Synthesis of Mesoporous Zeolites and Their Opportunities in Heterogeneous Catalysis

Currently, zeolites are one of the most important classes of heterogeneous catalysts in chemical industries owing to their unique structural characteristics such as molecular-scale size/shape-selectivity, heterogenized single catalytic sites in the framework, and excellent stability in harsh industrial processes. However, the microporous structure of conventional zeolite materials limits their applications to small-molecule reactions. To alleviate this problem, mesoporous zeolitic frameworks were developed. In the last few decades, several methods have been developed for the synthesis of mesoporous zeolites; these zeolites have demonstrated greater lifetime and better performance than their bulk microporous counterparts in many catalytic processes, which can be explained by the rapid diffusion of reactant species into the zeolite framework and facile accessibility to bulky molecules through the mesopores. Mesoporous zeolites provide versatile opportunities not only in conventional chemical industries but also in emerging catalysis fields. This review presents many state-of-the-art mesoporous zeolites, discusses various strategies for their synthesis, and details their contributions to catalytic reactions including catalytic cracking, isomerization, alkylation and acylation, alternative fuel synthesis via methanol-to-hydrocarbon (MTH) and Fischer–Tropsch synthesis (FTS) routes, and different fine-chemical syntheses.

Advances in Catalytic Applications of Zeolite-Supported Metal Catalysts

Zeolites possessing large specific surface areas, ordered micropores, and adjustable acidity/basicity have emerged as ideal supports to immobilize metal species with small sizes and high dispersities. In recent years, the zeolite-supported metal catalysts have been widely used in diverse catalytic processes, showing excellent activity, superior thermal/hydrothermal stability, and unique shape-selectivity. In this review, a comprehensive summary of the state-of-the-art achievements in catalytic applications of zeolite-supported metal catalysts are presented for important heterogeneous catalytic processes in the last five years, mainly including 1) the hydrogenation reactions (e.g., CO/CO₂ hydrogenation, hydrogenation of unsaturated compounds, and hydrogenation of nitrogenous compounds); 2) dehydrogenation reactions (e.g., alkane dehydrogenation and dehydrogenation of chemical hydrogen storage materials); 3) oxidation reactions (e.g., CO oxidation, methane oxidation, and alkene epoxidation); and 4) other reactions (e.g., hydroisomerization reaction and selective catalytic reduction of NO_x with ammonia reaction). Finally, some current limitations and future perspectives on the challenge and opportunity for this subject are pointed out. It is believed that this review will inspire more innovative research on the synthesis and catalysis of zeolite-supported metal catalysts and promote their future developments to meet the emerging demands for practical applications.

Total Oxidation of Toluene and Propane over Supported Co3O4 Catalysts: Effect of Structure/Acidity of MWW Zeolite and Cobalt Loading

A set of supported Co₃O₄ catalysts have been designed and prepared to study the effect of textural characteristics and Brønsted acid sites concentration of MWW zeolite support, as well as cobalt loading on catalyst activity. Detailed characterization of the catalysts with a thorough study on their performance in the total oxidation of toluene and propane revealed that MCM-22 is the optimal support and that increasing Si/Al and decreasing external surface of MCM-22 positively affect the activity of supported Co₃O₄ catalysts, which is determined by their low-temperature reducibility. The activity of the Co/MCM-22 catalysts increased with cobalt content (5-20 wt %), consistent with enhancing the amount of low-temperature reducible Co₃O₄. The optimized catalyst containing 20% Co supported on dealuminated MCM-22 presented high turnover frequency (TOF) values in both toluene (2.6 × 10^-5 s^-1 at 270 °C) and propane (3.9 × 10^-5 s^-1 at 215 °C) oxidation and was characterized by outstanding cycling stability, long-term durability, water tolerance, and sintering resistance.

