Competition between Mononuclear and Binuclear Copper Sites across Different Zeolite Topologies

A key challenge for metal-exchanged zeolites is the determination of metal cation speciation and nuclearity under synthesis and reaction conditions. Copper-exchanged zeolites, which are widely used in automotive emissions control and potential catalysts for partial methane oxidation, have in particular evidenced a wide variety of Cu structures that are observed to change with exposure conditions, zeolite composition, and topology. Here, we develop predictive models for Cu cation speciation and nuclearity in CHA, MOR, BEA, AFX, and FER zeolite topologies using interatomic potentials, quantum chemical calculations, and Monte Carlo simulations to interrogate this vast configurational and compositional space. Model predictions are used to rationalize experimentally observed differences between Cu-zeolites in a wide-body of literature, including nuclearity populations, structural variations, and methanol per Cu yields. Our results show that both topological features and commonly observed Al-siting biases in MOR zeolites increase the population of binuclear Cu sites, explaining the small population of mononuclear Cu sites observed in these materials relative to other zeolites such as CHA and BEA. Finally, we used a machine learning classification model to determine the preference to form mononuclear or binuclear Cu sites at different Al configurations in 200 zeolites in the international zeolite database. Model results reveal several zeolite topologies at extreme ends of the mononuclear vs binuclear spectrum, highlighting synthetic options for realization of zeolites with strong Cu nuclearity preferences.

Boosting the catalytic performance of Cu-SAPO-34 in NOx removal via hydrothermal treatment

Phosphate ions promoted Cu-SAPO-34 (P-Cu-SAPO-34) were prepared using bulk CuO particles as Cu2+ precursor by a solid-state ion exchange technique for the selective catalytic reduction of NOx with NH3 (NH3-SCR). The effects of high temperature (H-T) hydrothermal aging on the NOx removal (de-NOx) performance of Cu-SAPO-34 with and without phosphate ions were systematically investigated at atomic level. The results displayed that both Cu-SAPO-34 and P-Cu-SAPO-34 presented relatively poor NOx removal activity with a low conversion (< 30%) at 250-500°C. However, after H-T hydrothermal treatment (800°C for 10 hr at 10% H2O), these two samples showed significantly satisfied NOx elimination performance with a quite high conversion (70%-90%) at 250-500°C. Additionally, phosphate ions decoration can further enhance the catalytic performance of Cu-SAPO-34 after hydrothermal treatment (Cu-SAPO-34H). The textural properties, morphologies, structural feature, acidity, redox characteristic, and surface-active species of the fresh and hydrothermally aged samples were analyzed using various characterization methods. The systematical characterization results revealed that increases of 28% of the isolated Cu2+ active species (Cu2+-2Z, Cu (OH)+-Z) mainly from bulk CuO and 50% of the Brønsted acid sites, the high dispersion of isolated Cu2+ active component as well as the Brønsted acid sites were mainly responsible for the accepted catalytic activity of these two hydrothermally aged samples, especially for P-Cu-SAPO-34H.

Si/Al Ratio Determines the SCR Performance of Cu-SSZ-13 Catalysts in the Presence of NO2

A comparative study was performed to investigate the NH₃-selective catalytic reduction (SCR) reaction activity of Cu-SSZ-13 zeolites having Si/Al ratios (SARs) of 5, 18, and 30. Remarkably, the Cu-SSZ-13 zeolite catalysts exhibited completely opposite behaviors as a function of SAR under standard SCR (SSCR) and fast SCR (FSCR) reaction atmospheres. Under SSCR conditions, the NO_x conversion increased as expected with the decreasing SAR. Under FSCR conditions, however, the NO_x conversion decreased as the SAR decreased, contrary to expectations. In this study, based on characterization of the catalysts by X-ray diffraction, transmission electron microscopy, electron paramagnetic resonance, H₂-temperature-programmed reduction, temperature-programmed desorption, and diffuse reflectance infrared Fourier transform spectroscopy, together with theoretical calculations, the authors found that the amount of Brønsted acid sites goes up while the SAR goes down, leading to an increase in the accumulation of NH₄NO₃ under FSCR reaction conditions. Moreover, the accumulated NH₄NO₃ is of greater stability for those low SAR Cu-SSZ-13 catalysts. These two reasons cause the FSCR performance of Cu-SSZ-13 to decrease with a decrease in SAR. As a result, the NO₂ effect on SCR activity changes from promotion to inhibition as the SAR decreases.

