Discerning the Location and Nature of Coke Deposition from Surface to Bulk of Spent Zeolite Catalysts

Recent developments in (bio)ethanol conversion to fuels and chemicals over heterogeneous catalysts

Bioethanol is one of the most important bio-resources produced from biomass fermentation and is an environmentally friendly alternative to fossil-based fuels as it is regarded as renewable and clean. Bioethanol and its derivatives are used as feedstocks in petrochemical processes as well as fuel and fuel additives in motor vehicles to compensate for the depletion of fossil fuels. This review chronicles the recent developments in the catalytic conversion of ethanol to diethyl ether, ethylene, propylene, long-chain hydrocarbons and other important products. Various heterogeneous catalysts, such as zeolites, metal oxides, heteropolyacids, mesoporous materials and metal-organic frameworks, have been used in the ethanol conversion processes and are discussed extensively. The significance of various reaction parameters such as pressure, temperature, water content in the ethanol feed and the effect of catalyst modification based on various kinds of literature are critically evaluated. Further, coke formation and coke product analysis using various analytical and spectroscopic techniques during the ethanol conversion are briefly discussed. The review concludes by providing insights into possible research paths pertaining to catalyst design aimed at enhancing the catalytic conversion of (bio)ethanol.

Polyethylene upcycling to aromatics by pulse pressurized catalytic pyrolysis

To address the challenging issues of waste plastic pollution and petroleum shortage, we report herein a pulse pressurized catalytic pyrolysis process where polyethylene is continuously converted into aromatics using HZSM-5 catalyst incorporated with hydrated SiO2. Pressurization improves the activity of single-pulse pyrolysis of polyethylene by 14.42%. In contrast to the linear decrease of BTEXS relative yield with a K value of - 0.23 under non-pressurized conditions, pressurization results in a notable stability in the latter stage, characterized by a K value of only - 0.063. Comprehensive catalyst characterization demonstrates that pressurization promotes the release of water from hydrated SiO2, enabling HZSM-5 to effectively undergo dealumination and obtain suitable acidity and pore structure, and ultimately enhancing the resistance to carbon deposition. In summary, pressurization improves both pyrolysis activity and catalysis stability, offering a promising strategy for the high-value utilization of waste plastics.

Resolving protein-mineral interfacial interactions during in vitro mineralization by atom probe tomography

Organic macromolecules exert remarkable control over the nucleation and growth of inorganic crystallites during (bio)mineralization, as exemplified during enamel formation where the protein amelogenin regulates the formation of hydroxyapatite (HAP). However, it is poorly understood how fundamental processes at the organic-inorganic interface, such as protein adsorption and/or incorporation into minerals, regulates nucleation and crystal growth due to technical challenges in observing and characterizing mineral-bound organics at high-resolution. Here, atom probe tomography techniques were developed and applied to characterize amelogenin-mineralized HAP particles in vitro, revealing distinct organic-inorganic interfacial structures and processes at the nanoscale. Specifically, visualization of amelogenin across the mineralized particulate demonstrates protein can become entrapped during HAP crystal aggregation and fusion. Identification of protein signatures and structural interpretations were further supported by standards analyses, i.e., defined HAP surfaces with and without amelogenin adsorbed. These findings represent a significant advance in the characterization of interfacial structures and, more so, interpretation of fundamental organic-inorganic processes and mechanisms influencing crystal growth. Ultimately, this approach can be broadly applied to inform how potentially unique and diverse organic-inorganic interactions at different stages regulates the growth and evolution of various biominerals.

Real-time regeneration of a working zeolite monitored via operando X-ray diffraction and crystallographic imaging: how coke flees the MFI framework

X-ray diffraction is used to investigate regeneration of an H-ZSM-5 zeolite catalyst used in the conversion of methanol to hydrocarbons.

