Recent Progress in Methanol-to-Olefins (MTO) Catalysts

Environmental Benefits of Circular Ethylene Production from Polymer Waste

The linear nature of the current plastics economy and increasing demand for polymers poses a pressing global problem. In this work, we explore the environmental and economic performance of a circular alternative for polymer production through chemical plastic recycling following the waste-to-methanol-to-olefins (WMO) route. We assess the life-cycle environmental impacts and techno-economic feasibility of this novel circular production route (CPR) in 2020 and 2050, and compare them to the existing linear production route (LPR), deploying naphtha steam cracking for olefin production, and a mix of landfill and incineration as end-of-life treatment. Our results showcase that CPR could enable significant impact reductions, notably in 2050 assuming a low-carbon electricity mix based on renewables. However, the shift from linear to circular comes with burden-shifting, increasing the impacts relative to LPR on five environmental indicators in 2020 (i.e., terrestrial and freshwater eutrophication, particulate matter formation, acidification, and metal/mineral resources use). From the techno-economic viewpoint, we found that ethylene from waste polymers could become competitive with fossil ethylene when deployed at large scale. Moreover, it is significantly cheaper than its green analogs, which deploy methanol-to-olefins with green methanol from captured CO2 and electrolytic H2, showcasing the potential of implementing high-readiness level technologies to close the loop for polymers.

Thermochemical CO2 Reduction to Methanol over Metal-Based Single-Atom Catalysts (SACs): Outlook and Challenges for Developments

The conversion of thermodynamically inert CO2 into methanol holds immense promise for addressing the pressing environmental and energy challenges of our time. This article offers a succinct overview of the development of single-atom catalysts (SACs) for thermochemical hydrogenation of CO2 to methanol, encompassing research advancements, advantages, potential hurdles, and other essential aspects related to these catalysts. Our aim of this work is to provide a deeper understanding of the intricacies of the catalytic structures of the single-atom sites and their unique structure-activity relationships in catalyzing the conversion of CO2 to methanol. We also present insights into the optimal design of SACs, drawing from our own research and those of fellow scientists. This research thrust is poised to contribute significantly to the development of next-generation SACs, which are crucial in advancing the sustainable production of methanol from CO2.

Designing Dual-Site Catalysts for Selectively Converting CO2 into Methanol

The variability of CO2 hydrogenation reaction demands new potential strategies to regulate the fine structure of the catalysts for optimizing the reaction pathways. Herein, we report a dual-site strategy to boost the catalytic efficiency of CO2-to-methanol conversion. A new descriptor, τ, was initially established for screening the promising candidates with low-temperature activation capability of CO2, and sequentially a high-performance catalyst was fabricated centred with oxophilic Mo single atoms, who was further decorated with Pt nanoparticles. In CO2 hydrogenation, the obtained dual-site catalysts possess a remarkably-improved methanol generation rate (0.27 mmol gcat. -1 h-1). For comparison, the singe-site Mo and Pt-based catalysts can only produce ethanol and formate acid at a relatively low reaction rate (0.11 mmol gcat. -1 h-1 for ethanol and 0.034 mmol gcat. -1 h-1 for formate acid), respectively. Mechanism studies indicate that the introduction of Pt species could create an active hydrogen-rich environment, leading to the alterations of the adsorption configuration and conversion pathways of the *OCH2 intermediates on Mo sites. As a result, the catalytic selectivity was successfully switched.

High-Yield Synthesis of Hierarchical SAPO-34 by Recrystallization Method for Efficient Methanol-to-Olefin Reactions

Prolonging the lifetime of SAPO-34 catalysts and enhancing their olefin selectivity in methanol-to-olefin (MTO) reactions are critical yet challenging objectives. Here, a series of hierarchical SAPO-34 catalysts were synthesized using a straightforward recrystallization method. The incorporation of triethylamine into the recrystallization mother liquor facilitated the formation of mesopores, achieving a high solid yield of up to 90%. Notably, the addition of phosphoric acid and ammonium polyvinyl phosphate alcohol during the recrystallization process significantly enhanced the crystallinity and regularity of the hierarchical SAPO-34 crystals, consequently increasing the mesopore size. Due to the substantially improved mass transfer efficiency and moderated acidity, the SP34-0.14P-0.06R catalysts exhibited a prolonged lifetime of 344 min and 80.3% selectivity for ethylene and propylene at a weight hourly space velocity (WHSV) of 2 h-1. This performance markedly surpasses that of the parent SP34 catalyst, which demonstrated a lifetime of 136 min and a selectivity of 78.0%. Remarkably, the SP34-0.14P-0.06R maintained a lifetime of 166 min even at a high WHSV of 10 h-1, which is more than 5-fold greater than that of the original microporous SP34. This research offers valuable insights into the design and development of hierarchically porous zeolites with high yields, enhancing the efficiency of MTO reactions and other applications.