Rate Controlling in Low-Temperature Standard NH3-SCR: Implications from Operando EPR Spectroscopy and Reaction Kinetics

A series of seven Cu/SSZ-13 catalysts with Si/Al = 6.7 are used to elucidate key rate-controlling factors during low-temperature standard ammonia-selective catalytic reduction (NH₃-SCR), via a combination of SCR kinetics and operando electron paramagnetic resonance (EPR) spectroscopy. Strong Cu-loading-dependent kinetics, with Cu atomic efficiency increasing nearly by an order of magnitude, is found when per chabazite cage occupancy for Cu ion increases from ∼0.04 to ∼0.3. This is due mainly to the release of intercage Cu transfer constraints that facilitates the redox chemistry, as evidenced from detailed Arrhenius analysis. Operando EPR spectroscopy studies reveal strong connectivity between Cu-ion dynamics and SCR kinetics, based on which it is concluded that under low-temperature steady-state SCR, kinetically most relevant Cu species are those with the highest intercage mobility. Transient binuclear Cu species are mechanistically relevant species, but their splitting and cohabitation are indispensable for low-temperature kinetics.

Reaction Pathways of Standard and Fast Selective Catalytic Reduction over Cu-SSZ-39

Cu-SSZ-39 exhibits excellent hydrothermal stability and is expected to be used for NO_x purification in diesel vehicles. In this work, the selective catalytic reduction (SCR) activities in the presence or absence of NO₂ were tested over Cu-SSZ-39 catalysts with different Cu contents. The results showed that the NO_x conversion of Cu-SSZ-39 was improved by NO₂ when NO₂/NO_x = 0.5, especially for the catalysts with low Cu loadings. The kinetic studies showed two kinetic regimes for fast SCR from 150 to 220 °C due to a change in the rate-controlling mechanism. The activity test and diffuse reflectance infrared Fourier transform spectra demonstrated that the reduction of NO mainly occurred on the Cu species in the absence of feed NO₂, and when NO₂/NO = 1, NO could react with NH₄NO₃ on the Brønsted acid sites in addition to undergoing reduction on Cu species. Thus, NO₂ can promote the SCR reaction over Cu-SSZ-39 by facilitating the formation of surface nitrate species.

Selective catalytic reduction of NO x with NH3: opportunities and challenges of Cu-based small-pore zeolites

Zeolites, as efficient and stable catalysts, are widely used in the environmental catalysis field. Typically, Cu-SSZ-13 with small-pore structure shows excellent catalytic activity for selective catalytic reduction of NO _x with ammonia (NH₃-SCR) as well as high hydrothermal stability. This review summarizes major advances in Cu-SSZ-13 applied to the NH₃-SCR reaction, including the state of copper species, standard and fast SCR reaction mechanism, hydrothermal deactivation mechanism, poisoning resistance and synthetic methodology. The review gives a valuable summary of new insights into the matching between SCR catalyst design principles and the characteristics of Cu²⁺-exchanged zeolitic catalysts, highlighting the significant opportunity presented by zeolite-based catalysts. Principles for designing zeolites with excellent NH₃-SCR performance and hydrothermal stability are proposed. On the basis of these principles, more hydrothermally stable Cu-AEI and Cu-LTA zeolites are elaborated as well as other alternative zeolites applied to NH₃-SCR. Finally, we call attention to the challenges facing Cu-based small-pore zeolites that still need to be addressed.

Revealing scenarios of interzeolite conversion from FAU to AEI through the variation of starting materials

Interzeolite conversion, which refers to the synthesis of zeolites using a pre-made zeolite as the starting material, has enabled promising outcomes that could not be easily achieved by the conventional synthesis from a mixture of amorphous aluminum and silicon sources. Understanding the mechanism of interzeolite conversion is of particular interest to exploit this synthesis route for the preparation of tailor-made zeolites as well as the discovery of new structures. It has been assumed that the structural similarity between the starting zeolite and the target one is crucial to a successful interzeolite conversion. Nevertheless, an image as to how one type of zeolite evolves into another one remains unclear. In this work, a series of dealuminated FAU zeolites were created through acid leaching and employed as the starting zeolites in the synthesis of AEI zeolite under various conditions. This experimental design allowed us to create a comprehensive diagram of the interzeolite conversion from FAU to AEI as well as to figure out the key factors that enable this kinetically favourable crystallization pathway. Our results revealed different scenarios of the interzeolite conversion from FAU to AEI and pinpointed the importance of the structure of the starting FAU in determining the synthesis outcomes. A prior dealumination was proven effective to modify the structure of the initial FAU zeolite and consequently facilitate its conversion to the AEI zeolite. In addition, this strategy allowed us to directly transfer the knowledge obtained from the interzeolite conversion to a successful synthesis of the AEI zeolite from dealuminated amorphous aluminosilicate precursors. These results offer new insights to the design and fabrication of zeolites via the interzeolite conversion as well as to the understandings of the crystallization mechanisms.

