Architecture-Dependent Distribution of Mesopores in Steamed Zeolite Crystals as Visualized by FIB-SEM Tomography

Review and perspectives on TS-1 catalyzed propylene epoxidation

Titanium silicate zeolite (TS-1) is widely used in the research on selective oxidations of organic substrates by H2O2. Compared with the chlorohydrin process and the hydroperoxidation process, the TS-1 catalyzed hydroperoxide epoxidation of propylene oxide (HPPO) has advantages in terms of by-products and environmental friendliness. This article reviews the latest progress in propylene epoxidation catalyzed by TS-1, including the HPPO process and gas phase epoxidation. The preparation and modification of TS-1 for green and sustainable production are summarized, including the use of low-cost feedstocks, the development of synthetic routes, strategies to enhance mass transfer in TS-1 crystal and the enhancement of catalytic performance after modification. In particular, this article summarizes the catalytic mechanisms and advanced characterization techniques for propylene epoxidation in recent years. Finally, the present situation, development prospect and challenge of propylene epoxidation catalyzed by TS-1 were prospected.

Understanding the Fundamentals of Microporosity Upgrading in Zeolites: Increasing Diffusion and Catalytic Performances

Hierarchical zeolites are regarded as promising catalysts due to their well-developed porosity, increased accessible surface area, and minimal diffusion constraints. Thus far, the focus has been on the creation of mesopores in zeolites, however, little is known about a microporosity upgrading and its effect on the diffusion and catalytic performance. Here the authors show that the "birth" of mesopore formation in faujasite (FAU) type zeolite starts by removing framework T atoms from the sodalite (SOD) cages followed by propagation throughout the crystals. This is evidenced by following the diffusion of xenon (Xe) in the mesoporous FAU zeolite prepared by unbiased leaching with NH4 F in comparison to the pristine FAU zeolite. A new diffusion pathway for the Xe in the mesoporous zeolite is proposed. Xenon first penetrates through the opened SOD cages and then diffuses to supercages of the mesoporous zeolite. Density functional theory (DFT) calculations indicate that Xe diffusion between SOD cage and supercage occurs only in hierarchical FAU structure with defect-contained six-member-ring separating these two types of cages. The catalytic performance of the mesoporous FAU zeolite further indicates that the upgraded microporosity facilitates the intracrystalline molecular traffic and increases the catalytic performance.

Chemical Imaging of Hierarchical Porosity Formation within a Zeolite Crystal Visualized by Small-Angle X-Ray Scattering and In-Situ Fluorescence Microscopy

Introducing hierarchical porosity to zeolites is vital for providing molecular access to microporous domains. Yet, the dynamics of meso- and macropore formation has remained elusive and pore space ill-characterized by a lack of (in situ) microscopic tools sensitive to nanoporosity. Here, we probe hierarchical porosity formation within a zeolite ZSM-5 crystal in real-time by in situ fluorescence microscopy during desilication. In addition, we introduce small-angle X-ray scattering microscopy as novel characterization tool to map intracrystal meso- and macropore properties. It is shown that hierarchical porosity formation initiates at the crystal surface and propagates to the crystal core via a pore front with decreasing rate. Also, hierarchical porosity only establishes in specific (segments of) subunits which constitute ZSM-5. Such space-dependent meso- and macroporosity implies local discrepancies in diffusion, performance and deactivation behaviors even within a zeolite crystal.

Single-molecule observation of diffusion and catalysis in nanoporous solids

Nanoporous solids, including microporous, mesoporous and hierarchically structured porous materials, are of scientific and technological interest because of their high surface-to-volume ratio and ability to impose shape- and size-selectivity on molecules diffusing through them. Enormous efforts have been put in the mechanistic understanding of diffusion–reaction relationships of nanoporous solids, with the ultimate goal of developing materials with improved catalytic performance. Single-molecule localization microscopy can be used to explore the pore space via the trajectories of individual molecules. This ensemble-free perspective directly reveals heterogeneities in diffusion and diffusion-related reactivity of individual molecules, which would have been obscured in bulk measurements. In this article, we review developments in the spatial and temporal characterization of nanoporous solids using single-molecule localization microscopy. We illustrate various aspects of this approach, and showcase how it can be used to follow molecular diffusion and reaction behaviors in nanoporous solids.

