupling for effective acetic acid synthesis. Furthermore, the methyl-group carbon in acetic acid originates solely from methane, while its carbonyl-group carbon is derived exclusively from CO, rather than the conversion of other C1 oxygenates. The proposed bimetallic catalyst design not only overcomes the limitations of current catalysts but also generalizes the oxidative carbonylation of other alkanes, demonstrating promising advancements in sustainable chemical synthesis.

Highly Selective Synthesis of Acetic Acid from Hydroxyl-Mediated Oxidation of Methane at Low Temperatures

Direct methane conversion and, in particular, the aerobic oxidation to acetic acid, remain an eminent challenge. Here, we reported a zeolite-supported Au-Fe catalyst (Au-Fe/ZSM-5) that converted methane to acetic acid with molecular oxygen as an oxidant in the presence of CO. Specifically, Au nanoparticles catalyzed the formation of hydroxyl species from the reaction of CO, O2, and H2O, meanwhile ZSM-5-supported atomically dispersed Fe species were responsible for the hydroxyl-mediated coupling of CH4 and CO to generate acetic acid. The reaction over 50 mg of Au-Fe/ZSM-5 under 62 bar (CH4 : CO : O2=14 : 14 : 3) at 120 °C for 3.0 h yielded 5.7 millimoles of acetic acid per gram of the catalyst (mmol gcat -1) with the selectivity of 92 %, outperformed most of reported catalysts. Significantly, the catalyst remained active even at 60 °C. We anticipate that this hydroxyl-mediated route may guide the design of optimized catalysts for the direct methane functionalization at low temperatures.

Rutile TiO2-Supported Pt Nanoparticle Catalysts for the Low-Temperature Oxidation of Ethane to Ethanol

Structure-function relationships of supported metal nanoparticle catalysts in the CO-assisted oxidation of ethane to ethanol were investigated. A rutile TiO2-supported Pt nanoparticle catalyst exhibited the highest ethanol production rate and selectivity. During the reaction, sequential changes in the geometric/electronic states and the particle size of the Pt nanoparticles were observed. The comparison of the catalytic performances of model catalysts with controlled metal-support interactions revealed that Pt0 nanoparticles of 2-3 nm with a high fraction of the surface Ptδ+ species are highly active for the oxidation of ethane to ethanol. The coadded CO plays a pivotal role not only in tuning the oxidation state of the surface Pt but also in producing H2O2, which is the true oxidant for the reaction. The supported Pt nanoparticle uses in situ-generated H2O2 to activate ethane, where the C2H5OOH intermediate is formed through a nonradical mechanism and subsequently converted to C2H5OH. This reaction occurs even at 50 °C with an apparent activation energy of 32 kJ mol-1. The present study sheds light on the usefulness of surface-engineered Pt nanoparticles for the low-temperature oxidation of ethane to ethanol.

Selective C-H Bond Activation in Propane with Molecular Oxygen over Cu(I)-ZSM-5 at Ambient Conditions

Selective activation of C-H bonds in light alkanes under mild conditions is challenging but holds the promise of efficient upgrading of abundant hydrocarbons. In this work, we report the conversion of propane to propylene with ∼95% selectivity on Cu(I)-ZSM-5 with O2 at room temperature and pressure. The intraporous Cu(I) species was oxidized to Cu(II) during the reaction but could be regenerated with H2 at 220 °C. Diffuse reflectance ultraviolet spectroscopy indicated the presence of both Cu+-O2 and Cu2(μ-O2)2+ species in the zeolite pores during the reaction, and electron paramagnetic resonance results showed that propane activation occurred via a radical-mediated pathway distinct from that with H2O2 as the oxidant. Correlation between spectroscopic and reactivity results on Cu(I)-ZSM-5 with different Cu loadings suggests that the isolated intraporous Cu(I) species is the main active species in propane activation.

Conversion of Polypropylene into Light Hydrocarbons and Aromatics by Metal Exchanged Zeolite Catalysts