Atomic layer deposition of silica to improve the high-temperature hydrothermal stability of Cu-SSZ-13 for NH3 SCR of NOx

The improvement of stability is a crucial and challenging issue for industrial catalyst, which affects not only the service time but also the cost of catalyst. This is especially prominent for that applied in harsh environment atmospheres, such as the exhaust of diesel vehicles. Herein, we reported a new strategy to improve the high-temperature hydrothermal stability of Cu-SSZ-13, which is a promising catalyst for the treatment of exhaust emitted from diesel vehicles through the NH₃-SCR NO_x route. Different from that reported in literature, we managed to improve the high-temperature hydrothermal stability of Cu-SSZ-13 by coating the surface with a nanolayer of stable SiO₂ material using the atomic layer deposition (ALD) method. The coating of SiO₂ layers effectively suppressed the leaching of alumina from the SSZ-13 molecular sieve even after the hydrothermal aging at 800 °C for 16 h with 12.5% water in air. Meanwhile, the ultra-thin SiO₂ nanolayer does not block the pores of zeolites and affect the catalytic activity of Cu-SSZ-13 contribute to the superiority of the ALD technology.

Kinetic and spectroscopic insights into the behaviour of Cu active site for NH3-SCR over zeolites with several topologies

Zeolite topology has a great effect on the dependence of NH₃-SCR rates over Cu–zeolites at 473 K on Cu density. It is revealed by the time-resolved UV-vis measurements that zeolites mainly affect the oxidation property of Cu ion by O₂.

Structure and solvation of confined water and water-ethanol clusters within microporous Brønsted acids and their effects on ethanol dehydration catalysis

Water networks confined within zeolites solvate clustered reactive intermediates and must rearrange to accommodate transition states that differ in size and polarity, with thermodynamic penalties that depend on the shape of the confining environment.

Aqueous-phase reactions within microporous Brønsted acids occur at active centers comprised of water-reactant-clustered hydronium ions, solvated within extended hydrogen-bonded water networks that tend to stabilize reactive intermediates and transition states differently. The effects of these diverse clustered and networked structures were disentangled here by measuring turnover rates of gas-phase ethanol dehydration to diethyl ether (DEE) on H-form zeolites as water pressure was increased to the point of intrapore condensation, causing protons to become solvated in larger clusters that subsequently become solvated by extended hydrogen-bonded water networks, according to in situ IR spectra. Measured first-order rate constants in ethanol quantify the stability of S_N2 transition states that eliminate DEE relative to (C₂H₅OH)(H⁺)(H₂O)_n clusters of increasing molecularity, whose structures were respectively determined using metadynamics and ab initio molecular dynamics simulations. At low water pressures (2–10 kPa H₂O), rate inhibition by water (–1 reaction order) reflects the need to displace one water by ethanol in the cluster en route to the DEE-formation transition state, which resides at the periphery of water–ethanol clusters. At higher water pressures (10–75 kPa H₂O), water–ethanol clusters reach their maximum stable size ((C₂H₅OH)(H⁺)(H₂O)_4–5), and water begins to form extended hydrogen-bonded networks; concomitantly, rate inhibition by water (up to –3 reaction order) becomes stronger than expected from the molecularity of the reaction, reflecting the more extensive disruption of hydrogen bonds at DEE-formation transition states that contain an additional solvated non-polar ethyl group compared to the relevant reactant cluster, as described by non-ideal thermodynamic formalisms of reaction rates. Microporous voids of different hydrophilic binding site density (Beta; varying H⁺ and Si–OH density) and different size and shape (Beta, MFI, TON, CHA, AEI, FAU), influence the relative extents to which intermediates and transition states disrupt their confined water networks, which manifest as different kinetic orders of inhibition at high water pressures. The confinement of water within sub-nanometer spaces influences the structures and dynamics of the complexes and extended networks formed, and in turn their ability to accommodate the evolution in polarity and hydrogen-bonding capacity as reactive intermediates become transition states in Brønsted acid-catalyzed reactions.