Onset of High Methane Combustion Rates over Supported Palladium Catalysts: From Isolated Pd Cations to PdO Nanoparticles

Industrial low-temperature methane combustion catalyst Pd/Al₂O₃ suffers from H₂O-induced deactivation. It is imperative to design Pd catalysts free from this deactivation and with high atomic efficiency. Using a small-pore zeolite SSZ-13 as support, herein we report well-defined Pd catalysts with dominant active species as finely dispersed Pd cations, uniform PdO particles embedded inside the zeolite framework, or PdO particles decorating the zeolite external surface. Through detailed reaction kinetics and spectroscopic and microscopic studies, we show that finely dispersed sites are much less active than PdO nanoparticles. We further demonstrate that H₂O-induced deactivation can be readily circumvented by using zeolite supports with high Si/Al ratios. Finally, we provide a few rational catalyst design suggestions for methane oxidation based on the new knowledge learned in this study.

Molecular elucidating of an unusual growth mechanism for polycyclic aromatic hydrocarbons in confined space

Extension and clustering of polycyclic aromatic hydrocarbons (PAHs) are key mechanistic steps for coking and deactivation in catalysis reactions. However, no unambiguous mechanistic picture exists on molecule-resolved PAHs speciation and evolution, due to the immense experimental challenges in deciphering the complex PAHs structures. Herein, we report an effective strategy through integrating a high resolution MALDI FT-ICR mass spectrometry with isotope labeling technique. With this strategy, a complete route for aromatic hydrocarbon evolution is unveiled for SAPO-34-catalyzed, industrially relevant methanol-to-olefins (MTO) as a model reaction. Notable is the elucidation of an unusual, previously unrecognized mechanistic step: cage-passing growth forming cross-linked multi-core PAHs with graphene-like structure. This mechanistic concept proves general on other cage-based molecule sieves. This preliminary work would provide a versatile means to decipher the key mechanistic step of molecular mass growth for PAHs involved in catalysis and combustion chemistry.

Coke-induced catalyst deactivation draws increasing concerns in industrially catalytic processes. Here the authors provide a strategy integrating advanced mass spectroscopy and isotope labeling to uncover a cage-passing molecular route of coking species in molecular sieve catalysts.

Atom Probe Tomography for Catalysis Applications: A Review

Atom probe tomography is a well-established analytical instrument for imaging the 3D structure and composition of materials with high mass resolution, sub-nanometer spatial resolution and ppm elemental sensitivity. Thanks to recent hardware developments in Atom Probe Tomography (APT), combined with progress on site-specific focused ion beam (FIB)-based sample preparation methods and improved data treatment software, complex materials can now be routinely investigated. From model samples to complex, usable porous structures, there is currently a growing interest in the analysis of catalytic materials. APT is able to probe the end state of atomic-scale processes, providing information needed to improve the synthesis of catalysts and to unravel structure/composition/reactivity relationships. This review focuses on the study of catalytic materials with increasing complexity (tip-sample, unsupported and supported nanoparticles, powders, self-supported catalysts and zeolites), as well as sample preparation methods developed to obtain suitable specimens for APT experiments.

Probing the Location and Speciation of Elements in Zeolites with Correlated Atom Probe Tomography and Scanning Transmission X-Ray Microscopy

Characterizing materials at nanoscale resolution to provide new insights into structure property performance relationships continues to be a challenging research target due to the inherently low signal from small sample volumes, and is even more difficult for nonconductive materials, such as zeolites. Herein, we present the characterization of a single Cu-exchanged zeolite crystal, namely Cu-SSZ-13, used for NOX reduction in automotive emissions, that was subject to a simulated 135,000-mile aging. By correlating Atom Probe Tomography (APT), a single atom microscopy method, and Scanning Transmission X-ray Microscopy (STXM), which produces high spatial resolution X-ray Absorption Near Edge Spectroscopy (XANES) maps, we show that a spatially non-uniform proportion of the Al was removed from the zeolite framework. The techniques reveal that this degradation is heterogeneous at length scales from micrometers to tens of nanometers, providing complementary insight into the long-term deactivation of this catalyst system.

