Activation of Mo/HZSM-5 for methane aromatization

Effective factors on performance of zeolite based metal catalysts in light hydrocarbon aromatization

Aromatic hydrocarbons are essential compounds, that the presence of which in fuels can improve the octane number. The conversion of the light alkanes to high value aromatics is vital from theoretical and industrial standpoints. Zeolites such as ZSM-5 play an essential role in the aromatization of light alkanes. This paper highlights the mechanism of aromatization of light alkanes such as methane, ethane, propane, butane, and its isomers. Furthermore, effective factors on the aromatization of light alkanes including metal type, crystallinity, acidity, space velocity, pretreatment of zeolites, co-feeding of light hydrocarbon, and operating factors such as temperature have been investigated to determine how a system of zeolite with metals can be useful to reach aromatization with high conversion.

Promoters for Improvement of the Catalyst Performance in Methane Valorization Processes

In this work, the introduction of modifying additives in the composition of catalysts is considered as an effective mode of improving functional characteristics of materials for two processes of methane conversion into valuable products – methane dehydroaromatization (DHA of CH4) into benzene and hydrogen and autothermal reforming of methane (ATR of CH4) into synthesis gas. The effect of type and content of promoters on the structural and electronic state of the active component as well as catalyst activity and stability against deactivation is discussed. For DHA of CH4 the operation mode of additives M = Ag, Ni, Fe in the composition of Mo-M/ZSM-5 catalysts was elucidated and correlated with the product yield and coke content. It was shown that when Ag serves as a promoter, the duration of the catalyst stable operation is enhanced due to a decrease in the rate of the coke formation. In the case of Ni and Fe additives, the Ni-Мо and Fe-Mo alloys are formed that retain the catalytic activity for a long time in spite of the carbon accumulation. For ATR of CH4, the influence of M = Pd, Pt, Re, Mo, Sn in the composition of Ni-M catalysts supported on La2O3 or Ce0.5Zr0.5O2/Al2O3 was elucidated. It was demonstrated that for Ni-M/La2O3 catalysts, Pd is a more efficient promoter that improves the reducibility of Ni cations and increases the content of active Nio centers. In the case of Ni-M/Ce0.5Zr0.5O2/Al2O3 samples, Re is considered the best promoter due to the formation of an alloy with anti-coking and anti-sintering properties. The use of catalysts with optimal promoter type and its content provides high efficiency of methane valorization processes.

Direct synthesis of p-methyl benzaldehyde from acetaldehyde via an organic amine-catalyzed dehydrogenation mechanism

p-Methyl benzaldehyde (p-MBA) is a class of key chemical intermediates of pharmaceuticals. Conventional industrial processes for p-MBA production involve the consecutive photochlorination, amination, and acid hydrolysis of petroleum-derived p-xylene, while producing vast pollutants and waste water. Herein, we report a direct, green route for selective synthesis of p-MBA from acetaldehyde using a diphenyl prolinol trimethylsilyl ether catalyst. The optimized p-MBA selectivity is up to 90% at an acetaldehyde conversion as high as 99.8%. Intermediate structure and ¹⁸O-isotope data revealed that the conversion of acetaldehyde to p-methylcyclohexadienal intermediates proceeds in an enamine-iminium intermediate mechanism. Then, controlled experiments and D-isotope results indicated that the dehydrogenation of p-methylcyclohexadienal to p-MBA and H₂ is catalyzed by the same amines through an iminium intermediate. This is an example that metal-free amines catalyze the dehydrogenation (releasing H₂), rather than using metals or stoichiometric oxidants.

•

A direct route to produce p-methyl benzaldehyde from biomass-derived acetaldehyde

•

Revealing the reaction kinetics and mechanism under reaction conditions

•

An example of an organic amine-catalyzed dehydrogenation-aromatization reaction

Ultrasound-Assisted Preparation of Mo/ZSM-5 Zeolite Catalyst for Non-Oxidative Methane Dehydroaromatization

The activity and selectivity of Mo/ZSM-5, benchmarking catalyst for the non-oxidative dehydroaromatization of methane, strongly depend on the cluster size, spatial distribution, and chemical environment of the Mo-based active sites. This study discloses the use of an ultrasound-assisted ion-exchange (US-IE) technique as an alternative Mo/ZSM-5 synthesis procedure in order to promote metal dispersion along the zeolite framework. For this purpose, a plate transducer (91.8 kHz) is employed to transmit the ultrasonic irradiation (US) into the ion-exchange reactor. The physico-chemical properties and catalytic activity of samples prepared under the said irradiation procedure and traditional impregnation (IWI) method are critically evaluated. Characterization results suggest that US neither affects the crystalline structure nor the particle size of the parent zeolite. However, US-IE promotes molybdenum species dispersion, avoids clustering at the external fresh zeolite surface and enhances molybdate species anchoring to the zeolite framework with respect to IWI. Despite the improved metal dispersion, the catalytic activity between catalysts synthesized by US-IE and IWI is comparable. This suggests that the sole initial dispersion enhancement does not suffice to boost the catalyst productivity and further actions such ZSM-5 support and catalyst pre-conditioning are required. Nevertheless, the successful implementation of US-IE and the resulting metal dispersion enhancement pave the way toward the application of this technique to the synthesis of other dispersed catalysts and materials of interest.