Carbon-based catalysts for Fischer-Tropsch synthesis

Fischer-Tropsch synthesis (FTS) is an essential approach to convert coal, biomass, and shale gas into fuels and chemicals, such as lower olefins, gasoline, diesel, and so on. In recent years, there has been increasing motivation to deploy FTS at commercial scales which has been boosting the discovery of high performance catalysts. In particular, the importance of support in modulating the activity of metals has been recognized and carbonaceous materials have attracted attention as supports for FTS. In this review, we summarised the substantial progress in the preparation of carbon-based catalysts for FTS by applying activated carbon (AC), carbon nanotubes (CNTs), carbon nanofibers (CNFs), carbon spheres (CSs), and metal-organic frameworks (MOFs) derived carbonaceous materials as supports. A general assessment of carbon-based catalysts for FTS, concerning the support and metal properties, activity and products selectivity, and their interactions is systematically discussed. Finally, current challenges and future trends in the development of carbon-based catalysts for commercial utilization in FTS are proposed.

Sustainable development and enhancement of cracking processes using metallic composites

Metallic composites represent a vital class of materials that has gained increased attention in crude oil processing as well as the production of biofuel from other sources in recent times. Several catalytic materials have been reported in the literature for catalytic cracking, particularly, of crude oil. This review seeks to provide a comprehensive overview of existing and emerging methods/technologies such as metal–organic frameworks (MOFs), metal–matrix composites (MMCs), and catalytic support materials, to bridge information gaps toward sustainable advancement in catalysis for petrochemical processes. There is an increase in industrial and environmental concern emanating from the sulphur levels of oils, hence the need to develop more efficient catalysts in the hydrotreatment (HDS and HDN) processes, and combating the challenge of catalyst poisoning and deactivation; in a bid to improving the overall quality of oils and sustainable use of catalyst. Structural improvement, high thermal stability, enhanced cracking potential, and environmental sustainability represent the various benefits accrued to the use of metallic composites as opposed to conventional catalysts employed in catalytic cracking processes.

Application of magnetic field to CO hydrogenation using a confined-space catalyst: effect on reactant gas diffusivity and reactivity

An external magnetic field has recently been applied in reaction processes to promote movement and avoid agglomeration of magnetic particles, and also reduce the activation energy through improving the gas-solid contact. In this work, the effect of an external magnetic field on reactant gas diffusivity and reactivity in CO hydrogenation within a confined-space catalyst was investigated for the first time using a conventional reactor packed with a bimetallic 5Fe-5Co/ZSM-5 molecular sieve catalyst. The synergistic effect between magnetic field and limited mass transfer within zeolite cavities improved the mass transfer ability and reaction phenomena of the reactant molecules, leading to enhancement of catalytic activity with tailored reaction pathways. As a result, CO conversion and CH4 selectivity were increased by factors of 1.9 and 1.3 compared to those without a magnetic field. These synergistic interactions are able to provide an innovative challenge for green and sustainable chemical processes and separation processes by means of selective reactant and product mass transfer designed for selective catalytic conversion in the future.

Effective synthesis of zeolite-encapsulated Ni nanoparticles with excellent catalytic performance for hydrogenation of CO2 to CH4

A simple and effective "synchronous exchange deposition" method was developed, for the first time, for the synthesis of an encapsulation of Ni nanoparticles uniformly distributed in X-zeolite (Ni@NaX). The short-range joint effects of the Ni nanoparticles and the 3D negatively charged grid of the X-zeolite endowed Ni@NaX with an excellent catalytic performance for the hydrogenation of CO2 to CH4.

Number and intrinsic activity of cobalt surface sites in platinum promoted zeolite catalysts for carbon monoxide hydrogenation

A larger number and a more uniform distribution of cobalt sites with almost the same intrinsic activity results in higher carbon monoxide hydrogenation rate in the mordenite compared to ZSM-5 zeolite.

New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels

Recent advances in bifunctional catalysis for conversion of syngas and hydrogenation of CO₂ into chemicals and fuels have been highlighted.

Incorporating silicon carbide nanoparticles into Al2O3@Al to achieve an efficient support for Co-based catalysts to boost their catalytic performance towards Fischer–Tropsch synthesis

The SiC nanoparticles modified Al₂O₃@Al composites were used as an efficient supports for Co-based catalysts to boost the FTS performance via a synergy effect.