Mechanistic insight into the effect of active site motif structures on direct oxidation of methane to methanol over Cu-ZSM-5

Direct oxidation of methane to methanol (DMTM), a highly challenging reaction in C1 chemistry, has attracted lots of attention. Herein, we investigate the continuous H2O-mediated N2O-DMTM over a series of Cu-ZSM-5-n zeolites prepared by a solid-state ion-exchange method. Excellent CH3OH productivity (194.8 μmol gcat-1 h-1) and selectivity (67.1%) can be achieved over Cu-ZSM-5-0.3%, which surpasses most recently reported zeolite catalysts. The effect of the active site motif structure on the reaction was systematically investigated by the combined experimental and theoretical studies. It has been revealed that both the monomeric [Cu]+ and binuclear [Cu]+-[Cu]+ sites function to produce CH3OH, following the radical rebound mechanism, wherein the latter one plays a dominant role due to the synergistic effect of neighboring [Cu]+ that can efficiently reduce the N2O dissociation barrier to generate active oxygen for CH4 oxidation. Microkinetic modeling results further show that the dicopper site possesses a much higher net reaction rate (1.23 × 105 s-1) than the monomeric Cu site (0.962 s-1); moreover, H2O can shift the rate determining step from the CH3OH desorption step to the N2O dissociation step over the dicopper site, thereby efficiently favoring CH3OH production and resisting carbon deposition. Generally, the study in the present work would substantially favor other highly efficient catalyst designs.

Understanding and tackling the activity and selectivity issues for methane to methanol using single atom alloys

The process for the direct oxidation of methane to methanol is investigated on single atom alloys using density functional theory. A catalyst search is performed across FCC metal single atom alloys. 7 single atom alloys are found as candidates and microkinetic modelling is performed. The activity and selectivity are remarkably improved over that of pure palladium metal, yet remain unideal.

Selective oxidation of methane to methanol and methyl hydroperoxide over palladium modified MoO3 photocatalyst under ambient conditions

In situ generated H2O2 from water on Pd–MoO3 catalyst can oxide methane into methanol and methyl hydroperoxide with high selectivity under simulated solar light irradiation.

Selective formation of propan-1-ol from propylene via a chemical looping approach

A novel chemical looping approach for propan-1-ol production from propylene.

Harnessing of Diluted Methane Emissions by Direct Partial Oxidation of Methane to Methanol over Cu/Mordenite

The upgrading of diluted methane emissions into valuable products can be accomplished at low temperatures (200 °C) by the direct partial oxidation of methanol over copper-exchanged zeolite catalysts. The reaction has been studied in a continuous fixed-bed reactor loaded with a Cu–mordenite catalyst, according to a three-step cyclic process: adsorption of methane, desorption of methanol, and reactivation of the catalyst. The purpose of the work is the use of methane emissions as feedstocks, which is challenging due to their low methane concentration and the presence of oxygen. Methane concentration had a marked influence on methane adsorption and methanol production (decreased from 164 μmol/g Cu for pure methane to 19 μmol/g Cu for 5% methane). The presence of oxygen, even in low concentrations (2.5%), reduced methane adsorption drastically. However, methanol production was only affected slightly (average decrease of 9%), concluding that methane adsorbed on the active centers yielding methanol is not influenced by oxygen.

Methane Over-Oxidation by Extra-Framework Copper-Oxo Active Sites of Copper-Exchanged Zeolites: Crucial Role of Traps for the Separated Methyl Group

Copper-exchanged zeolites are useful for stepwise conversion of methane to methanol at moderate temperatures. This process also generates some over-oxidation products like CO and CO₂ . However, mechanistic pathways for methane over-oxidation by copper-oxo active sites in these zeolites have not been previously described. Adequate understanding of methane over-oxidation is useful for developing systems with higher methanol yields and selectivities. Here, we use density functional theory (DFT) to examine methane over-oxidation by [Cu₃ O₃ ]²⁺ active sites in zeolite mordenite MOR. The methyl group formed after activation of a methane C-H bond can be stabilized at a μ-oxo atom of the active site. This μ-(O-CH₃ ) intermediate can undergo sequential hydrogen atom abstractions till eventual formation of a copper-monocarbonyl species. Adsorbed formaldehyde, water and formates are also formed during this process. The overall mechanistic path is exothermic, and all intermediate steps are facile at 200 °C. Release of CO from the copper-monocarbonyl costs only 3.4 kcal/mol. Thus, for high methanol selectivities, the methyl group from the first hydrogen atom abstraction step must be stabilized away from copper-oxo active sites. Indeed, it must be quickly trapped at an unreactive site (short diffusion lengths) while avoiding copper-oxo species (large paths between active sites). This stabilization of the methyl group away from the active sites is central to the high methanol selectivities obtained with stepwise methane-to-methanol conversion.