Polyolefins can be converted into C2-C5 hydrocarbons and benzene-toluene-xylene (BTX) aromatics as high-demand petrochemical feedstocks via catalytic pyrolysis on acidic zeolites. Bro̷nsted and Lewis acid sites are responsible for cracking polyolefins into olefins and subsequent aromatic formation. In this study, we have subjected the parent HZSM-5 zeolite to postsynthetic partial metal exchange with Fe, Co, Ni, Cu, and Ce cations to perturb Bro̷nsted/Lewis acidity. We have investigated these metal-modified HZSM-5 on the catalytic pyrolysis of polypropylene (PP) in a micropyrolyzer connected to a two-dimensional gas chromatograph coupled to a time-of-flight mass spectrometer and flame ionization detector (Tandem Pyrolyzer-GC × GC-TOF-MS/FID setup). Whereas Fe-, Co-, Cu-, and Ce-exchanged zeolites (with 2.5, 2.3, 1.9, and 0.8 wt % metal, respectively) had comparable product yields with the parent zeolite, Ni-exchanged zeolites with Ni content of 0.5 to 2 wt % were associated with enhanced BTX formation (28-38 wt %) compared to that of the parent zeolite (22 wt %). Pyridine-FTIR indicated that the Bro̷nsted/Lewis acid ratio of the parent zeolite decreased upon metal ion exchange. According to Pyridine-TPD, the parent zeolite's medium-strength acid sites were redistributed into weak and strong acid sites in Ni-exchanged zeolites. The higher amount of carbon deposits on Ni-exchanged zeolites compared to the parent and other metal ion exchanged zeolites was attributed to the enhanced aromatization activity by the simultaneous decrease in the Bro̷nsted/Lewis acid ratio and emergence of strong acid sites.

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.

Hydrothermal Aging Enhances Nitrogen Oxide Reduction over Iron-Exchanged Zeolites at 150 °C

Ammonia selective catalytic reduction (NH3-SCR) over copper- and iron-exchanged zeolites is a state-of-the-art technology for removal of nitrogen oxides (NOx, NO, and NO2) from exhaust emissions but suffers from poor low-temperature (i.e., 150 °C) activity. Here we show that hydrothermal aging of Fe-beta, Fe-ZSM-5, and Fe-ferrierite at 650 °C or higher leads to a remarkable increase in NOx conversion from ∼30 to ∼80% under fast NH3-SCR conditions at 150 °C. The practical relevance of this finding becomes more evident as an aged Fe-beta/fresh Cu-SSZ-13 composite catalyst exhibits ∼90% conversion. We propose that a neutral heteronuclear bis-μ-oxo ironaluminum dimer might be created within iron zeolites during hydrothermal aging and catalyze ammonium nitrate reduction by NO at 150 °C. Density functional theory calculations reveal that the activation free energy (125 versus 147 kJ mol-1) for the reaction of NO with adsorbed NO3- species, the rate-determining step of ammonium nitrate reduction, is considerably lower on the bis-μ-oxo ironaluminum site than on the well-known mononuclear iron-oxo cation site, thus greatly enhancing the overall SCR activity.

Zeolite Synthesis in the Presence of Metallosiloxanes for the Quantitative Encapsulation of Metal Species for the Selective Catalytic Reduction (SCR) of NOx

Metal encapsulation in zeolitic materials through one-pot hydrothermal synthesis (HTS) is an attractive technique to prepare zeolites with a high metal dispersion. Due to its simplicity and the excellent catalytic performance observed for several catalytic systems, this method has gained a great deal of attention over the last few years. While most studies apply synthetic methods involving different organic ligands to stabilize the metal under synthesis conditions, here we report the use of metallosiloxanes as an alternative metal precursor. Metallosiloxanes can be synthesized from simple and cost-affordable chemicals and, when used in combination with zeolite building blocks under standard synthesis conditions, lead to quantitative metal loading and high dispersion. Thanks to the structural analogy of siloxane with TEOS, the synthesis gel stabilizes by forming siloxane bridges that prevent metal precipitation and clustering. When focusing on Fe-encapsulation, we demonstrate that Fe-MFI zeolites obtained by this method exhibit high catalytic activity in the NH3 -mediated selective catalytic reduction (SCR) of NOx along with a good H2 O/SO2 tolerance. This synthetic approach opens a new synthetic route for the encapsulation of transition metals within zeolite structures.

Solar-Driven Reforming of Methane and Nitrogen to Methanol and Ammonium on Iron-Modified Zeolite under Ambient Conditions in Water

Artificial photosynthesis from selective methane oxidation or nitrogen reduction to value-added chemicals provides a promising pathway for the sustainable chemical industry, while still remaining a great challenge due to the extreme difficulty in C-H and N≡N bond cleavage under ambient conditions. Catalysts that can cocatalyze these two reactions simultaneously are rarely reported. Here, Fe-ZSM-5 with highly dispersed extra-framework Fe-oxo species enables efficient and selective photocatalytic conversion of methane and nitrogen to coproduce methanol and ammonia using H2O as the redox reagent under ambient conditions. The optimized Fe-ZSM-5 photocatalyst achieves up to 0.88 mol/molFe·h of methanol products with 97% selectivity. Meanwhile, the productivity of ammonia is 0.61 mol/molFe·h. In situ EPR and DRIFT studies disclose that water serves as a redox reagent to provide hydroxyl radicals for methane oxidation and protons for nitrogen hydrogenation. Quantum chemical calculations revealed that Fe-oxo species play a significant role in the coactivation of methane and nitrogen molecules, which lowers the energy barriers of rate-determining steps for methanol and ammonia generation.