Zeolite (In)Stability under Aqueous or Steaming Conditions

Zeolites are among the most environmentally friendly materials produced industrially at the Megaton scale. They find numerous commercial applications, particularly in catalysis, adsorption, and separation. Under ambient conditions aluminosilicate zeolites are stable when exposed to water or water vapor. However, at extreme conditions as high temperature, high water vapor pressure or increased acidity/basicity, their crystalline framework can be destroyed. The stability of the zeolite framework under aqueous conditions also depends on the concentration and character of heteroatoms (other than Al) and the topology of the zeolite. The factors critical for zeolite (in)stability in the presence of water under various conditions are reviewed from the experimental as well as computational sides. Nonreactive and reactive interactions of water with zeolites are addressed. The goal of this review is to provide a comparative overview of all-silica zeolites, aluminosilicates and zeolites with other heteroatoms (Ti, Sn, and Ge) when contacted with water. Due attention is also devoted to the situation when partial zeolite hydrolysis is used beneficially, such as the formation of hierarchical zeolites, synthesis of new zeolites or fine-tuning catalytic or adsorption characteristics of zeolites.

3D Raman Spectroscopy of Large Zeolite ZSM-5 Crystals

Hydrothermal treatment is a common method used to modify the physicochemical properties of zeolite‐based catalyst materials. It alters the number and type of acid sites through dealumination and increases molecular diffusion by mesopore formation. Steaming also reduces the structural integrity of zeolite frameworks. In this study, Raman microscopy has been used to map large zeolite ZSM‐5 crystals before and after steaming. 3D elemental maps of T−O (T: Al or Si) sites of the zeolite were obtained. The Raman active vibrational bands were determined, which are indicative of (non‐) framework Al, as well as of structural integrity. Zeolite steaming caused the introduction of additional heterogeneities within the zeolite framework. Al migration and the formation of extra‐framework Al species were observed. The described experiments demonstrate the capability of 3D Raman spectroscopy as a valuable tool to obtain information on the spatial distributions of framework elements as well as defects within a zeolite‐based material.

Collective action of water molecules in zeolite dealumination

Water molecules cooperate to facilitate Al–O bond hydrolysis during zeolite dealumination at real steaming conditions.

Operando micro-spectroscopy on ZSM-5 containing extrudates during the oligomerization of 1-hexene

The influence of the binder material in an industrial-type catalyst material is often neglected, although the addition of a binder can cause a significant change in the performance of the catalyst.

Single Molecule Nanospectroscopy Visualizes Proton-Transfer Processes within a Zeolite Crystal

Visualizing proton-transfer processes at the nanoscale is essential for understanding the reactivity of zeolite-based catalyst materials. In this work, the Brønsted-acid-catalyzed oligomerization of styrene derivatives was used for the first time as a single molecule probe reaction to study the reactivity of individual zeolite H-ZSM-5 crystals in different zeolite framework, reactant and solvent environments. This was accomplished via the formation of distinct dimeric and trimeric fluorescent carbocations, characterized by their different photostability, as detected by single molecule fluorescence microscopy. The oligomerization kinetics turned out to be very sensitive to the reaction conditions and the presence of the local structural defects in zeolite H-ZSM-5 crystals. The remarkably photostable trimeric carbocations were found to be formed predominantly near defect-rich crystalline regions. This spectroscopic marker offers clear prospects for nanoscale quality control of zeolite-based materials. Interestingly, replacing n-heptane with 1-butanol as a solvent led to a reactivity decrease of several orders and shorter survival times of fluorescent products due to the strong chemisorption of 1-butanol onto the Brønsted acid sites. A similar effect was achieved by changing the electrophilic character of the para-substituent of the styrene moiety. Based on the measured turnover rates we have established a quantitative, single turnover approach to evaluate substituent and solvent effects on the reactivity of individual zeolite H-ZSM-5 crystals.

X-ray Excited Optical Fluorescence and Diffraction Imaging of Reactivity and Crystallinity in a Zeolite Crystal: Crystallography and Molecular Spectroscopy in One

Structure-activity relationships in heterogeneous catalysis are challenging to be measured on a single-particle level. For the first time, one X-ray beam is used to determine the crystallographic structure and reactivity of a single zeolite crystal. The method generates μm-resolved X-ray diffraction (μ-XRD) and X-ray excited optical fluorescence (μ-XEOF) maps of the crystallinity and Brønsted reactivity of a zeolite crystal previously reacted with a styrene probe molecule. The local gradients in chemical reactivity (derived from μ-XEOF) were correlated with local crystallinity and framework Al content, determined by μ-XRD. Two distinctly different types of fluorescent species formed selectively, depending on the local zeolite crystallinity. The results illustrate the potential of this approach to resolve the crystallographic structure of a porous material and its reactivity in one experiment via X-ray induced fluorescence of organic molecules formed at the reactive centers.

