Ni-ZSM-5 catalysts: Detailed characterization of metal sites for proper catalyst design

Synthesis and Application of ZSM-5 Catalyst Supported with Zinc and/or Nickel in the Conversion of Pyrolytic Gases from Recycled Polypropylene and Polystyrene Mixtures under Hydrogen Atmosphere

Currently, catalytic pyrolysis has become a versatile and highly useful technology in the treatment of different plastic wastes. Thus, the development of selective catalysts to carry out cracking reactions and obtain a greater fraction of the desired products is essential. This study focuses on the synthesis of monometallic (Ni) and bimetallic (Ni-Zn) catalysts supported on ZSM-5 zeolite using an impregnation and co-impregnation method, respectively. The obtained catalysts were characterized by FTIR spectroscopy, N2 adsorption/desorption measurements, scanning electron microscopy (SEM) and energy dispersive X-Ray spectroscopy (EDS), temperature programmed NH3 desorption (TPD-NH3) and thermogravimetric analysis (TGA). In this way, a mixture of polystyrene and polypropylene recycled with a catalyst/plastic waste ratio of 1:500 was used for pyrolysis tests. The best results were obtained using the Ni-Zn/ZSM-5 catalyst, which included better impregnation, increased surface acidity, decreased dispersion and a shorter reaction time in the catalytic pyrolysis process. Under the optimized conditions, catalytic pyrolysis showed an excellent performance to generate hydrocarbons of greater industrial interest.

Facile and Eco-Friendly Approach To Produce Confined Metal Cluster Catalysts

Zeolite-supported metal nanocluster catalysts have attracted significant attention due to their broad application in heterogeneously catalyzed reactions. The preparation of highly dispersed metal catalysts commonly involves the use of organic compounds and requires the implementation of complicated procedures, which are neither green nor deployable at the large scale. Herein, we present a novel facile method (vacuum-heating) which employs a specific thermal vacuum processing protocol of catalysts to promote the decomposition of metal precursors. The removal of coordinated H₂O via vacuum-heating restricts the formation of intermediates (metal-bound OH species), resulting in catalysts with a uniform, metal nanocluster distribution. The structure of the intermediate was determined by in situ Fourier transform infrared, temperature-programmed decomposition, and X-ray absorption spectroscopy (XAS) measurements. This alternative synthesis method is eco-friendly and cost-effective as the procedure occurs in the absence of organic compounds. It can be widely used for the preparation of catalysts from different metal species (Ni, Fe, Cu, Co, Zn) and precursors and is readily scaled-up.

Insight into the interdependence of Ni and Al in bifunctional Ni/ZSM-5 catalysts at the nanoscale

Catalyst design is crucial for improving catalytic activity and product selectivity. In a bifunctional Ni/ZSM-5 zeolite type catalyst, catalytic properties are usually tuned via varying Al and Ni contents. While changes in acid properties associated with Al sites are usually closely investigated, Ni phases, however, receive inadequate attention. Herein, we present a systematic structural study of Ni in the Ni/ZSM-5 materials by using Ni K-edge XANES and EXAFS analyses, complemented by XRD and TEM, to resolve the changes in the local environment of Ni species induced by the different Al contents of the parent ZSM-5 prepared by a "green", template free technique. Ni species in Ni/ZSM-5 exist as NiO crystals (3-50 nm) and as charge compensating Ni²⁺ cations. The Ni K-edge XANES and EXAFS results enabled the quantification of Ni-containing species. At a low Al to Si ratio (n _Al/n _Si ≤ 0.04), the NiO nanoparticles predominate in the samples and account for over 65% of Ni phases. However, NiO is outnumbered by Ni²⁺ cations attached to the zeolite framework in ZSM-5 with a high Al to Si ratio (n _Al/n _Si = 0.05) due to a higher number of framework negative charges imparted by Al. The obtained results show that the number of highly reducible and active NiO crystals is strongly correlated with the framework Al sites present in ZSM-5 zeolites, which depend greatly on the synthesis conditions. Therefore, this kind of study is beneficial for any further investigation of the catalytic activities of Ni/ZSM-5 and other metal-modified bifunctional catalysts.

The role of Ni sites located in mesopores for the selectivity of anisole hydrodeoxygenation

A highly-dispersed Ni catalyst with an increased number of Ni sites selectively distributed in the mesopores of HBEA has been developed and applied in anisole hydrodeoxygenation (HDO) in a continuous-flow...