Selectivity Descriptors of Methanol-to-Aromatics Process over 3-Dimensional Zeolites

The zeolite-catalyzed methanol-to-aromatics (MTA) process is a promising avenue for industrial decarbonization. This process predominantly utilizes 3-dimensional 10-member ring (10-MR) zeolites like ZSM-5 and ZSM-11, chosen for their confinement effect essential for aromatization. Current research mainly focuses on enhancing selectivity and mitigating catalyst deactivation by modulating zeolites' physicochemical properties. Despite the potential, the MTA technology is at a low Technology Readiness Level, hindered by mechanistic complexities in achieving the desired selectivity towards liquid aromatics. To bridge this knowledge gap, this study proposes a roadmap for MTA catalysis by strategically combining controlled catalytic experiments with advanced characterization methods (including operando conditions and "mobility-dependent" solid-state NMR spectroscopy). It identifies the descriptor-role of Koch-carbonylated intermediates, longer-chain hydrocarbons, and the zeolites' intersectional cavities in yielding preferential liquid aromatics selectivity. Understanding these selectivity descriptors and architectural impacts is vital, potentially advancing other zeolite-catalyzed emerging technologies.

A rapid and eco-friendly approach for the synthesis of low-silica SAPO-34 with excellent MTO catalytic performance

A rapid and eco-friendly route has been developed for the synthesis of SAPO-34 with short crystallization time (1-3 h), low silica content (as low as 6.2 wt%) and excellent methanol-to-olefin (MTO) catalytic performance by utilization of a recycled mother liquid at elevated crystallization temperature.

Modulation of Al Distribution in High-Silica ZSM-5 Zeolites for Enhancing Catalytic Performance

The spatial distribution of framework Al (AlF) has been one of the important factors that affect the catalytic properties of zeolites in diverse chemical reactions; however, the synthesis of high-silica zeolites with special AlF distribution remains a challenge. In this study, we successfully synthesized high-silica ZSM-5 zeolites with a unique AlF distribution by employing pentaerythritol (PET) as an additive in the presence of a few tetrapropylammonium hydroxide (TPAOH). The results demonstrated that the introduction of PET led to a higher proportion of Al atoms located at the sinusoidal and/or straight channels. It was observed that the addition of PET prevented the interaction between TPA+ and tetrahedral [AlO4]- during the crystallization process, resulting in enhanced availability of TPA species in the form of ion-paired TPA+. This effect leads to AlF atoms dominantly distributed away from the intersection and located in narrow channels, where acidic sites more effectively inhibit hydrogen transfer and coke formation. In the reaction of dimethyl ether (DME) to olefins, the catalyst with a unique Al distribution exhibited a significant prolonged catalytic lifetime, surpassing traditional TPA-ZSM-5 by more than 2-fold and maintaining DME conversion above 90% for a maximum of 148 h. The results of multiple pulse experiments also showed that these PET-assisted ZSM-5 zeolites significantly enhanced the selectivity of propene and butene. This approach provides an effective strategy to regulate AlF distribution in high-silica ZSM-5 catalysts with the assistance of neutral alcohol. It holds great potential for application in the synthesis of other high-silica zeolites, thereby enriching the diversity of zeolite catalysis.

Tricoordinated Single-Atom Cobalt in Zeolite Boosting Propane Dehydrogenation

Propane dehydrogenation (PDH) reaction has emerged as one of the most promising propylene production routes due to its high selectivity for propylene and good economic benefits. However, the commercial PDH processes usually rely on expensive platinum-based and poisonous chromium oxide based catalysts. The exploration of cost-effective and ecofriendly PDH catalysts with excellent catalytic activity, propylene selectivity, and stability is of great significance yet remains challenging. Here, we discovered a new active center, i.e., an unsaturated tricoordinated cobalt unit (≡Si-O)CoO(O-Mo) in a molybdenum-doped silicalite-1 zeolite, which afforded an unprecedentedly high propylene formation rate of 22.6 molC3H6 gCo-1 h-1 and apparent rate coefficient of 130 molC3H6 gCo-1 h-1 bar-1 with >99% of propylene selectivity at 550 °C. Such activity is nearly one magnitude higher than that of previously reported Co-based catalysts in which cobalt atoms are commonly tetracoordinated, and even superior to that of most of Pt-based catalysts under similar operating conditions. Density functional theory calculations combined with the state-of-the-art characterizations unravel the role of the unsaturated tricoordinated Co unit in facilitating the C-H bond-breaking of propane and propylene desorption. The present work opens new opportunities for future large-scale industrial PDH production based on inexpensive non-noble metal catalysts.

