Synthesis-property-performance relationships of amorphous silica-alumina catalysts for the production of methylenedianiline and higher homologues

Hierarchical LTL Zeolite as an Efficient and Sustainable Solid Acid Catalyst for Replacing HCl in the Production of Polyurethane Intermediates

In many industrially important reactions, caustic mineral acid catalysts have been successfully replaced with green solid acids such as zeolites. In this context, extensive efforts have been devoted to replacing HCl to produce methylenedianiline (MDA), a key intermediate in polyurethane production. Unfortunately, limited success has been achieved thus far due to low activity, selectivity towards the desired 4,4'-MDA, and rapid catalyst deactivation. Here we report that meso-/microporous hierarchical LTL zeolite exhibits unprecedentedly high activity, selectivity, and stability. The one-dimensional cage-like micropores of LTL promote the bimolecular reaction between two para-aminobenzylaniline intermediates to selectively produce 4,4'-MDA and inhibit the formation of undesired isomers and heavy oligomers. Meanwhile, the secondary mesopores alleviate mass transfer limitations, resulting in a 7.8-fold higher MDA formation rate compared to solely microporous LTL zeolite. Due to suppressed oligomer formation and fast mass transfer, the catalyst exhibits inappreciable deactivation in an industrially relevant continuous flow reactor.

Engineering the Distinct Structure Interface of Subnano-alumina Domains on Silica for Acidic Amorphous Silica-Alumina toward Biorefining

Amorphous silica-aluminas (ASAs) are important solid catalysts and supports for many industrially essential and sustainable processes, such as hydrocarbon transformation and biorefining. However, the wide distribution of acid strength on ASAs often results in undesired side reactions, lowering the product selectivity. Here we developed a strategy for the synthesis of a unique class of ASAs with unvarying strength of Brønsted acid sites (BAS) and Lewis acid sites (LAS) using double-flame-spray pyrolysis. Structural characterization using high-resolution transmission electron microscopy (TEM) and solid-state nuclear magnetic resonance (NMR) spectroscopy showed that the uniform acidity is due to a distinct nanostructure, characterized by a uniform interface of silica-alumina and homogeneously dispersed alumina domains. The BAS population density of as-prepared ASAs is up to 6 times higher than that obtained by classical methods. The BAS/LAS ratio, as well as the population densities of BAS and LAS of these ASAs, could be tuned in a broad range. In cyclohexanol dehydration, the uniform Brønsted acid strength provides a high selectivity to cyclohexene and a nearly linear correlation between acid site densities and cyclohexanol conversion. Moreover, the concerted action of these BAS and LAS leads to an excellent bifunctional Brønsted-Lewis acid catalyst for glucose dehydration, affording a superior 5-hydroxymethylfurfural yield.

Pentacoordinated Aluminum Species: New Frontier for Tailoring Acidity-Enhanced Silica-Alumina Catalysts

Silica-alumina catalysts, including zeolites and amorphous silica-aluminas (ASAs), are among the most widely used solid acid catalysts and supports to produce petrochemicals, fine chemicals, and renewable energy. The coordination, distribution, and interactions of aluminum in ASAs have an enormous impact on their acidic properties and catalytic performance. Unsaturated tetracoordinated aluminum (Al^IV) species are commonly accepted as the key sites in generating catalytically active Brønsted acid sites (BASs) in silica-alumina catalysts. Extensive efforts focus on increasing the concentration of Al^IV as the main route to enhance their Brønsted acidity for efficient catalysis. However, increasing the Al^IV concentration either weakens the acid strength in zeolites or lowers Brønsted acidity in ASAs at high Al/Si ratios, impeding acidity enhancement of these popular catalysts."Pentacoordinated aluminum (Al^V) species" are potential unsaturated Al species like Al^IV but rarely observed in silica-aluminas, and thus, are widely considered unavailable for BAS formation or surface reactions. In this Account, we will describe novel strategies for the controlled synthesis of Al^V-enriched ASAs using flame-spray pyrolysis (FSP) techniques and highlight the contribution of Al^V species in acidity enhancement, together with their structure-activity relationship in the conversion of biomass-derived compounds into valuable chemicals. Using various in situ and advanced 2D solid-state NMR (SSNMR) experiments, the studies of the acidic properties and local structure of Al^V-enriched ASAs reveal that Al^V species can highly populate on ASA surfaces, promote BASs formation, and facilitate adaptable tuning of BASs from moderate to zeolitic strength by synergy with neighboring Al sites. Moreover, the BASs with enhanced acidity can work jointly with surface Lewis acid sites or metal active species for bifunctional catalysis on Al^V-enriched ASAs. Compared to zeolites, these Al^V-enriched ASAs are highly active in acid-catalyzed biomass conversion, including alcohol dehydration and sugar conversion reactions, as well as in promoting the performance of supported metal catalysts in chemoselective hydrogenation of aromatic ketones. These new insights provide a state-of-the-art strategy for strongly enhancing the acidity of these popular silica-alumina catalysts, which offers an interesting potential for a wide range of acid and multifunctional catalysis.