Upgrading of Light Bio-oil from Solvothermolysis Liquefaction of an Oil Palm Empty Fruit Bunch in Glycerol by Catalytic Hydrodeoxygenation Using NiMo/Al2O3 or CoMo/Al2O3 Catalysts

Hydrodeoxygenation (HDO) of bio-oil derived from liquefaction of a palm empty fruit bunch (EFB) in glycerol was investigated. To enhance the heating value and reduce the oxygen content of upgraded bio-oil, hydrodeoxygenation of light bio-oil over Ni- and Co-based catalysts on an Al2O3 support was performed in a rotating-bed reactor. Two consecutive steps were conducted to produce bio-oil from EFB including (1) microwave-assisted wet torrefaction of EFB and (2) solvothermolysis liquefaction of treated EFB in a Na2CO3/glycerol system. The HDO of as-prepared bio-oil was subsequently performed in a unique design reactor possessing a rotating catalyst bed for efficient interaction of a catalyst with bio-oil and facile separation of the catalyst from upgraded bio-oil after the reaction. The reaction was carried out in the presence of each mono- or bimetallic catalyst, namely, Co/Al2O3, Ni/Al2O3, NiMo/Al2O3, and CoMo/Al2O3, packed in the rotating-mesh host with a rotation speed of 250 rpm and kept at 300 and 350 °C, 2 MPa hydrogen for 1 h. From the results, the qualities of upgraded bio-oil were substantially improved for all catalysts tested in terms of oxygen reduction and increased high heating value (HHV). Particularly, the NiMo/Al2O3 catalyst exhibited the most promising catalyst, providing favorable bio-oil yield and HHV. Remarkably greater energy ratios and carbon recovery together with high H/O, C/O, and H/C ratios were additionally achieved from the NiMo/Al2O3 catalyst compared with other catalysts. Cyclopentanone and cyclopentene were the main olefins found in hydrodeoxygenated bio-oil derived from liquefied EFB. It was observed that cyclopentene was first generated and subsequently converted to cyclopentanone under the hydrogenation reaction. These compounds can be further used as a building block in the synthesis of jet-fuel range cycloalkanes.

The Effect of Ni-ZSM-5 Catalysts on Catalytic Pyrolysis and Hydro-Pyrolysis of Biomass

With the demand of energy and re-utilization of wastes, the renewable lignocellulosic biomass, has attracted increasing and significant attention for alleviating the growing energy crisis and environment problems. As main components of lignocellulosic biomass, lignin, cellulose, and hemicellulose are connected by hydrogen bond to form a compact skeleton structure, resulting the trenchant condition of biomass pyrolysis. Also, pyrolysis products of above three main constituents contain a large amount of oxygenates that cause low heating value, high corrosiveness, high viscosity, and instability. Meanwhile, zeolites are of considerable significance to the conversion of lignocellulosic biomass to desirable chemical products on account of fine shape selectivity and moderate acid sites and strength. Among numerous zeolites, ZSM-5-based catalysts have been most extensively studied, and the acidity and porosity of ZSM-5 can be tuned by changing the content of Si or Al in zeolite. Beyond that, doping of other metal elements, such as Mn, Co, Ni, Ga, Ce, Pt, into ZSM-5 is also an efficient way to regulate the strength and density of acid sites in zeolite precisely. This review focused on the recent investigation of Ni-modified microporous ZSM-5 used in catalytic pyrolysis of lignin and cellulose. The application of metal-modified hierarchical ZSM-5 is also covered.

Zeolite-Supported Ni Catalysts for CO2 Methanation: Effect of Zeolite Structure and Si/Al Ratio

The urgent need to reduce CO2 emissions requires the development of efficient catalysts for the conversion of CO2 into chemicals and fuels. In this study, a series of nickel catalysts supported on ITQ-2 and ZSM-5 zeolites have been prepared, characterized and tested in the hydrogenation reaction of CO2 towards methane. Specifically, two ITQ-2 and two ZSM 5 zeolites with different aluminum content have been studied. For both types, the higher Si/Al ratio of the material, the more active the catalyst due probably to its higher hydrophobicity. The largest difference was found for the ITQ-2 samples, being the CO2 conversion for the sample with a greater Si/Al ratio 50 points higher at 350 °C. Comparing both zeolite structures, while similar catalytic results were obtained with the samples with lower Si/Al ratio, a distinctly higher activity was found for the ITQ-2 zeolite without aluminum, pure silica. Therefore, this result suggests that the presence of aluminum is of particular relevance. Among the studied materials, the catalyst supported on the delaminated ITQ-2 zeolite without Al was the most active catalyst. Its higher activity was mainly attributed to the smaller crystallite size of nickel supported on the large external surface area presented by this zeolite.