Methane to Methanol through Heterogeneous Catalysis and Plasma Catalysis

Direct oxidation of methane to methanol (DOMTM) is attractive for the increasing industrial demand of feedstock. In this review, the latest advances in heterogeneous catalysis and plasma catalysis for DOMTM are summarized, with the aim to pinpoint the differences between both, and to provide some insights into their reaction mechanisms, as well as the implications for future development of highly selective catalysts for DOMTM.

Investigating the innate selectivity issues of methane to methanol: consideration of an aqueous environment

The higher reactivity of the methanol product over the methane reactant for the direct oxidation of methane to methanol is explored. C-H activation, C-O coupling, and C-OH coupling are investigated as key steps in the selective oxidation of methane using DFT. These elementary steps are initially considered in the gas phase for a variety of fcc (111) pristine metal surfaces. Methanol is found to be consistently more reactive for both C-H activation and subsequent oxidation steps. With an aqueous environment being understood experimentally to have a profound effect on the selectivity of this process, these steps are also considered in the aqueous phase by ab initio molecular dynamics calculations. The water solvent is modelled explicity, with each water molecule given the same level of theory as the metal surface and surface species. Free energy profiles for these steps are generated by umbrella sampling. It is found that an aqueous environment has a considerable effect on the kinetics of the elementary steps yet has little effect on the methane/methanol selectivity-conversion limit. Despite this, we find that the aqueous phase promotes the C-OH pathway for methanol formation, which could enhance the selectivity for methanol formation over that of other oxygenates.

Effects of single and double active sites of Cu oxide clusters over the MFI zeolite for direct conversion of methane to methanol: DFT calculations

In this work, we investigate the effect of various species of Cu oxide clusters including single and double active sites incorporated in the MFI zeolite framework for the direct conversion of methane to methanol. An M06-2X density functional calculation is employed to fine-tune the suitable number and species of active sites and to provide insights into the effect of the active sites on the reaction mechanism of methane to methanol. Two models, single and double active sites of Cu oxide clusters, have been chosen, in which the single active site of Cu oxide clusters, (mono(μ-oxo)dicopper(ii)), is located at the Al1'-Al12' pair ([Cu(μ-O)Cu]2+@Al1'-Al12'/MFI) or at the Al6-Al7 pair ([Cu(μ-O)Cu]2+@Al6-Al7/MFI) in the MFI framework. For the double active sites of Cu oxide clusters, two species of double active sites of Cu oxide are considered. The first one is the double active site of mono(μ-oxo)dicopper(ii) containingtwo Al-Al pairs (Al1'-Al12' and Al6-Al7 pairs) in the MFI framework (2[Cu(μ-O)Cu]2+/MFI) and the other is the double active site of trans-μ-1,2-peroxo dicopper(ii), which occupies two Al-Al pairs (Al1'-Al12' and Al6-Al7 pairs) in the MFI framework (2[Cu(μ-1,2-peroxo)Cu]2+/MFI). Furthermore, the activation energy for C-H bond dissociation in direct methane conversion to methanol is considered. Compared with the single active site of [Cu(μ-O)Cu]2+/MFI, the double active sites, in particular (2[Cu(μ-O)Cu]2+/MFI), exhibited the lowest activation energy, approximately 12.5 kcal mol-1. The high charge transfer between activated methane and Cu oxide active sites and also the high negative partial charge at the bridging oxygen of Cu oxide active sites, which directly interact with the methane molecule and abstracts its H atom, are considered as the important factors which affect the catalytic activity of Cu oxide clusters for direct methane conversion to methanol. These findings strongly support that the number and species of Cu oxide active sites incorporated in the MFI framework can highly affect the reaction mechanism of methane to methanol.

Data science assisted investigation of catalytically active copper hydrate in zeolites for direct oxidation of methane to methanol using H2O2

Dozens of Cu zeolites with MOR, FAU, BEA, FER, CHA and MFI frameworks are tested for direct oxidation of CH₄ to CH₃OH using H₂O₂ as oxidant. To investigate the active structures of the Cu zeolites, 15 structural variables, which describe the features of the zeolite framework and reflect the composition, the surface area and the local structure of the Cu zeolite active site, are collected from the Database of Zeolite Structures of the International Zeolite Association (IZA). Also analytical studies based on inductively coupled plasma-optical emission spectrometry (ICP-OES), X-ray fluorescence (XRF), N₂ adsorption specific surface area measurement and X-ray absorption fine structure (XAFS) spectral measurement are performed. The relationships between catalytic activity and the structural variables are subsequently revealed by data science techniques, specifically, classification using unsupervised and supervised machine learning and data visualization using pairwise correlation. Based on the unveiled relationships and a detailed analysis of the XAFS spectra, the local structures of the Cu zeolites with high activity are proposed.