Revealing long- and short-range structural modifications within phosphorus-treated HZSM-5 zeolites by atom probe tomography, nuclear magnetic resonance and powder X-ray diffraction

The average and the local structure of phosphorus-treated HZSM-5 zeolites were investigated by means of atom probe tomography, powder X-ray diffraction (at ambient and cryogenic temperatures) and 1H, 29Si, 27Al, and 31P magic angle spinning (MAS) solid state nuclear magnetic resonance (NMR) spectroscopy. Phosphatation to yield a product with P/Al ≤ 1 followed by thermal treatment leads to breaking of the Si-OH-Al bridging groups, and subsequent partial dealumination of the zeolite framework, as shown by the contraction of the orthorhombic unit-cell volume and by the loss of tetrahedral framework Al, as observed in the 27Al Multiple Quantum (MQ) MAS NMR spectrum. Most of the framework Al is present in an electronic environment distorted by the presence of phosphorus and appears not to be involved in classic Si-OH-Al Brønsted acid sites. The 31P MAS NMR signals indicate that phosphorus interacts with the zeolitic framework to locally form silico-aluminophosphate (SAPO) domains and the presence of a new kind of acidic site was confirmed by the resonance at ∼8.6 ppm in the 1H MAS NMR spectra, attributed to P-OH groups. Increasing the phosphorus loading (P/Al ≫ 1) promotes further dealumination of the framework and cross-dehydroxylation between P-OH and Si-OH species, leading to the formation of a crystalline silicon orthophosphate phase. With decreasing Al content, the monoclinic HZSM-5 structure becomes preferred, especially at 85 K where the strain relaxation is higher. However, the presence of a higher amount of silicophosphate impurities hinders the low-temperature strain release of the framework, indicating that some of these species are localized in the zeolite pores and contribute to the strain build up.

Nanoscale Chemical Imaging of Zeolites Using Atom Probe Tomography

Understanding structure-composition-property relationships in zeolite-based materials is critical to engineering improved solid catalysts. However, this can be difficult to realize as even single zeolite crystals can exhibit heterogeneities spanning several orders of magnitude, with consequences for, for example, reactivity, diffusion as well as stability. Great progress has been made in characterizing these porous solids using tomographic techniques, though each method has an ultimate spatial resolution limitation. Atom probe tomography (APT) is the only technique so far capable of producing 3D compositional reconstructions with sub-nanometer-scale resolution, and has only recently been applied to zeolite-based catalysts. Herein, we discuss the use of APT to study zeolites, including the critical aspects of sample preparation, data collection, assignment of mass spectral peaks including the predominant CO peak, the limitations of spatial resolution for the recovery of crystallographic information, and proper data analysis. All sections are illustrated with examples from recent literature, as well as previously unpublished data and analyses to demonstrate practical strategies to overcome potential pitfalls in applying APT to zeolites, thereby highlighting new insights gained from the APT method.

Isolating Clusters of Light Elements in Molecular Sieves with Atom Probe Tomography

Understanding the 3-D distribution and nature of active sites in heterogeneous catalysts is critical to developing structure–function relationships. However, this is difficult to achieve in microporous materials as there is little relative z-contrast between active and inactive framework elements (e.g., Al, O, P, and Si), making them difficult to differentiate with electron microscopies. We have applied atom probe tomography (APT), currently the only nanometer-scale 3-D microscopy to offer routine light element contrast, to the methanol-to-hydrocarbons (MTH) catalyst SAPO-34, with Si as the active site, which may be present in the framework as either isolated Si species or clusters (islands) of Si atoms. ²⁹Si solid-state NMR data on isotopically enriched and natural abundance materials are consistent with the presence of Si islands, and the APT results have been complemented with simulations to show the smallest detectable cluster size as a function of instrument spatial resolution and detector efficiency. We have identified significant Si–Si affinity in the materials, as well as clustering of coke deposited by the MTH reaction (¹³CH₃OH used) and an affinity between Brønsted acid sites and coke. A comparison with simulations shows that the ultimate spatial resolution that can be attained by APT applied to molecular sieves is 0.5–1 nm. Finally, the observed ¹³C clusters are consistent with hydrocarbon pool mechanism intermediates that are preferentially located in regions of increased Brønsted acidity.