X-ray Excited Optical Fluorescence and Diffraction Imaging of Reactivity and Crystallinity in a Zeolite Crystal: Crystallography and Molecular Spectroscopy in One

Structure-activity relationships in heterogeneous catalysis are challenging to be measured on a single-particle level. For the first time, one X-ray beam is used to determine the crystallographic structure and reactivity of a single zeolite crystal. The method generates μm-resolved X-ray diffraction (μ-XRD) and X-ray excited optical fluorescence (μ-XEOF) maps of the crystallinity and Brønsted reactivity of a zeolite crystal previously reacted with a styrene probe molecule. The local gradients in chemical reactivity (derived from μ-XEOF) were correlated with local crystallinity and framework Al content, determined by μ-XRD. Two distinctly different types of fluorescent species formed selectively, depending on the local zeolite crystallinity. The results illustrate the potential of this approach to resolve the crystallographic structure of a porous material and its reactivity in one experiment via X-ray induced fluorescence of organic molecules formed at the reactive centers.

FIB-SEM Tomography Probes the Mesoscale Pore Space of an Individual Catalytic Cracking Particle

The overall performance of a catalyst particle strongly depends on the ability of mass transport through its pore space. Characterizing the three-dimensional structure of the macro- and mesopore space of a catalyst particle and establishing a correlation with transport efficiency is an essential step toward designing highly effective catalyst particles. In this work, a generally applicable workflow is presented to characterize the transport efficiency of individual catalyst particles. The developed workflow involves a multiscale characterization approach making use of a focused ion beam-scanning electron microscope (FIB-SEM). SEM imaging is performed on cross sections of 10.000 μm², visualizing a set of catalyst particles, while FIB-SEM tomography visualized the pore space of a large number of 8 μm³ cubes (subvolumes) of individual catalyst particles. Geometrical parameters (porosity, pore connectivity, and heterogeneity) of the material were used to generate large numbers of virtual 3D volumes resembling the sample's pore space characteristics, while being suitable for computationally demanding transport simulations. The transport ability, defined as the ratio of unhindered flow over hindered flow, is then determined via transport simulations through the virtual volumes. The simulation results are used as input for an upscaling routine based on an analogy with electrical networks, taking into account the spatial heterogeneity of the pore space over greater length scales. This novel approach is demonstrated for two distinct types of industrially manufactured fluid catalytic cracking (FCC) particles with zeolite Y as the active cracking component. Differences in physicochemical and catalytic properties were found to relate to differences in heterogeneities in the spatial porosity distribution. In addition to the characterization of existing FCC particles, our method of correlating pore space with transport efficiency does also allow for an up-front evaluation of the transport efficiency of new designs of FCC catalyst particles.

Topological analysis of non-granular, disordered porous media: determination of pore connectivity, pore coordination, and geometric tortuosity in physically reconstructed silica monoliths

Different approaches are applied and compared, which are universally applicable to quantify pore coordination, pore and pore-throat connectivity, and geometric tortuosity.

Structural analysis of hierarchically organized zeolites

Advances in materials synthesis bring about many opportunities for technological applications, but are often accompanied by unprecedented complexity. This is clearly illustrated by the case of hierarchically organized zeolite catalysts, a class of crystalline microporous solids that has been revolutionized by the engineering of multilevel pore architectures, which combine unique chemical functionality with efficient molecular transport. Three key attributes, the crystal, the pore and the active site structure, can be expected to dominate the design process. This review examines the adequacy of the palette of techniques applied to characterize these distinguishing features and their catalytic impact.

Noninvasive Nanoscopy Uncovers the Impact of the Hierarchical Porous Structure on the Catalytic Activity of Single Dealuminated Mordenite Crystals

Spatial restrictions around catalytic sites, provided by molecular-sized micropores, are beneficial to reaction selectivity but also inherently limit diffusion. The molecular transport can be enhanced by introducing meso- and macropores. However, the impact of this extraframework porosity on the local nanoscale reactivity is relatively unexplored. Herein we show that the area of enhanced reactivity in hierarchical zeolite, examined with super-resolution fluorescence microscopy, is spatially restricted to narrow zones around meso- and macropores, as observed with focused ion-beam-assisted scanning electron microscopy. This comparison indicates that reagent molecules efficiently reach catalytic active sites only in the micropores surrounding extraframework porosity and that extensive macroporosity does not warrant optimal reactivity distribution throughout a hierarchical porous zeolite.