An Aging Model of NH3 Storage Sites for Predicting Kinetics of NH3 Adsorption, Desorption and Oxidation over Hydrothermally Aged Cu-Chabazite

A unified transient kinetic model which can predict the adsorption, desorption and oxidation kinetics of NH3 over hydrothermally aged Cu-chabazite was developed. The model takes into account the variation of fractional coverages of NH3 storage sites due to hydrothermal aging. In order to determine the fractional coverage of these sites, the catalyst was aged for various times at a certain temperature followed by NH3 adsorption, desorption and temperature-programmed desorption (TPD) experiments. TPD profiles were deconvoluted mainly into three peaks with centres at 317, 456 and 526 °C, respectively. Hydrothermal aging resulted in the progressive increase in the intensity of the peak at 317 °C and decrease in the intensity of the peaks at 456 and 526 °C, along with decreased NH3 oxidation at high temperatures. A model for hydrothermal aging kinetics of the fractional coverage of storage sites was developed using three reactions with appropriate rate expressions with parameters regressed from experimental data. The model was then incorporated into a multi-site kinetic model for the degreened Cu-Chabazite by the addition of aging reactions on each storage site. The effects of both aging time and temperature on the kinetics NH3 adsorption, desorption and oxidation were successfully predicted in the 155-540 °C range. This study is the first step towards the development of a hydrothermal aging-unified kinetic model of NH3-Selective Catalytic Reduction over Cu-chabazite.

Consequences of exchange-site heterogeneity and dynamics on the UV-visible spectrum of Cu-exchanged SSZ-13

The speciation and structure of Cu ions and complexes in chabazite (SSZ-13) zeolites, which are relevant catalysts for nitrogen oxide reduction and partial methane oxidation, depend on material composition and reaction environment. Ultraviolet-visible (UV-Vis) spectra of Cu-SSZ-13 zeolites synthesized to contain specific Cu site motifs, together with ab initio molecular dynamics and time-dependent density functional theory calculations, were used to test the ability to relate specific spectroscopic signatures to specific site motifs. Geometrically distinct arrangements of two framework Al atoms in six-membered rings are found to exchange Cu2+ ions that become spectroscopically indistinguishable after accounting for the finite-temperature fluctuations of the Cu coordination environment. Nominally homogeneous single Al exchange sites are found to exchange a heterogeneous mixture of [CuOH]+ monomers, O- and OH-bridged Cu dimers, and larger polynuclear complexes. The UV-Vis spectra of the latter are sensitive to framework Al proximity, to precise ligand environment, and to finite-temperature structural fluctuations, precluding the precise assignment of spectroscopic features to specific Cu structures. In all Cu-SSZ-13 samples, these dimers and larger complexes are reduced by CO to Cu+ sites at 523 K, leaving behind isolated [CuOH]+ sites with a characteristic spectroscopic identity. The various mononuclear and polynuclear Cu2+ species are distinguishable by their different responses to reducing environments, with implications for their relevance to catalytic redox reactions.

Tuning the Aluminum Distribution in Zeolites to Increase their Performance in Acid-Catalyzed Reactions

The organization of Al atoms in the framework of Si-rich zeolites is very important and includes two classes: (i) the Al siting that determines which individual, crystallographically distinguishable framework T sites are occupied by Al atoms and (ii) the Al distribution, which describes the relation of two or more Al atoms in the framework, their distances, and the possibility of neighboring Al atoms to cooperate in the formation of active sites. The organization of Al significantly affects the catalytic properties of Si-rich, zeolite-based catalysts in acid and redox catalysis. Herein, what is known about the organization of Al in the framework of industrially very important pentasil-ring Si-rich zeolites (ZSM-5, beta zeolite, mordenite, ferrierite, MCM-22, and TNU-9), as well as the very promising SSZ-13 Si-rich zeolite with the CHA structure, is summarized.

Simulation of exotherms from the oxidation of accumulated carbonaceous species over a VSCR catalyst

A model is built to simulate the burn-off process of accumulated carbonaceous species over a VSCR catalyst.