Understanding the effect of spatially separated Cu and acid sites in zeolite catalysts on oxidation of methane

Unraveling the effect of spatially separated bifunctional sites on catalytic reactions is significant yet challenging. In this report, we investigate the role of spatial separation on the oxidation of methane in a series of Cu-exchanged aluminosilicate zeolites. Regulation of the bifunctional sites is done either through studying a physical mixture of Cu-exchanged zeolites and acidic zeolites or by systematically varying the Cu and acid density within a family of zeolite materials. We show that separated Cu and acid sites are beneficial for the formation of hydrocarbons while high-density Cu sites, which are closer together, facilitate the production of CO2. By contrast, a balance of the spatial separation of Cu and acid sites shows more favorable formation of methanol. This work will further guide approaches to methane oxidation to methanol and open an avenue for promoting hydrocarbon synthesis using methanol as an intermediate.

Impurities in Polymer-Lined Autoclaves Affect Zeolite Synthesis and Si Incorporation Behavior

Polymer-lined autoclaves are commonly believed to be highly durable and inert in hydrothermal reactions. Herein, we use the hydrothermal synthesis of AlPO-18 zeolite as a case study to demonstrate that the choice of autoclave materials (polytetrafluoroethylene or para-polyphenylene) does significantly affect the product of zeolite synthesis. A small amount of glass fiber in the PPL-lined autoclave unexpectedly functions as a source of silicon and yields SAPO-34 instead of AlPO-18 as the product. The outcomes of 19 successive experiments conducted with a single PPL-lined autoclave exhibit significant variations, further highlighting that the impurities arising from the autoclaves should be considered during the hydrothermal synthesis procedure. In contrast to SAPO-34 synthesized by the conventional method, which displays only Si(4Al) at a low Si/Al ratio, SAPO-34 synthesized in the PPL-lined autoclave exhibits multiple silicon coordination environments. This outcome provides new physical insights into the silicon incorporation mechanism and proposes a viable strategy for regulating the silicon coordination environment at low Si/Al ratios.

Water structures on acidic zeolites and their roles in catalysis

The local reaction environment of catalytic active sites can be manipulated to modify the kinetics and thermodynamic properties of heterogeneous catalysis. Because of the unique physical-chemical nature of water, heterogeneously catalyzed reactions involving specific interactions between water molecules and active sites on catalysts exhibit distinct outcomes that are different from those performed in the absence of water. Zeolitic materials are being applied with the presence of water for heterogeneous catalytic reactions in the chemical industry and our transition to sustainable energy. Mechanistic investigation and in-depth understanding about the behaviors and the roles of water are essentially required for zeolite chemistry and catalysis. In this review, we focus on the discussions of the nature and structures of water adsorbed/stabilized on Brønsted and Lewis acidic zeolites based on experimental observations as well as theoretical calculation results. The unveiled functions of water structures in determining the catalytic efficacy of zeolite-catalyzed reactions have been overviewed and the strategies frequently developed for enhancing the stabilization of zeolite catalysts are highlighted. Recent advancement will contribute to the development of innovative catalytic reactions and the rationalization of catalytic performances in terms of activity, selectivity and stability with the presence of water vapor or in condensed aqueous phase.

In Situ UV-Vis-NIR Absorption Spectroscopy and Catalysis

This review highlights in situ UV-vis-NIR range absorption spectroscopy in catalysis. A variety of experimental techniques identifying reaction mechanisms, kinetics, and structural properties are discussed. Stopped flow techniques, use of laser pulses, and use of experimental perturbations are demonstrated for in situ studies of enzymatic, homogeneous, heterogeneous, and photocatalysis. They access different time scales and are applicable to different reaction systems and catalyst types. In photocatalysis, femto- and nanosecond resolved measurements through transient absorption are discussed for tracking excited states. UV-vis-NIR absorption spectroscopies for structural characterization are demonstrated especially for Cu and Fe exchanged zeolites and metalloenzymes. This requires combining different spectroscopies. Combining magnetic circular dichroism and resonance Raman spectroscopy is especially powerful. A multitude of phenomena can be tracked on transition metal catalysts on various supports, including changes in oxidation state, adsorptions, reactions, support interactions, surface plasmon resonances, and band gaps. Measurements of oxidation states, oxygen vacancies, and band gaps are shown on heterogeneous catalysts, especially for electrocatalysis. UV-vis-NIR absorption is burdened by broad absorption bands. Advanced analysis techniques enable the tracking of coking reactions on acid zeolites despite convoluted spectra. The value of UV-vis-NIR absorption spectroscopy to catalyst characterization and mechanistic investigation is clear but could be expanded.