Morphological Analysis of Physically Reconstructed Silica Monoliths with Submicrometer Macropores: Effect of Decreasing Domain Size on Structural Homogeneity

Silica monoliths are increasingly used as fixed-bed supports in separation and catalysis because their bimodal pore space architecture combines excellent mass transport properties with a large surface area. To optimize their performance, a quantitative relationship between morphology and transport characteristics has to be established, and synthesis conditions that lead to a desired morphology optimized for a targeted application must be identified. However, the effects of specific synthesis parameters on the structural properties of silica monoliths are still poorly understood. An important question is how far the macropore and domain size can be reduced without compromising the structural homogeneity. We address this question with quantitative morphological data derived for a set of eight macroporous-mesoporous silica monoliths with an average macropore size (d(macro)) of between 3.7 and 0.1 μm, prepared following an established route involving the sol-gel transition and phase separation. The macropore space of the silica monolith samples is reconstructed using focused ion beam scanning electron microscopy followed by a quantitative assessment of geometrical and topological properties based on chord length distributions (CLDs) and branch-node analysis of the pore network, respectively. We observe a significant increase in structural heterogeneity, indicated by a decrease in the parameter k derived from fitting a k-gamma function to the CLDs, when d(macro) reaches the submicrometer range. The compromised structural homogeneity of silica monoliths with submicrometer macropores could possibly originate from early structural freezing during the competitive processes of sol-gel transition and phase separation. It is therefore questionable if the common approach of reducing the morphological features of silica monoliths into the submicrometer regime by changing the point of sol-gel transition can be successful. Alternative strategies and a better understanding of the involved competitive processes should be the focus of future research.

Binder Effects in SiO2- and Al2O3-Bound Zeolite ZSM-5-Based Extrudates as Studied by Microspectroscopy

Microspectroscopic methods were explored to investigate binder effects occurring in ZSM-5-containing SiO2- and Al2O3-bound millimetre-sized extrudates. Using thiophene as a selective probe for Brønsted acidity, coupled with time-resolved in situ UV/Vis and confocal fluorescence microspectroscopy, variations in reactivity and selectivity between the two distinct binder types were established. It was found that aluminium migration occurs in ZSM-5-containing Al2O3-bound extrudates, forming additional Brønsted acid sites. These sites strongly influence the oligomer selectivity, favouring the formation of thiol-like species (i.e., ring-opened species) in contrast to higher oligomers, predominantly formed on SiO2-bound ZSM-5-containing extrudates. Not only were the location and distribution of these oligomers visualised by 3 D analysis, it was also observed that more conjugated species appeared to grow off the surface of the zeolite ZSM-5 crystals (containing less conjugated species) into the surrounding binder material. Furthermore, a higher binder content resulted in an increasing overall reactivity owing to the greater number of stored thiophene monomers available per Brønsted acid site.

Tailoring and visualizing the pore architecture of hierarchical zeolites

This review provides an overview of the different synthesis methods and microscopy techniques for tailoring and visualizing the pore architecture of hierarchical zeolites.

Intergrowth of components and ramps in coffin-shaped ZSM-5 zeolite crystals unraveled by focused ion beam-assisted transmission electron microscopy

Scanning electron microscopy, focused ion beam (FIB), and transmission electron microscopy are combined to study the intergrowth of 90° rotational components and of ramps in coffin-shaped ZSM-5 crystals. The 90° rotational boundaries with local zig-zag features between different intergrowth components are observed in the main part of crystal. Also a new kind of displacement boundary is described. At the displacement boundary there is a shift of the unit cells along the boundary without a change in orientation. Based on lamellae prepared with FIB from different positions of the ramps and crystal, the orientation relationships between ramps and the main part of the crystal are studied and the three-dimensional morphology and growth mechanism of the ramp are illustrated.

Selective staining of Brønsted acidity in zeolite ZSM-5-based catalyst extrudates using thiophene as a probe

Brønsted acid site density dictates the reaction pathway in ZSM-5-based extrudates during thiophene oligomerization, visualized non-invasively in 3D using micro-spectroscopy.

Visualization of hierarchically structured zeolite bodies from macro to nano length scales

A major challenge in the implementation of laboratory-designed catalysts is the scale-up into technically relevant forms. Advanced characterization is essential to understand and optimize catalyst assembly and function in industrial reactors. This Article presents an integrated approach to visualizing millimetre-sized extrudates and granules of a hierarchical MFI-type zeolite, displaying trimodal networks of micropores (0.56 nm), intracrystalline mesopores (∼10 nm) and macropores (∼200-300 nm). As exemplified for the conversion of methanol to olefins, the hierarchical zeolite yields a superior performance compared to its conventional analogue. The combination of dedicated specimen preparation with state-of-the-art optical, X-ray and electron-based microscopic and tomographic techniques proves a powerful methodology to reveal otherwise inaccessible information regarding structural organization over the whole range of length scales. It is expected that these tools will play a crucial role in the rationalization of scale-up principles in catalyst development.