Effect of calcium addition in plasma catalysis for toluene removal by Ni/ZSM-5 : Acidity/basicity, catalytic activity and reaction mechanism

The effect of Ca modification on the Ni/ZSM-5 catalyst for efficient toluene oxidation was studied in a plasma-catalytic system. The Ni/ZSM-5 and Ca-Ni/ZSM-5 catalysts were prepared by a wet impregnation method and characterized by X-ray diffraction (XRD), Brunauer-Emmett-Teller (BET), Fourier transform infrared (FTIR) spectroscopy, X-ray photoelectron spectroscopy (XPS), Pyridine-FTIR spectroscopy and temperature programmed desorption of ammonia (NH₃-TPD). Among the catalysts tested, the Ca-Ni/ZSM-5 sample showed the best potential for toluene conversion (90.2%) and CO₂ selectivity (70.7%). Pyridine-FTIR spectra and NH₃-TPD results proved that the introduction of Ca and Ni onto ZSM-5 caused a decrease in the strong and weak acidic sites. In addition, gas chromatography/mass spectrometry (GC-MS) result showed that the Ca-Ni/ZSM-5 catalyst reduced the production of undesirable byproducts (such as p-nitrotoluene and methyl benzoate). Calcium in the Ni/ZSM-5 system influenced the acidity and other surface characteristic of the catalyst, as well as directly impacting the reactive plasma species and the intermediates. Finally, possible reaction mechanisms in the plasma catalysis of toluene were also proposed.

The role of acid and metal sites in hydrodeoxygenation of guaiacol over Ni/Beta catalysts

Hydrodeoxygenation (HDO) of guaiacol over Ni supported on zeolites (HBeta, HZSM-5) with different Si/Al ratios and different metal loadings (2.3–23.4 wt%) was studied in order to elucidate the role of catalyst acidity and Ni structure in the HDO.

Ketal Sugar Conversion Into Green Hydrocarbons by Faujasite Zeolite in a Typical Catalytic Cracking Process

Fluidized catalytic cracking (FCC) converts hydrocarbons in the presence of a catalyst based on faujasite zeolite (USY and REY). While hydrocarbon is poorly reactive, biomass and its derived compounds are highly functionalized and not suitable to a typical FCC process. To overcome this limitation biomass was first converted into a dense and stable bio-crude composed mainly of ketal-sugar derivatives by using acetone in diluted acid. Here, a representative compound of this bio-crude, 1,2:3,5-di-O-isopropylidene-α-D-xylofuranose (DX) in n-hexane, was converted by USY and a commercial FCC catalyst containing USY, at 500°C, in a fixed bed and fluidized bed reactors, respectively. Faujasite Y is very efficient in converting DX. More than 95% conversion was observed in all tests. Over 60 wt.% was liquid products, followed by gas products and only around 10% or less in coke. The higher the catalyst activity the greater the aromatics in the liquid products and yet higher coke yields were observed. In particular, simulating more practical application conditions: using deactivated catalyst in a fluidized bed reactor, improved green hydrocarbons production (mono-aromatic up to 10 carbons and light hydrocarbon up to eight carbons) and unprecedented lower coke yield (≈5 wt.%) for bio-feeds. The present results further suggest that catalyst will play a primary role to convert the bio-crude into target hydrocarbons and overcome the transition of a non-renewable to a renewable refinery feed.

Enhancement of light aromatics from catalytic fast pyrolysis of cellulose over bifunctional hierarchical HZSM-5 modified by hydrogen fluoride and nickel/hydrogen fluoride

Pore structure and accessible active sites of HZSM-5 (Z5) are the key factors for its catalysis. The bifunctional hierarchical Z5 were prepared with leaching agent HF and loading Ni, and their performance for catalytic fast pyrolysis (CFP) of cellulose was investigated in a drop tube quartz reactor. Z5 modified with 0.5 mol/L HF (0.5F-Z5) showed excellent light aromatics (LAs) yield, which can be attributed to the enhancement in the small mesopores (2-10 nm) and the decrease of Brønsted acid sites during dealumination. Simultaneously, the loading of a 1 wt% Ni produced more LAs than 0.5F-Z5, due to the improvement in deoxidation/hydrogenation reactions. The highest LAs yield (31.3%) was obtained over 1%Ni-0.5 mol/LHF-Z5, which increased by 44.9% compared to the parent Z5. In addition, the reaction routes over different active centers and acid-catalyzed reactions were analyzed, based upon the composition of bio-oils and catalyst characterization.