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.

Catalytic direct oxidation of methane to methanol by redox of copper mordenite

Catalytic production of CH₃OH by direct oxidation of CH₄ with O₂ was performed using Cu zeolites in a CH₄/O₂/H₂O flow reaction, where Cu-MOR exhibited relatively high CH₃OH production with the redox of Cu(i)/Cu(ii) species.

Catalytic oxidation of methane to methanol over Cu-CHA with molecular oxygen

Catalytic production of CH3OH in a CH4–O2–H2O flow reaction is improved using Cu-CHA having improved redox property involved in the C–H activation of CH4.

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.

The mechanism and ligand effects of single atom rhodium supported on ZSM-5 for the selective oxidation of methane to methanol

The mechanism for the partial oxidation of methane to methanol on single atom rhodium supported on ZSM-5 is investigated by DFT. The most favoured mechanism for methane activation is shown to be via oxidative addition at an undercoordinated rhodium metal centre and not through a typical metal oxo intermediate. The formation of a C-OH bond, and not methane activation, is found to be the rate determining step. CO coordinated to the rhodium centre is observed to strongly promote this bond formation. Water is required in the system to help prevent catalyst poisoning by CO, which greatly hinders the methane activation step, and to protonate an intermediate RhOOH species. These results suggest that more focus is required on methyl-oxygen bond formation and that exclusive consideration of methane activation will not completely explain some methane partial oxidation systems.

Active sites and mechanisms in the direct conversion of methane to methanol using Cu in zeolitic hosts: a critical examination

In this critical review we examine the current state of our knowledge in respect of the nature of the active sites in copper containing zeolites for the selective conversion of methane to methanol.

Cu oxo nanoclusters for direct oxidation of methane to methanol: formation, structure and catalytic performance

Cu oxo nanoclusters hosted in microporous solids have emerged in the past decades as promising materials for catalyzing the selective conversion of methane to methanol.

The effect of oxidant species on direct, non-syngas conversion of methane to methanol over an FePO4 catalyst material

The effect of the phase transformation of a FePO₄ catalyst material from the tridymite-like (tdm) FePO₄ to the α-domain (α-Fe₃(P₂O₇)₂) during the direct selective oxidation of methane to methanol was studied using oxidant species O₂, H₂O and N₂O. The main reaction products were CH₃OH, carbon dioxide and carbon monoxide, whereas formaldehyde was produced in rather minute amounts. Results showed that the single-step non-syngas activation of CH₄ to oxygenate(s) on a solid FePO₄ phase-specific catalyst was influenced by the nature of the oxidizer used for the CH₄ turnover. Fresh and activated FePO₄ powder samples and their modified physicochemical surface and bulk properties, which affected the conversion and selectivity in the partial oxidation (POX) mechanism of CH₄, were investigated. Temperature-programmed re-oxidation (TPRO) profiles indicated that the type of moieties utilised in the procedures, determined the re-oxidizing pathway of the reduced multiphase FePO₄ system. Mössbauer spectroscopy measurements along with X-ray diffraction (XRD) examination of neat, hydrogenated and spent catalytic compounds, demonstrated a variation of the phosphate into a mixture of crystallites, which depended on operating process conditions (for example time-on-stream). The Mössbauer spectra revealed the change of the initial ferric orthophosphate, FePO₄ (tdm), to the divalent metal form, iron(ii) pyrophosphate (Fe₂P₂O₇); thereafter, reactivity was governed by the interaction (strength) with individual oxidizing agents. The Fe³⁺ ↔ Fe²⁺ chemical redox cycle can play a key mechanistic role in tailored multistep design, while the advantage of iron-based heterogeneous catalysis primarily lies in being inexpensive and comprising non-critical raw resources. When compared to the other catalysts reported in the literature, the FePO₄-tdm phase catalysts showed in this work exhibited a high activity towards methanol i.e., 12.3 × 10⁻³ μmol_MeOH g_cat h⁻¹ using N₂O as an oxidant. This catalyst also showed a high activity with O₂ as an oxidant (5.3 × 10⁻³ μmol_MeOH g_cat h⁻¹). Further investigations will include continuous reactor unit engineering optimisation.

The effect of the phase transformation of a FePO₄ catalyst material from the tridymite-like (tdm) FePO₄ to the α-domain (α-Fe₃(P₂O₇)₂) during the direct selective oxidation of methane to methanol was studied using oxidant species O₂, H₂O and N₂O.