Liquid metals for boosting stability of zeolite catalysts in the conversion of methanol to hydrocarbons

Methanol-to-hydrocarbons (MTH) process has been considered one of the most practical approaches for producing value-added products from methanol. However, the commonly used zeolite catalysts suffer from rapid deactivation due to coke deposition and require regular regeneration treatments. We demonstrate that low-melting-point metals, such as Ga, can effectively promote more stable methanol conversion in the MTH process by slowing coke deposition and facilitating the desorption of carbonaceous species from the zeolite. The ZSM-5 zeolite physically mixed with liquid gallium exhibited an enhanced lifetime in the MTH reaction, which increased by a factor of up to ~14 as compared to the parent ZSM-5. These results suggest an alternative route to the design and preparation of deactivation-resistant zeolite catalysts.

Recent progress of heterogeneous catalysts for transfer hydrogenation under the background of carbon neutrality

Under the background of carbon neutrality, the direct conversion of greenhouse CO2 to high value added fuels and chemicals is becoming an important and promising technology. Among them, the generation of liquid C1 products (formic acid and methanol) has made great progress; nevertheless, it encounters the problem of how to use it efficiently to solve the overcapacity issue. In this review, we suggest that the catalytic transfer hydrogenation using formic acid and methanol as the hydrogen sources is a critical and potential route for the substitution for the fossil fuel-derived H2 to generate essential bulk and fine chemicals. We mainly focus on summarizing the recent progress of heterogeneous catalysts in such reactions, including thermal- and photo-catalytic processes. Finally, we also propose some challenges and opportunities for this development.

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Evaluating the efficacy of zeolites synthesized from natural clay for the methanol-to-hydrocarbon process

Introducing sustainability into advanced catalytic material design is essential to address growing environmental concerns. Among them, synthesizing inorganic zeolite materials from non-traditional sources (like natural clay) offers several advantages, contributing to sustainability and environmental stewardship. With this objective, we used kaolin to synthesize zeolites with different topologies: SSZ-13 (8-MR with CHA topology), ZSM-5 (10-MR with MFI topology), and Beta (12-MR with BEA topology) (MR: member ring), where a simple and flexible synthetic protocol was adopted without any significant changes. All these zeolites were subjected to catalytic performance evaluation concerning the industrially relevant methanol-to-hydrocarbon (MTH) process. Herein, the kaolin-derived zeolites, especially ZSM-5, led to superior performance and demonstrated enhanced catalyst deactivation-resistant behavior compared to their zeolite counterparts prepared from traditional synthetic routes. Various characterization tools (including under operando conditions) were employed to understand their reactions and deactivation mechanisms. Overall, making zeolites from non-traditional sources presents a pathway for sustainable and environmentally friendly material production, offering benefits such as reduced resource dependence, lower energy consumption, and tailored physicochemical properties beneficial to catalysis. In a broader context, such a research approach contributes to the transition toward a more sustainable and circular economy.

Intergrowth Zeolites, Synthesis, Characterization, and Catalysis

Microporous zeolites that can act as heterogeneous catalysts have continued to attract a great deal of academic and industrial interest, but current progress in their synthesis and application is restricted to single-phase zeolites, severely underestimating the potential of intergrowth frameworks. Compared with single-phase zeolites, intergrowth zeolites possess unique properties, such as different diffusion pathways and molecular confinement, or special crystalline pore environments for binding metal active sites. This review first focuses on the structural features and synthetic details of all the intergrowth zeolites, especially providing some insightful discussion of several potential frameworks. Subsequently, characterization methods for intergrowth zeolites are introduced, and highlighting fundamental features of these crystals. Then, the applications of intergrowth zeolites in several of the most active areas of catalysis are presented, including selective catalytic reduction of NOx by ammonia (NH3-SCR), methanol to olefins (MTO), petrochemicals and refining, fine chemicals production, and biomass conversion on Beta, and the relationship between structure and catalytic activity was profiled from the perspective of intergrowth grain boundary structure. Finally, the synthesis, characterization, and catalysis of intergrowth zeolites are summarized in a comprehensive discussion, and a brief outlook on the current challenges and future directions of intergrowth zeolites is indicated.