Biomass-mediated ZSM-5 zeolite synthesis: when self-assembly allows to cross the Si/Al lower limit

A family of Al-rich ZSM-5 zeolites with Si/Al = 8 ± 0.5 was prepared according to a biomass-mediated supramolecular approach. A combination of advanced characterisation techniques and periodic density functional theory (DFT) calculations unraveled the purity and stability of un-expected Al-enriched ZSM-5 structures, hence allowing to cross the frontier of Si/Al lower limit. In addition, these Al-rich ZSM-5 zeolites demonstrated high catalytic activity in n-hexane cracking and methanol conversion into hydrocarbons, being in line with the presence of numerous Brønsted acid sites.

Vapor-Phase Hydrogenation of Levulinic Acid to γ-Valerolactone Over Bi-Functional Ni/HZSM-5 Catalyst

The hydrogenation of levulinic acid (LA) to γ-valerolactone (GVL) in vapor-phase is economically more viable route if compared to reaction in liquid-phase. To improve the GVL yield in the vapor-phase reaction, the optimization of nickel modified zeolite as bi-functional catalyst (Ni/HZSM-5) was studied. Ni/HZSM-5 materials with fixed Al/Si molar ratio of 0.04 and different nominal Ni/Si molar ratios (from 0.01 to 0.05) were synthesized without the use of organic template and with the most affordable sources of silica and alumina. Materials were characterized by X-ray powder diffraction, SEM-EDX, TEM-EDX, pyridine TPD and DRIFTS, H₂-TPR, N₂ physisorption and isoelectric point. In the synthesized materials, 61–83% of nickel is present as bulk NiO and increases with nickel content. Additionally, in all catalysts, a small fraction of Ni²⁺ which strongly interacts with the zeolite support was detected (10–18%), as well as Ni²⁺ acting as charge compensating cations for Brønsted acid sites (7–21%). Increasing the nickel content in the catalysts leads to a progressive decrease of Brønsted acid sites (BAS) and concomitant increase of Lewis acid sites (LAS). When BAS/LAS is approaching to 1 and at the same time the amount of NiO reducible active sites is around 80%, the bi-functional Ni/HZSM-5-3 catalyst (Ni/Al = 0.59) leads to 99% conversion of LA and 100% selectivity to GVL at 320°C. This catalyst also shows stable levulinic acid hydrogenation to GVL in 3 reaction cycles conducted at 320°C. The concerted action of the following active sites in the catalyst is a key element for its optimized performance: (1) Ni metallic active sites with hydrogenation effect, (2) Lewis acid sites with dehydration effect, and (3) nickel aluminate sites with synergetic and stabilizing effects of all active sites in the catalyst.

Hydrocracking of Jatropha Oil over non-sulfided PTA-NiMo/ZSM-5 Catalyst

The PTA-NiMo/ZSM-5 catalyst impregnated with phosphotungstic acid (PTA) was designed for the transformation of Jatropha oil into benzene, toluene, and xylenes (BTX) aromatics. The produced catalyst was characterized by N₂ adsorption-desorption, powder X-ray diffraction (XRD), Fourier transform infrared (FT-IR), X-ray photoelectron spectroscopy (XPS), and the temperature-programmed desorption of ammonia (NH₃-TPD). The catalytic performance was evaluated by gas chromatography (GC). The liquid products were 70 wt% of the feed oil, and the majority of the liquid products were BTX. The aromatization activity of the catalyst was improved by the addition of PTA and the hierarchical process. The favorable PTA amount was 20 wt% and the yield of BTX was 59 wt% at 380 °C, 3 MPa, H₂/oil (v/v) = 1000 and LHSV = 1 h⁻¹ over the PTA20-NiMo/HZ0.5 catalyst (PTA 20 wt%) without sulfurization.

Crude oil to chemicals: light olefins from crude oil

The possibility to fulfill the increasing market demand and producers' needs in processing straightforwardly crude oil, a cheap and universally available feedstock, to produce petrochemicals appears to be a very attractive strategy.

Isoparaffin-rich gasoline synthesis from DME over Ni-modified HZSM-5

Nickel modified HZSM-5 exhibits an improved performance in isoparaffin formation due to the moderate acid strength and NiO_x hydroisomerization.