Recent Progress in Direct Conversion of Methane to Methanol Over Copper-Exchanged Zeolites

The conversion of methane into an easily transportable liquid fuel or chemicals has become a highly sought-after goal spurred by the increasing availability of cheap and abundant natural gas. While utilization of methane for the production of syngas and its subsequent conversion via an indirect route is typical, it is cost-intensive, and alternative direct conversion routes have been investigated actively. One of the most promising directions among these is the low-temperature partial oxidation of methane to methanol over a metal-loaded zeolite, which mimics facile enzymatic chemistry of methane oxidation. Thus mono-, bi-, and trinuclear oxide compounds of iron and copper stabilized on ZSM-5 or mordenite, which are structurally analogous to those found in methane monooxygenases, have demonstrated promising catalytic performances. The two major problems of theses metal-loaded zeolites are low yield to methanol and batch-like non-catalytic reaction systems challenging to extend to an industrial scale. In this mini-review, attention was given to the direct methane oxidation to methanol over copper-loaded zeolite systems. A brief introduction on the catalytic methane direct oxidation routes and current status of the applied metal-containing zeolites including the ones with copper ions are given. Next, by analyzing the extensive experimental and theoretical data available, the consensus among the researchers to achieve the target of high methanol yield is discussed in terms of zeolite topology, active species, and reaction parameters. Finally, the recent efforts on continuous methanol production from the direct methane oxidation aiming for an industrial process are summarized.

Selective Methane Oxidation to Methanol on Cu-Oxo Dimers Stabilized by Zirconia Nodes of an NU-1000 Metal-Organic Framework

Mononuclear and dinuclear copper species were synthesized at the nodes of an NU-1000 metal-organic framework (MOF) via cation exchange and subsequent oxidation at 200 °C in oxygen. Copper-exchanged MOFs are active for selectively converting methane to methanol at 150-200 °C. At 150 °C and 1 bar methane, approximately a third of the copper centers are involved in converting methane to methanol. Methanol productivity increased by 3-4-fold and selectivity increased from 70% to 90% by increasing the methane pressure from 1 to 40 bar. Density functional theory showed that reaction pathways on various copper sites are able to convert methane to methanol, the copper oxyl sites with much lower free energies of activation. Combining studies of the stoichiometric activity with characterization by in situ X-ray absorption spectroscopy and density functional theory, we conclude that dehydrated dinuclear copper oxyl sites formed after activation at 200 °C are responsible for the activity.

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.

Increasing the activity of copper exchanged mordenite in the direct isothermal conversion of methane to methanol by Pt and Pd doping

PtCu- and PdCu-mordenite allow for isothermal reaction at 200 °C for the stepwise methane to methanol conversion with comparably high yields. In contrast to traditional Cu-zeolites, these materials are more reactive under isothermal conditions than after high temperature activation.

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.

Rationally designing mixed Cu–(μ-O)–M (M = Cu, Ag, Zn, Au) centers over zeolite materials with high catalytic activity towards methane activation

The direct conversion of methane to methanol on [Cu(μ-O)M]²⁺ (M = Cu, Ag, Zn, Au) bimetal centers in ZSM-5 zeolite is investigated using periodic DFT for the first time.

Cation-exchanged zeolites for the selective oxidation of methane to methanol

Development of an ideal methane activation catalyst presents a trade-off between stability and reactivity of the active site that can be achieved by tuning the transition metal cation, active site motif and the zeolite topology.

Cu-CHA – a model system for applied selective redox catalysis

We review the structural chemistry and reactivity of copper-exchanged molecular sieves with chabazite (CHA) topology, as an industrially applied catalyst in ammonia mediated reduction of harmful nitrogen oxides (NH₃-SCR) and as a general model system for red-ox active materials (also the recent results in the direct conversion of methane to methanol are considered).

Probing Gas Adsorption in Zeolites by Variable-Temperature IR Spectroscopy: An Overview of Current Research

The current state of the art in the application of variable-temperature IR (VTIR) spectroscopy to the study of (i) adsorption sites in zeolites, including dual cation sites; (ii) the structure of adsorption complexes and (iii) gas-solid interaction energy is reviewed. The main focus is placed on the potential use of zeolites for gas separation, purification and transport, but possible extension to the field of heterogeneous catalysis is also envisaged. A critical comparison with classical IR spectroscopy and adsorption calorimetry shows that the main merits of VTIR spectroscopy are (i) its ability to provide simultaneously the spectroscopic signature of the adsorption complex and the standard enthalpy change involved in the adsorption process; and (ii) the enhanced potential of VTIR to be site specific in favorable cases.