Hydrocarbon Products Occluded within Zeolite Micropores Impose Transport Barriers that Regulate Brønsted Acid-Catalyzed Propene Oligomerization

Brønsted acid zeolites catalyze alkene oligomerization to heavier hydrocarbon products of varied size and branching. Propene dimerization rates decrease monotonically with increasing crystallite size for MFI zeolites synthesized with fixed H⁺-site density, revealing the strong influence of intrazeolite transport limitations on measured rates, which has gone unrecognized in previous studies. Transient changes in dimerization rates upon step-changes in reactant pressure (150-470 kPa C₃H₆) or temperature (483-523 K) reveal that intrazeolite diffusion limitations become more severe under reaction conditions that favor the formation of heavier products. Together with effectiveness factor formalisms, these data reveal that product and reactant diffusion, and consequently oligomerization rates and selectivity, are governed by the composition of hydrocarbon products that accumulate within zeolitic micropores during alkene oligomerization. This occluded organic phase strongly influences rates and selectivities of alkene oligomerization on medium-pore zeolites (MFI, MEL, TON). Recognizing the coupled influences of kinetic factors and intrazeolite transport limitations imposed by occluded reaction products provides opportunities to competently tailor rates and selectivity in alkene oligomerization and other molecular chain-growth reactions through judicious selection of zeolite topology and reaction conditions.

Maximizing sinusoidal channels of HZSM-5 for high shape-selectivity to p-xylene

The shape-selective catalysis enabled by zeolite micropore’s molecular-sized sieving is an efficient way to reduce the cost of chemical separation in the chemical industry. Although well studied since its discovery, HZSM-5′s shape-selective capability has never been fully exploited due to the co-existence of its different-sized straight channels and sinusoidal channels, which makes the shape-selective p-xylene production from toluene alkylation with the least m-xylene and o-xylene continue to be one of the few industrial challenges in the chemical industry. Rather than modifications which promote zeolite shape-selectivity at the cost of stability and reactivity loss, here inverse Al zoned HZSM-5 with sinusoidal channels predominantly opened to their external surfaces is constructed to maximize the shape-selectivity of HZSM-5 sinusoidal channels and reach > 99 % p-xylene selectivity, while keeping a very high activity and good stability ( > 220 h) in toluene methylation reactions. The strategy shows good prospects for shape-selective control of molecules with tiny differences in size.

Full utilization of ZSM-5 shape-selectivity is restricted by crystal external surface acid sites and co-existence of two different sized channels. Here, the authors synthesize reverse Al zoned ZSM-5 with sinusoidal channel preferentially opened to its inert external surface to achieve 99.3% p-xylene selectivity.

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.

Shape-selective Valorization of Biomass-derived Glycolaldehyde using Tin-containing Zeolites

A highly selective self-condensation of glycolaldehyde to different C₄ molecules has been achieved using Lewis acidic stannosilicate catalysts in water at moderate temperatures (40-100 °C). The medium-sized zeolite pores (10-membered ring framework) in Sn-MFI facilitate the formation of tetrose sugars while hindering consecutive aldol reactions leading to hexose sugars. High yields of tetrose sugars (74 %) with minor amounts of vinyl glycolic acid (VGA), an α-hydroxyacid, are obtained using Sn-MFI with selectivities towards C₄ products reaching 97 %. Tin catalysts having large pores or no pore structure (Sn-Beta, Sn-MCM-41, Sn-SBA-15, tin chloride) led to lower selectivities for C₄ sugars due to formation of hexose sugars. In the case of Sn-Beta, VGA is the main product (30 %), illustrating differences in selectivity of the Sn sites in the different frameworks. Under optimized conditions, GA can undergo further conversion, leading to yields of up to 44 % of VGA using Sn-MFI in water. The use of Sn-MFI offers multiple possibilities for valorization of biomass-derived GA in water under mild conditions selectively producing C₄ molecules.

Potential and challenges of zeolite chemistry in the catalytic conversion of biomass

This review emphasizes the progress, potential and future challenges in zeolite catalysed biomass conversions and relates these to concepts established in existing petrochemical processes.

Towards biolubricant compatible vegetable oils by pore mouth hydrogenation with shape-selective Pt/ZSM-5 catalysts

Pore mouth hydrogenation of vegetable oil with Pt/ZSM-5 is confirmed by the similar intermediately melting product selectivity for various crystal sizes.

Shape-selective zeolite catalysis for bioplastics production

Biodegradable and renewable polymers, such as polylactic acid, are benign alternatives for petrochemical-based plastics. Current production of polylactic acid via its key building block lactide, the cyclic dimer of lactic acid, is inefficient in terms of energy, time, and feedstock use. We present a direct zeolite-based catalytic process, which converts lactic acid into lactide. The shape-selective properties of zeolites are essential to attain record lactide yields, outperforming those of the current multistep process by avoiding both racemization and side-product formation. The highly productive process is strengthened by facile recovery and practical reactivation of the catalyst, which remains structurally fit during at least six consecutive reactions, and by the ease of solvent and side-product recycling.

Hydrophobic zeolites coated with microporous organic polymers: adsorption behavior of ammonia under humid conditions

ZSM-5 nanoparticles coated with microporous organic polymers showed 88% retention of ammonia adsorption capacity at 43% RH.