Cavity-controlled methanol conversion over zeolite catalysts

The successful development and application in industry of methanol-to-olefins (MTO) process brought about an innovative and efficient route for olefin production via non-petrochemical resources and also attracted attention of C1 chemistry and zeolite catalysis. Molecular sieve catalysts with diversified microenvironments embedding unique channel/cavity structure and acid properties, exhibit demonstrable features and advantages in the shape-selective catalysis of MTO. Especially, shape-selective catalysis over 8-MR and cavity-type zeolites with acidic supercage environment and narrow pore opening manifested special host-guest interaction between the zeolite catalyst and guest reactants, intermediates and products. This caused great differences in product distribution, catalyst deactivation and molecular diffusion, revealing the cavity-controlled methanol conversion over 8-MR and cavity-type zeolite catalyst. Furthermore, the dynamic and complicated cross-talk behaviors of catalyst material (coke)-reaction-diffusion over these types of zeolites determines the catalytic performance of the methanol conversion. In this review, we shed light on the cavity-controlled principle in the MTO reaction including cavity-controlled active intermediates formation, cavity-controlled reaction routes with the involvement of these intermediates in the complex reaction network, cavity-controlled catalyst deactivation and cavity-controlled diffusion. All these were exhibited by the MTO reaction performances and product selectivity over 8-MR and cavity-type zeolite catalysts. Advanced strategies inspired by the cavity-controlled principle were developed, providing great promise for the optimization and precise control of MTO process.

A modified group contribution method for estimating thermodynamic parameters of methanol-to-olefins over a SAPO-34 catalyst

Group contribution (GC) methods, a semi-empirical approach based on the additivity of guest molecular properties, are widely applied to obtain the thermodynamic properties of complex reaction networks. In molecular sieve catalyzed processes, however, the interaction between guest molecules and host active sites also affects thermodynamic properties. In this study, therefore, we propose a modified group contribution (mGC) method by considering the interaction between the groups of guest molecules and independent active site functional groups (IASFGs) in molecular sieves. The mGC method has been used to estimate the thermodynamic properties of guest molecules as well as elementary reactions for the initial stage of methanol to olefins (MTO) reaction over SAPO-34 molecular sieves. It shows that mGC is more accurate than the conventional GC (cGC) methods when compared with the reference data calculated by density functional theory (DFT), indicating that mGC provides an effective way for batch calculation of thermodynamic properties in molecular sieve catalyzed processes.

Neutron Scattering Studies of Heterogeneous Catalysis

Understanding the structural dynamics/evolution of catalysts and the related surface chemistry is essential for establishing structure-catalysis relationships, where spectroscopic and scattering tools play a crucial role. Among many such tools, neutron scattering, though less-known, has a unique power for investigating catalytic phenomena. Since neutrons interact with the nuclei of matter, the neutron-nucleon interaction provides unique information on light elements (mainly hydrogen), neighboring elements, and isotopes, which are complementary to X-ray and photon-based techniques. Neutron vibrational spectroscopy has been the most utilized neutron scattering approach for heterogeneous catalysis research by providing chemical information on surface/bulk species (mostly H-containing) and reaction chemistry. Neutron diffraction and quasielastic neutron scattering can also supply important information on catalyst structures and dynamics of surface species. Other neutron approaches, such as small angle neutron scattering and neutron imaging, have been much less used but still give distinctive catalytic information. This review provides a comprehensive overview of recent advances in neutron scattering investigations of heterogeneous catalysis, focusing on surface adsorbates, reaction mechanisms, and catalyst structural changes revealed by neutron spectroscopy, diffraction, quasielastic neutron scattering, and other neutron techniques. Perspectives are also provided on the challenges and future opportunities in neutron scattering studies of heterogeneous catalysis.

Recognizing the Minimum Structural Units Driving the Crystallization of SAPO-34 in a Top-Down Process

Recognizing the structure and nature of the nuclei for zeolites crystallization on an atomic level is of great importance, which can provide guidance on the control of crystallization kinetics and the rational synthesis of zeolites. However, it remains a long-standing challenge due to the difficulty in characterization of amorphous precursor with limited crystal nuclei. Herein, a top-down synthesis system was designed for SAPO-34 molecular sieve and well investigated. A clear precursor solution with abundant SAPO-34 crystal nuclei was obtained under a depolymerization-dominant condition. The species in the liquid precursor were identified by FT-ICR MS, solid-state MAS NMR and atomic pair distribution function analyses. In combination with various designed experiments, it is revealed that both the formation of small species containing Si-O-Al bonds and reaching a certain concentration, is crucial for driving the crystallization of SAPO-34, rather than structural units with specific spatial conformation. This work provides an important understanding on the (pre)nucleation of SAPO-34 and sheds light on the synthesis control of SAPO molecular sieves.