Ultrafast synthesis of AFX-Type zeolite with enhanced activity in the selective catalytic reduction of NOx and hydrothermal stability

Shortening the synthesis time of SSZ-16 (AFX type) zeolite from several days to 2 h has been achieved using an ultrafast synthesis route involving N,N,N′,N′-tetraethylbicyclo[2.2.2]oct-7-ene-2,3:5,6-dipyrrolidinium (TEBOP) as an organic structure-directing agent (OSDA) in a tubular reactor assisted by seed crystals. Recently, copper exchanged SSZ-16 has been looked upon as one of the few equivalents to SSZ-13 for the selective catalytic reduction of NOx with ammonia (NH₃-SCR) from automobile exhausts. Hydrothermal stability is one of the crucial properties for any zeolites that compete for automobile applications. All the samples prepared were analyzed using sophisticated physio-chemical techniques and those prepared from TEBOP were subjected to SCR of NOx reactions. The rapid crystal growth induced by high synthesis temperature bestowed the ultrafast prepared SSZ-16 with high crystallinity and hydrothermal stability as well as enhanced SCR of NOx activity even when aged at 800 °C. Compared to 1,1′-(1,4-butanediyl)bis-4-aza-1-azoniabicyclo[2.2.2]octane dibromide (DABCO), TEBOP was found to be desirable as an OSDA for high crystallinity and hydrothermal stability.

SSZ-16 (AFX-type) zeolite prepared in 2 h, so far the fastest, shows enhanced hydrothermal-stability and activity in selective-catalytic-reduction of NOx.

Cu-exchanged RTH-type zeolites for NH3-selective catalytic reduction of NOx: Cu distribution and hydrothermal stability

The Cu-exchanged RTH-type zeolites (Cu-RTH) were applied in ammonia-selective catalytic reduction (NH₃-SCR) of NO_x.

Small-Pore Zeolites: Synthesis and Catalysis

In the past decade or so, small-pore zeolites have received greater attention than large- and medium-pore molecular sieves that have historically dominated the literature. This is primarily due to the commercialization of two major catalytic processes, NOx exhaust removal and methanol conversion to light olefins, that take advantage of the properties of these materials with smaller apertures. Small-pore zeolites possess pores that are constructed of eight tetrahedral atoms (Si⁴⁺ and Al³⁺), each time linked by a shared oxygen These eight-member ring pores (8MR) provide small molecules access to the intracrystalline void space, e.g., to NOx during car exhaust cleaning (NOx removal) or to methanol en route to its conversion into light olefins, while restricting larger molecule entrance and departure that is critical to overall catalyst performance. In total, there are forty-four structurally different small-pore zeolites. Forty-one of these zeolites can be synthesized, and the first synthetic zeolite (KFI, 1948) was in fact a small-pore material. Although the field of 8MR zeolite chemistry has expanded in many directions, the progress in synthesis is framework-specific, leaving insights and generalizations difficult to realize. This review first focuses on the relevant synthesis details of all 8MR zeolites and provides some generalized findings and related insights. Next, catalytic applications where 8MR zeolites either have been commercialized or have dominated investigations are presented, with the aim of providing structure-activity relationships. The review ends with a summary that discusses (i) both synthetic and catalytic progress, (ii) a list of opportunities in the 8MR zeolite field, and (iii) a brief future outlook.

Nanoscale tomography reveals the deactivation of automotive copper-exchanged zeolite catalysts

Copper-exchanged zeolite chabazite (Cu-SSZ-13) was recently commercialized for the selective catalytic reduction of NO _X with ammonia in vehicle emissions as it exhibits superior reaction performance and stability compared to all other catalysts, notably Cu-ZSM-5. Herein, the 3D distributions of Cu as well as framework elements (Al, O, Si) in both fresh and aged Cu-SSZ-13 and Cu-ZSM-5 are determined with nanometer resolution using atom probe tomography (APT), and correlated with catalytic activity and other characterizations. Both fresh catalysts contain a heterogeneous Cu distribution, which is only identified due to the single atom sensitivity of APT. After the industry standard 135,000 mile simulation, Cu-SSZ-13 shows Cu and Al clustering, whereas Cu-ZSM-5 is characterized by severe Cu and Al aggregation into a copper aluminate phase (CuAl₂O₄ spinel). The application of APT as a sensitive and local characterization method provides identification of nanometer scale heterogeneities that lead to catalytic activity and material deactivation.