Controlled release of chlorhexidine from amorphous microporous silica

A new system for the controlled release of the antiseptic chlorhexidine is presented. Amorphous microporous silica (AMS) excipient material was synthesized via an acid catalyzed sol-gel method and shaped as powder or coating. Chlorhexidine diacetate was introduced into the pores of the AMS silica via the incipient wetness impregnation method. This silica reservoir maintained a slow release of chlorhexidine over more than 7days. Chlorhexidine release was controlled by configurational diffusion in the AMS pores having free diameters of less than 1nm. The release of chlorhexidine was fine tuned by adapting particle size and pore diameter. Controlled release of chlorhexidine from an AMS coating on silicon wafer was demonstrated.

Acylation reactions over zeolites and mesoporous catalysts

Molecular sieves are highly active and selective catalysts with industrial potential for acylation reactions. Zeolites are the catalysts of choice when shape selectivity influences the preferential formation of some products, while high conversions are achieved over mesoporous catalysts with enhanced diffusion rates of reactants and products. In this Minireview, we focus on the understanding of the relationship among the structure of molecular sieve, type and concentration of acid sites and activity/selectivity in various acylations of aromatic and olefinic hydrocarbons. The products of these acylation reactions are important compounds for the pharmaceutical industry, fragrance and flavor materials, dyes, polymers, agrochemicals, and other applications.

Single-Site Heterogeneous Catalysts

Intellectually, the advantages that flow from the availability of single-site heterogeneous catalysts (SSHC) are many. They facilitate the determination of the kinetics and mechanism of catalytic turnover-both experimentally and computationally-and make accessible the energetics of various intermediates (including short-lived transition states). These facts in turn offer a rational strategic principle for the design of new catalysts and the improvement of existing ones. It is generally possible to prepare soluble molecular fragments that circumscribe the single-site, thus enabling a direct comparison to be made, experimentally, between the catalytic performance of the same active site when functioning as a heterogeneous (continuous solid) as well as a homogeneous (dispersed molecular) catalyst. This approach also makes it possible to modify the immediate atomic environment as well as the central atomic structure of the active site. From the practical standpoint, SSHC exhibit very high selectivities leading to the production of sharply defined molecular products, just as do their homogeneous analogues. Given that mesoporous silicas with very large internal surface areas are ideal supports for SSHC, and that more than a quarter of the elements of the Periodic Table may be grafted as active sites onto such silicas, there is abundant scope for creating new catalytic opportunities.

High-Surface-Area Catalyst Design: Synthesis, Characterization, and Reaction Studies of Platinum Nanoparticles in Mesoporous SBA-15 Silica

Platinum nanoparticles in the size range of 1.7-7.1 nm were produced by alcohol reduction methods. A polymer (poly(vinylpyrrolidone), PVP) was used to stabilize the particles by capping them in aqueous solution. The particles were characterized by X-ray diffraction (XRD) and transmission electron microscopy (TEM). TEM investigations demonstrate that the particles have a narrow size distribution. Mesoporous SBA-15 silica with 9-nm pores was synthesized by a hydrothermal process and used as a catalyst support. After incorporation into mesoporous SBA-15 silica using low-power sonication, the catalysts were calcined to remove the stabilizing polymer from the nanoparticle surface and reduced by H2. Pt particle sizes determined from selective gas adsorption measurements are larger than those determined by bulk techniques such as XRD and TEM. Room-temperature ethylene hydrogenation was chosen as a model reaction to probe the activity of the Pt/SBA-15 materials. The reaction was shown to be structure insensitive over a series of Pt/SBA-15 materials with particle sizes between 1.7 and 3.6 nm. The hydrogenolysis of ethane on Pt particles from 1.7 to 7.1 nm was weakly structure sensitive with smaller particles demonstrating higher specific activity. Turnover rates for ethane hydrogenolysis increased monotonically with increasing metal dispersion, suggesting that coordinatively unsaturated metal atoms present in small particles are more active for C2H6 hydrogenolysis than the low index planes that dominate in large particles. An explanation for the structure sensitivity is suggested, and the potential applications of these novel supported nanocatalysts for further studies of structure-activity and structure-selectivity relationships are discussed.

Methylcyclohexane Ring-Contraction: A Sensitive Solid Acidity and Shape Selectivity Probe Reaction

In this paper we describe the utility of an acid-catalyzed isomerization reaction, specifically, ring-contraction of methylcyclohexane to an isomeric mixture of alkylcyclopentanes as a tool for characterizing the acidic properties of a wide range of platinum-loaded solid acids. Methylcyclohexane isomerization is particularly useful as a solid acidity probe reaction since it is a simple molecule containing one six-membered ring and a single methyl group substituent. As a solid acidity probe molecule methylcyclohexane has a number of advantages over cyclohexane. Ring-contraction of cyclohexane produces a single product, methlycyclopentane. Methylcyclohexane ring-contraction, in contrast, yields a richer and thus more informative product mixture including ethylcyclopentane, and five isomeric dimethylcyclopentanes. For the first time it will be shown that variations in the three primary descriptors of solid acids, acid site density, acid site strength, and shape selectivity, within a wide range of amorphous and crystalline solid acids can be simultaneously ranked using a single component probe reaction, namely, methylcyclohexane ring-contraction.