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.

Oxidation of methane and ethylene over Al incorporated N-doped graphene: A comparative mechanistic DFT study

It is generally recognized that developing effective methods for selective oxidation of hydrocarbons to generate more useful chemicals is a major challenge for the chemical industry. In the present study, density functional theory calculations are conducted to examine the catalytic partial oxidation of methane (CH₄) and ethylene (C₂H₄) by nitrous oxide (N₂O) over Al-incorporated porphyrin-like N-doped graphene (AlN₄-Gr). Adsorption energies for the most stable configurations of CH₄, C₂H₄, and N₂O molecules over the AlN₄-Gr catalyst are determined to be -0.25, -0.64, and -0.40 eV, respectively. According to our findings, N₂O can be efficiently split into N₂ and O_ads species with a negligible activation energy on the AlN₄-Gr surface. Meanwhile, CH₄ and C₂H₄ molecules compete for reaction with the activated oxygen atom (O_ads) that stays on the surface. The energy barriers for partial methane oxidation through the CH₄ + O_ads → CH₃° + HO_ads and CH₃° + HO_ads → CH₃OH reaction steps are 0.16 eV and 0.27 eV, respectively. Furthermore, the produced CH₃OH may be overoxidized by O_ads to give formaldehyde and water molecules by overcoming a relatively low activation barrier. The activation barriers for C₂H₄ epoxidation are small and comparable to those for CH₄ oxidation, implying that AlN₄-Gr is highly active for both reactions. The high energy barrier for the 1,2-hydrogen shift in the OCH₂CH₂ intermediate, on the other hand, makes the production of acetaldehyde impossible under normal conditions. According to the population analysis, the AlN₄-Gr serves as a strong electron donor to aid in the charge transfer between the Al atom and the O_ads moiety, which is necessary for the activation of CH₄ and C₂H₄. The findings of the present study may pave the way for a better understanding of the catalytic oxidation the CH₄ and C₂H₄, as well as for the development of highly efficient noble-metal free catalysts for these reactions.

Gas-Phase Selective Oxidation of Methane into Methane Oxygenates

Methane is an abundant resource and its direct conversion into value-added chemicals has been an attractive subject for its efficient utilization. This method can be more efficient than the present energy-intensive indirect conversion of methane via syngas, a mixture of CO and H2. Among the various approaches for direct methane conversion, the selective oxidation of methane into methane oxygenates (e.g., methanol and formaldehyde) is particularly promising because it can proceed at low temperatures. Nevertheless, due to low product yields this method is challenging. Compared with the liquid-phase partial oxidation of methane, which frequently demands for strong oxidizing agents in protic solvents, gas-phase selective methane oxidation has some merits, such as the possibility of using oxygen as an oxidant and the ease of scale-up owing to the use of heterogeneous catalysts. Herein, we summarize recent advances in the gas-phase partial oxidation of methane into methane oxygenates, focusing mainly on its conversion into formaldehyde and methanol.

Activity of Cu-Al-Oxo Extra-Framework Clusters for Selective Methane Oxidation on Cu-Exchanged Zeolites

Cu-zeolites are able to directly convert methane to methanol via a three-step process using O₂ as oxidant. Among the different zeolite topologies, Cu-exchanged mordenite (MOR) shows the highest methanol yields, attributed to a preferential formation of active Cu-oxo species in its 8-MR pores. The presence of extra-framework or partially detached Al species entrained in the micropores of MOR leads to the formation of nearly homotopic redox active Cu-Al-oxo nanoclusters with the ability to activate CH₄. Studies of the activity of these sites together with characterization by ²⁷Al NMR and IR spectroscopy leads to the conclusion that the active species are located in the 8-MR side pockets of MOR, and it consists of two Cu ions and one Al linked by O. This Cu-Al-oxo cluster shows an activity per Cu in methane oxidation significantly higher than of any previously reported active Cu-oxo species. In order to determine unambiguously the structure of the active Cu-Al-oxo cluster, we combine experimental XANES of Cu K- and L-edges, Cu K-edge HERFD-XANES, and Cu K-edge EXAFS with TDDFT and AIMD-assisted simulations. Our results provide evidence of a [Cu₂AlO₃]²⁺ cluster exchanged on MOR Al pairs that is able to oxidize up to two methane molecules per cluster at ambient pressure.