Industrial Regenerator Model for SMTO Technology

In order to alleviate the current domestic oil shortage, China has studied the technology of using coal as the source to produce low carbon olefins, among which methanol to olefin (MTO) is an important process. Since the coke deposition of MTO catalyst is inevitable, the deactivated MTO catalysts need to be regenerated by continuous coke combustion to recover the activity. This paper used the actual industrial data to study the gas-solid two-phase fluidized bed of a SMTO regenerator and the coke combustion kinetics of the deactivated SAPO-34 catalyst, and established the mathematical model of the SMTO industrial regenerator. The kinetic parameters in the model were obtained and validated with different data, which showed that the model is reliable and can accurately predict the industrial reaction results and provide guidance for the SMTO production operation.

Ca Cations Impact the Local Environment inside HZSM-5 Pores during the Methanol-to-Hydrocarbons Reaction

The methanol-to-hydrocarbons (MTH) process is an industrially relevant method to produce valuable light olefins such as propylene. One of the ways to enhance propylene selectivity is to modify zeolite catalysts with alkaline earth cations. The underlying mechanistic aspects of this type of promotion are not well understood. Here, we study the interaction of Ca²⁺ with reaction intermediates and products formed during the MTH reaction. Using transient kinetic and spectroscopic tools, we find strong indications that the selectivity differences between Ca/ZSM-5 and HZSM-5 are related to the different local environment inside the pores due to the presence of Ca²⁺. In particular, Ca/ZSM-5 strongly retains water, hydrocarbons, and oxygenates, which occupy as much as 10% of the micropores during the ongoing MTH reaction. This change in the effective pore geometry affects the formation of hydrocarbon pool components and in this way directs the MTH reaction toward the olefin cycle.

Regulation of the Si/Al ratios and Al distributions of zeolites and their impact on properties

Zeolites are typically a class of crystalline microporous aluminosilicates that are constructed by SiO4 and AlO4 tetrahedra. Because of their unique porous structures, strong Brönsted acidity, molecular-level shape selectivity, exchangeable cations, and high thermal/hydrothermal stability, zeolites are widely used as catalysts, adsorbents, and ion-exchangers in industry. The activity, selectivity, and stability/durability of zeolites in applications are closely related to their Si/Al ratios and Al distributions in the framework. In this review, we discussed the basic principles and the state-of-the-art methodologies for regulating the Si/Al ratios and Al distributions of zeolites, including seed-assisted recipe modification, interzeolite transformation, fluoride media, and usage of organic structure-directing agents (OSDAs), etc. The conventional and newly developed characterization methods for determining the Si/Al ratios and Al distributions were summarized, which include X-ray fluorescence spectroscopy (XRF), solid state 29Si/27Al magic-angle-spinning nuclear magnetic resonance spectroscopy (29Si/27Al MAS NMR), Fourier-transform infrared spectroscopy (FT-IR), etc. The impact of Si/Al ratios and Al distributions on the catalysis, adsorption/separation, and ion-exchange performance of zeolites were subsequently demonstrated. Finally, we presented a perspective on the precise control of the Si/Al ratios and Al distributions of zeolites and the corresponding challenges.

High-throughput synthesis of AlPO and SAPO zeolites by ink jet printing

Ink jet printing is for the first time introduced into the synthesis of aluminophosphate (AlPO) and silicoaluminophosphate (SAPO) zeolite. As a high-throughput technique, 256 zeolite precursors with multiple formulations could be obtained within 2 h, while the product phase was regulated relative to the variant compositions.

Molecular insights into the catalytic oxidation of methanol-to-olefins wastewater with phosphoric acid modified sludge biochar

With the development of methanol-to-olefin (MTO) process, the effective disposal of wastewater was one key factor for the long-period and benign development of this technology. Herein, a sludge-based biochar catalyst (GSC-P) was synthesized and used in photo-Fenton reaction for the degradation of MTO wastewater from the outlet of a biological aerated filter. More iron was distributed on the surface of GSC-P catalyst, facilitating the photo-Fenton oxidation of MTO wastewater, with chemical oxygen demand (COD) removal rate of 75.4% and total organic carbon (TOC) removal rate of 62.5%. The 2223 unique molecular formulas assigned by a Fourier transform ion cyclotron resonance mass spectrometry (FT-ICR MS) in the original MTO wastewater showed that CHO compounds shared the lowest peak numbers (20.2%) but the highest peak abundance (51.6%) among the four groups. Besides, lipids, unsaturated hydrocarbons, lignins and proteins were the main structural types. After photo-Fenton treatment of 60 min, there were 56.7%-74.0% of compounds removed by the analysis of van Krevelen diagram, indicating that the MTO wastewater was degraded efficiently. Three possible evolution processes of dissolved organic matters during the photo-Fenton reaction were disclosed at the molecular-level.