Reactivity, Selectivity, and Stability of Zeolite-Based Catalysts for Methane Dehydroaromatization

Non-oxidative dehydroaromatization is arguably the most promising process for the direct upgrading of cheap and abundant methane to liquid hydrocarbons. This reaction has not been commercialized yet because of the suboptimal activity and swift deactivation of benchmark Mo-zeolite catalysts. This progress report represents an elaboration on the recent developments in understanding of zeolite-based catalytic materials for high-temperature non-oxidative dehydroaromatization of methane. It is specifically focused on recent studies, relevant to the materials chemistry and elucidating i) the structure of active species in working catalysts; ii) the complex molecular pathways underlying the mechanism of selective conversion of methane to benzene; iii) structure, evolution and role of coke species; and iv) process intensification strategies to improve the deactivation resistance and overall performance of the catalysts. Finally, unsolved challenges in this field of research are outlined and an outlook is provided on promising directions toward improving the activity, stability, and selectivity of methane dehydroaromatization catalysts.

Structure and Evolution of Confined Carbon Species during Methane Dehydroaromatization over Mo/ZSM-5

Surface carbon (coke, carbonaceous deposits) is an integral aspect of methane dehydroaromatization catalyzed by Mo/zeolites. We investigated the evolution of surface carbon species from the beginning of the induction period until the complete catalyst deactivation by the pulse reaction technique, TGA, ¹³C NMR, TEM, and XPS. Isotope labeling was performed to confirm the catalytic role of confined carbon species during MDA. It was found that “hard” and “soft” coke distinction is mainly related to the location of coke species inside the pores and on the external surface, respectively. In addition, MoO₃ species act as an active oxidation catalyst, reducing the combustion temperature of a certain fraction of coke. Furthermore, after dissolving the zeolite framework by HF, we found that coke formed during the MDA reaction inside the zeolite pores is essentially a zeolite-templated carbon material. The possibility of preparing zeolite-templated carbons from the most available hydrocarbon feedstock is important for the development of these interesting materials.

Modeling and Design Optimization of Multifunctional Membrane Reactors for Direct Methane Aromatization

Due to the recent increase of natural gas production in the U.S., utilizing natural gas for higher-value chemicals has become imperative. Direct methane aromatization (DMA) is a promising process used to convert methane to benzene, but it is limited by low conversion of methane and rapid catalyst deactivation by coking. Past work has shown that membrane separation of the hydrogen produced in the DMA reactions can dramatically increase the methane conversion by shifting the equilibrium toward the products, but it also increases coke production. Oxygen introduction into the system has been shown to inhibit this coke production while not inhibiting the benzene production. This paper introduces a novel mathematical model and design to employ both methods in a multifunctional membrane reactor to push the DMA process into further viability. Multifunctional membrane reactors, in this case, are reactors where two different separations occur using two differently selective membranes, on which no systems studies have been found. The proposed multifunctional membrane design incorporates a hydrogen-selective membrane on the outer wall of the reaction zone, and an inner tube filled with airflow surrounded by an oxygen-selective membrane in the middle of the reactor. The design is shown to increase conversion via hydrogen removal by around 100%, and decrease coke production via oxygen addition by 10% when compared to a tubular reactor without any membranes. Optimization studies are performed to determine the best reactor design based on methane conversion, along with coke and benzene production. The obtained optimal design considers a small reactor (length = 25 cm, diameter of reaction tube = 0.7 cm) to subvert coke production and consumption of the product benzene as well as a high permeance (0.01 mol/s·m²·atm^1/4) through the hydrogen-permeable membrane. This modeling and design approach sets the stage for guiding further development of multifunctional membrane reactor models and designs for natural gas utilization and other chemical reaction systems.

A Selection of Recent Advances in C1 Chemistry

This review presents a selection of recent publications related to the chemistry and catalysis of C1 molecules, including methane, methanol, carbon monoxide, and carbon dioxide. These molecules play an important role in the current supply of energy and chemicals and will likely become even more relevant because of the need to decarbonize fuels (shift from coal to natural gas) in line with CO2 capture and use to mitigate global warming, as well as a gradual shift on the supply side from crude oil to natural gas. This review includes both recent industrial developments, such as the huge increase in methanol-to-olefins-capacity build in China and the demonstration of oxidative coupling of methane, and scientific developments in these chemistries facilitated by improved capabilities in, for example, analytical tools and computational modeling.