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.

Copper-Oxo Active Sites for Methane C-H Activation in Zeolites: Molecular Understanding of Impact of Methane Hydroxylation on UV-Vis Spectra

Here, we analyze changes in the optical spectra of activated copper-exchanged zeolites during methane activation with the Tamm-Dancoff time-dependent density functional theory, TDA-DFT, while using the ωB2PLYP functional. Two active sites, [Cu₂O]²⁺ and [Cu₃O₃]²⁺, were studied. For [Cu₂O]⁺, the 22 700 cm^-1 peak is associated with μ-oxo 2p → Cu 3d/4s charge transfer. Of the [Cu₂O]²⁺ methane C-H activation intermediates that we examined, only [Cu-O(H)(H)-Cu] and [Cu-O(H)(CH₃)-Cu] have spectra that match experimental observations. After methane activation, the μ-oxo 2p orbitals lose two electrons and become hybridized with methanol C 2p orbitals and/or H 1s orbitals. The frontier unoccupied orbitals become more Cu 4s/4p Rydberg-like, reducing overlap with occupied orbitals. These effects cause the disappearance of the 22 700 cm^-1 peak. For [Cu₃O₃]²⁺, the exact structures of the species formed after methane activation are unknown. Thus, we considered eight possible structures. Several of these provide a significant decrease in intensity near 23 000-38 000 cm^-1, as seen experimentally. Notably, these species involve either rebound of the separated methyl to a μ-oxo atom or its remote stabilization at a Brønsted acid site in exchange for the acidic proton. These spectral changes are caused by the same mechanism seen in [Cu₂O]²⁺ and are likely responsible for the observed reduced intensities near 23 000-38 000 cm^-1. Thus, TDA-DFT calculations with ωB2PLYP provide a molecular-level understanding of the evolution of copper-oxo active sites during methane-to-methanol conversion.

Identification of Kinetic and Spectroscopic Signatures of Copper Sites for Direct Oxidation of Methane to Methanol

Copper-exchanged zeolites of different topologies possess high activity in the direct conversion of methane to methanol via the chemical looping approach. Despite a large number of studies, identification of the active sites, and especially their intrinsic kinetic characteristics remain incomplete and ambiguous. In the present work, we collate the kinetic behavior of different copper species with their spectroscopic identities and track the evolution of various copper motifs during the reaction. Using time-resolved UV/Vis and in situ EPR, XAS, and FTIR spectroscopies, two types of copper monomers were identified, one of which is active in the reaction with methane, in addition to a copper dimeric species with the mono-μ-oxo structure. Kinetic measurements showed that the reaction rate of the copper monomers is somewhat slower than that of the dicopper mono-μ-oxo species, while the activation energy is two times lower.

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 C-H Activation by [Cu2O]2+ and [Cu3O3]2+ in Copper-Exchanged Zeolites: Computational Analysis of Redox Chemistry and X-ray Absorption Spectroscopy