Ketenes in the Induction of the Methanol-to-Olefins Process

Ketene (CH2 =C=O) has been postulated as a key intermediate for the first olefin production in the zeolite-catalyzed chemistry of methanol-to-olefins (MTO) and syngas-to-olefins (STO) processes. The reaction mechanism remains elusive, because the short-lived ethenone ketene and its derivatives are difficult to detect, which is further complicated by the low expected ketene concentration. We report on the experimental detection of methylketene (CH3 -CH=C=O) formed by the methylation of ketene on HZSM-5 via operando synchrotron photoelectron photoion coincidence (PEPICO) spectroscopy. Ketene is produced in situ from methyl acetate. The observation of methylketene as the ethylene precursor evidences a computationally predicted ketene-to-ethylene route proceeding via a methylketene intermediate followed by decarbonylation.

Light olefin synthesis from a diversity of renewable and fossil feedstocks: state-of the-art and outlook

Light olefins are important feedstocks and platform molecules for the chemical industry. Their synthesis has been a research priority in both academia and industry. There are many different approaches to the synthesis of these compounds, which differ by the choice of raw materials, catalysts and reaction conditions. The goals of this review are to highlight the most recent trends in light olefin synthesis and to perform a comparative analysis of different synthetic routes using several quantitative characteristics: selectivity, productivity, severity of operating conditions, stability, technological maturity and sustainability. Traditionally, on an industrial scale, the cracking of oil fractions has been used to produce light olefins. Methanol-to-olefins, alkane direct or oxidative dehydrogenation technologies have great potential in the short term and have already reached scientific and technological maturities. Major progress should be made in the field of methanol-mediated CO and CO₂ direct hydrogenation to light olefins. The electrocatalytic reduction of CO₂ to light olefins is a very attractive process in the long run due to the low reaction temperature and possible use of sustainable electricity. The application of modern concepts such as electricity-driven process intensification, looping, CO₂ management and nanoscale catalyst design should lead in the near future to more environmentally friendly, energy efficient and selective large-scale technologies for light olefin synthesis.

A Dual-Bed Strategy for Direct Conversion of Syngas to Light Paraffins

The authors studied the direct conversion of syngas to light paraffins in a dual-bed fixed-bed reactor. A dual-bed catalyst composed of three catalysts, a physically mixed methanol synthesis catalyst (CZA), and a methanol dehydration to dimethyl ether (DME) catalyst (Al2O3(C)) were put in the upper bed for direct conversion of syngas to DME, while the SAPO-34 (SP34-C) zeolite was put in the lower bed for methanol and DME conversion. The effects of the mass ratio of CZA to Al2O3(C), the H2/CO molar ratio, and the space velocity on catalytic performance of syngas to DME were studied in the upper bed. Moreover, a feed gas with a CO/CO2/DME/N2/H2 molar ratio of 9/6/4/5 balanced with H2 was simulated and studied in the lower bed over SP34-C; after optimizing the reaction conditions, the selectivity of light paraffins reached 90.8%, and the selectivity of propane was as high as 76.7%. For the direct conversion of syngas to light paraffins in a dual bed, 88.9% light paraffins selectivity in hydrocarbons was obtained at a CO conversion of 33.4%. This dual-bed strategy offers a potential route for the direct conversion of syngas to valuable chemicals.

Synthesis of Microporous Aluminosilicate by Direct Thermal Activation of Phenyl-Substituted Single-Source Aluminosilicate Molecular Precursors