There is an ongoing debate regarding the role of [Cu₃O₃]²⁺ in methane-to-methanol conversion by copper-exchanged zeolites. Here, we perform electronic structure analysis and localized orbital bonding analysis to probe the redox chemistry of its Cu and μ-oxo sites. Also, the X-ray absorption near-edge structure, XANES, of methane activation in [Cu₃O₃]²⁺ is compared to that of the more ubiquitous [Cu₂O]²⁺. Methane C-H activation is associated with only the Cu²⁺/Cu⁺ redox couple in [Cu₂O]²⁺. For [Cu₃O₃]²⁺, there is no basis for the Cu³⁺/Cu²⁺ couple's participation at the density functional theory ground state. In [Cu₃O₃]²⁺, there are many possible intrazeolite intermediates for methane activation. In the nine possibilities that we examined, methane activation is driven by a combination of the Cu²⁺/Cu⁺ and oxyl/O^2- redox couples. Based on this, the Cu 1s-edge XANES spectra of [Cu₂O]²⁺ and [Cu₃O₃]²⁺ should both have energy signatures of Cu²⁺ → Cu⁺ reduction during methane activation. This is indeed what we obtained from the calculated XANES spectra. [Cu₂O]²⁺ and [Cu₃O₃]²⁺ intermediates with one Cu⁺ site are shifted by 0.9-1.7 eV, while those with two Cu⁺ sites are shifted by 3.0-4.2 eV. These are near a range of 2.5-3.2 eV observed experimentally after contacting methane with activated copper-exchanged zeolites. Thus, activation of methane by [Cu₃O₃]²⁺ will lead to formation of Cu⁺ sites. Importantly, for future quantitative XANES studies, involvement of O^- + e^- → O^2- in [Cu₃O₃]²⁺ implies a disconnect between the overall reactivity and the number of electrons used in the Cu²⁺/Cu⁺ redox couple.

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.

Time-Dependent Density Functional Theory Study of Copper(II) Oxo Active Sites for Methane-to-Methanol Conversion in Zeolites

Copper-exchanged zeolites are useful materials for step-wise methane-to-methanol conversion (MMC). However, methanol yields on copper-exchanged zeolites are often modest, spurring interest in the development of active-site species that are activated at moderate temperatures, afford greater yields, and provide excellent methanol selectivities. Ultraviolet-visible (UV-vis) spectroscopy is a major tool for characterizing the active-sites and their evolution during the step-wise MMC process. However, computation of the UV-vis spectra of the copper-oxo active sites using Tamm-Dancoff time-dependent density functional theory (TDA-DFT) can be quite problematic. This has led to utilization of expensive methods based on multireference approaches, Green functions, and the Bethe-Salpeter equation. In this work, we examined the optical spectra of [CuO]⁺, [Cu₂O]²⁺, [Cu₂O₂]²⁺, and [Cu₃O₃]²⁺ species implicated in MMC in zeolites. For the larger species, we examined how agreement with experimental data is improved with increasingly larger cluster models. For [CuO]⁺, we compared TDA-DFT against restricted active space 2nd-order perturbation theory, RASPT2. We found that signature peaks for [CuO]⁺ have multireference behavior. The excited states have many configuration state functions with a double excitation character. These effects are likely responsible for the poor utility of conventional TDA-DFT methods. Indeed, we obtain good agreement with experimental data and RASPT2 after accounting for 2h/2p excitations within TDA-DFT with a previously described configuration interaction singles and doubles, CIS(D)-style scheme. This was the case for [CuO]⁺, [Cu₂O]²⁺, as well as a [Cu₂O₂]²⁺ species. Using a long-range corrected double-hybrid, ωB2PLYP, we provide for the first time computational evidence for the experimental UV-vis spectrum of the [Cu₃O₃]²⁺ active site motif.

Activation of the methane C–H bond by Al- and Ga-doped graphenes: a DFT investigation

The potential of Al- and Ge-embedded graphene to activate the C–H bond of CH4 in the presence of a N2O molecule was studied using DFT calculations.

Heterometallic [Cu–O–M]2+ active sites for methane C–H activation in zeolites: stability, reactivity, formation mechanism and relationship to other active sites

Formation energies and mechanisms, autoreduction and methane C–H reactivities were obtained for [Cu–O–M]²⁺ species (M = Ti–Cu, Zr–Mo and Ru–Ag) in mordenite with DFT. These reveal that [Cu₂O]²⁺ is best suited for MMC.

Importance of Methane Chemical Potential for Its Conversion to Methanol on Cu-Exchanged Mordenite

Copper-oxo clusters exchanged in zeolite mordenite are active in the stoichiometric conversion of methane to methanol at low temperatures. Here, we show an unprecedented methanol yield per Cu of 0.6, with a 90-95 % selectivity, on a MOR solely containing [Cu₃ (μ-O)₃ ]²⁺ active sites. DFT calculations, spectroscopic characterization and kinetic analysis show that increasing the chemical potential of methane enables the utilization of two μ-oxo bridge oxygen out of the three available in the tricopper-oxo cluster structure. Methanol and methoxy groups are stabilized in parallel, leading to methanol desorption in the presence of water.

Selective Oxidation of Methane over Fe-Zeolites by In Situ Generated H2O2

Liquid-phase selective oxidation of methane into methane oxygenates, including methanol and formic acid, with molecular oxygen was investigated using Fe-zeolites and Pd/activated carbon in the presence of molecular hydrogen as a reducing agent. Various Fe-zeolites such as Fe-ZSM-5, Fe-mordenite, Fe-β, Fe-Y, and Fe-ferrierite were prepared by ion-exchange and compared for this reaction. Among them, Fe-ZSM-5 was selected for further study because this catalyst showed high activity in the selective oxidation of methane with relatively less leaching. Further, the effect of reaction temperature, pH, and the amount of catalyst was examined, and detailed investigations revealed that the leached Fe species, which were facilitated in the presence of acid, were mainly responsible for methane oxidation under the given reaction conditions.

Oxidative Methane Conversion to Ethane on Highly Oxidized Pd/CeO2 Catalysts Below 400 °C

Methane upgrading into more valuable chemicals has received much attention. Herein, we report oxidative methane conversion to ethane using gaseous O₂ at low temperatures (<400 °C) and atmospheric pressure in a continuous reactor. A highly oxidized Pd deposited on ceria could produce ethane with a productivity as high as 0.84 mmol g_cat ^-1  h^-1 . The Pd-O-Pd sites, not Pd-O-Ce, were the active sites for the selective ethane production at low temperatures. Density functional theory calculations confirmed that the Pd-O-Pd site is energetically more advantageous for C-C coupling, whereas Pd-O-Ce promotes CH₄ dehydrogenation. The ceria helped Pd maintain a highly oxidic state despite reductive CH₄ flow. This work can provide new insight for methane upgrading into C₂ species.

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.

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.

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.

Performance of density functional theory for describing hetero-metallic active-site motifs for methane-to-methanol conversion in metal-exchanged zeolites

Methane-to-methanol conversion (MMC) can be facilitated with high methanol selectivities by copper-exchanged zeolites. There are however two open questions regarding the use of these zeolites to facilitate the MMC process. The first concerns the possibility of operating the three cycles in the stepwise MMC process by these zeolites in an isothermal fashion. The second concerns the possibility of improving the methanol yields by systematic substitution of some copper centers in these active sites with other earth-abundant transition metals. Quantum-mechanical computations can be used to compare methane activation by copper oxide species and analogous mixed-metal systems. To carry out such screening, it is important that we use theoretical methods that are accurate and computationally affordable for describing the properties of the hetero-metallic catalytic species. We have examined the performance of 47 exchange-correlation density functionals for predicting the relative spin-state energies and chemical reactivities of six hetero-metallic [M-O-Cu]²⁺ and [M-O₂ -Cu]²⁺ , (where MCo, Fe, and Ni), species by comparison with coupled cluster theory including iterative single, double excitations as well as perturbative treatment of triple excitations, CCSD(T). We also performed multireference calculations on some of these systems. We considered two types of reactions (hydrogen addition and oxygen addition) that are relevant to MMC. We recommend the use of τ-HCTH and OLYP to determine the spin-state energy splittings in the hetero-metallic motifs. ωB97, ωB97X, ωB97X-D3, and MN15 performed best for predicting the energies of the hydrogen and oxygen addition reactions. In contrast, local, and semilocal functionals do poorly for chemical reactivity. Using [Fe-O-Cu]²⁺ as a test, we see that the nonlocal functionals perform well for the methane CH activation barrier. In contrast, the semilocal functionals perform rather poorly. © 2018 Wiley Periodicals, Inc.