The construction of aluminosilicates from versatile molecular precursors (MPs) represents a promising alternative strategy to conventional processes based on monomeric molecular or polymeric Al and Si sources. However, the use of MPs often suffers from drawbacks such as the decomposition of the core structures in the presence of solvents, acids, or bases. In this work, we demonstrate a simple thermal synthesis of porous aluminosilicates from single-source spiro-7-type MPs that consist of a tetrahedral Al atom and six Si atoms functionalized with 12 phenyl (Ph) groups, (C⁺)[Al{Ph₂Si(OSiPh₂O)₂}₂]^- (C⁺[AlSi₆]^-; C⁺ = pyridinium cation (PyH⁺), Na⁺, K⁺, Rb⁺, or Cs⁺), without using a solvent or activator. Microporous aluminosilicates synthesized via the thermal treatment of C⁺[AlSi₆]^- under a 79% N₂ + 21% O₂ atmosphere exhibited extremely low carbon contents (0.10-1.28%), together with Si/Al ratios of 3.9-6.7 ± 0.2 and surface areas of 103.1-246.3 m²/g. The solid-state ²⁷Al and ²⁹Si MAS NMR spectra suggest that the obtained aluminosilicates with alkali cations retain a tetrahedral Al site derived from the spiro-7-type core structure. After a proton-exchange reaction, the aluminosilicates showed almost 1.5 times higher reactivity in the catalytic ring-opening of styrene oxide than the aluminosilicate before proton exchange due to the catalytically active OH site being predominantly bridged by tetrahedral Al and Si atoms. These results suggest that the present MP strategy is a promising method for the introduction of key structures into active inorganic materials.

First-Generation Organic Reaction Intermediates in Zeolite Chemistry and Catalysis

Zeolite chemistry and catalysis are expected to play a decisive role in the next decade(s) to build a more decentralized renewable feedstock-dependent sustainable society owing to the increased scrutiny over carbon emissions. Therefore, the lack of fundamental and mechanistic understanding of these processes is a critical "technical bottleneck" that must be eliminated to maximize economic value and minimize waste. We have identified, considering this objective, that the chemistry related to the first-generation reaction intermediates (i.e., carbocations, radicals, carbenes, ketenes, and carbanions) in zeolite chemistry and catalysis is highly underdeveloped or undervalued compared to other catalysis streams (e.g., homogeneous catalysis). This limitation can often be attributed to the technological restrictions to detect such "short-lived and highly reactive" intermediates at the interface (gas-solid/solid-liquid); however, the recent rise of sophisticated spectroscopic/analytical techniques (including under in situ/operando conditions) and modern data analysis methods collectively compete to unravel the impact of these organic intermediates. This comprehensive review summarizes the state-of-the-art first-generation organic reaction intermediates in zeolite chemistry and catalysis and evaluates their existing challenges and future prospects, to contribute significantly to the "circular carbon economy" initiatives.

Advanced design and development of catalysts in propane dehydrogenation

Propane dehydrogenation (PDH) is an industrial technology for direct propylene production, which has received extensive attention and realized large-scale application. At present, the commercial Pt/Cr-based catalysts suffer from fast deactivation and inferior stability resulting from active species sintering and coke depositing. To overcome the above problems, several strategies such as the modification of the support and the introduction of additives have been proposed to strengthen the catalytic performance and prolong the robust stability of Pt/Cr-based catalysts. This review firstly gives a brief description of the development of PDH and PDH catalysts. Then, the advanced research progress of supported noble metals and non-noble metals together with metal-free materials for PDH is systematically summarized along with the material design and active origin as well as the existing problems in the development of PDH catalysts. Furthermore, the review also emphasizes advanced synthetic strategies based on novel design of PDH catalysts with improved dehydrogenation activity and stability. Finally, the future challenges and directions of PDH catalysts are provided for the development of their further industrial application.

Unraveling templated-regulated distribution of isolated SiO4 tetrahedra in silicoaluminophosphate zeolites with high-throughput computations

Silicoaluminophosphate (SAPO) zeolites are well-known catalytic materials because of the mild acidity originating from the isolated SiO₄ tetrahedra in their frameworks. Regulating the distribution of isolated SiO₄ tetrahedra in SAPO zeolites is formidably challenging because SiO₄ tetrahedra tend to agglomerate to form Si islands and the isolated SiO₄ tetrahedra are difficult to determine using conventional characterization techniques. Here we synthesized Si-island-free SAPO-35 zeolites by using N-methylpiperidine as a new template, which exhibited excellent thermal stability compared to conventional SAPO-35 zeolites and a substantially improved methanol-to-olefins catalytic lifetime even comparable to that of commercial SAPO-34 zeolites. More strikingly, with the aid of high-throughput computations on 44 697 structure models combined with various state-of-the-art characterization techniques, for the first time, we reveal that the host–guest interactions between template molecules and SAPO frameworks determine the specific distributions of isolated SiO₄ tetrahedra, which are responsible for the improvement in the chemical properties of zeolites. Our work provides an insight into the template-based regulation of isolated SiO₄ tetrahedra in SAPO zeolites, which opens a new avenue in the discovery of promising zeolite catalysts with optimal SiO₄ distribution.