Mechanochemical approach for selective deactivation of external surface acidity of ZSM-5 zeolite catalyst

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.

Catalytic Cracking for Propylene Production over Au Catalyst Supported by External Surface-Modified ZSM-5 Zeolite

To improve the yield of propylene in fluidized catalytic cracking, a series of different Au/ZSM-5-TOS catalysts were prepared by modifying ZSM-5, using an external surface modification method and Au nanoparticles. The modified catalyst maintained the MFI structure of ZSM-5, whereas the pore-opening size of the zeolite relatively decreased, without affecting its internal structure. The acidity of ZSM-5, especially the Brønsted acidity, reduced. Among the studied catalysts, the 0.2 wt% Au/ZSM-5-1%TOS catalyst exhibited the best feedstock conversion and propylene selectivity, along with a significant increase in propylene selectivity and a slight decrease in the conversion of light diesel oil, even after water vapor treatment at 800 °C for 4 h. Its catalytic activity at 360 °C exceeded that of ZSM-5 at 460 °C, showing great application potential in petrochemical processes.

Catalytic Cracking of n-Dodecane to Chemicals: Effect of Variable-Morphological ZSM-5 Zeolites Synthesized Using Various Silica Sources

This study emphasizes tuning the synthesis conditions of MFI zeolites to achieve better catalytic properties by optimizing the mesoporosity, the balance between Brønsted and Lewis sites, and the zeolite particle sizes. The MFI zeolites were hydrothermally synthesized at various temperatures employing different silica sources. The synthesis temperature was varied between 110 to 180 °C at constant synthesis time (15 h). Different silicon sources led to variations in structure, morphology, and size of the MFI zeolite along with tuned Lewis and Brønsted acid sites in parallel correlation with shape selectivity of the reaction. The catalytic activities of synthesized zeolites were investigated in the catalytic cracking of n-dodecane to produce value-added chemicals. The zeolite synthesized at 180 °C using fumed silica presented the highest catalytic conversion (96.6%), while maximum light olefin gaseous products (73.1%) were obtained for the sample synthesized at 140 °C using tetraethyl orthosilicate as the silica source. The MFI zeolite synthesized at 180 °C employing tetraethyl orthosilicate as a silica source facilitated the formation of both naphthenes and aromatics (71.3%) as major liquid products.

New avenues for mechanochemistry in zeolite science

Zeolites are a class of microporous materials with tremendous value for large scale industrial applications such as catalysis, ion exchange, or gas separation. In addition to naturally ocurring variants, zeolites are made synthetically using hydrothermal synthesis, requiring temperatures beyond 100 °C and long reaction times up to weeks. Furthermore, specific applications may require more sophisticated synthesis conditions, expensive reagents, or post-synthetic modifications. Some of these issues can be tackled by using the reemerged technique of mechanochemistry. In 2014, Majano et al. reviewed the space and outlined several possibilities for the usage of mechanical forces in zeolite chemistry. Since then the field has seen many more publications employing mechanochemical methodology to further and improve the synthesis and properties of zeolite materials. The usage ranges from the activation of raw materials, rendering the synthesis of the widely used catalysts much more economical in terms of duration, atom efficiency, and production of waste, to post-synthetic modification of the materials leading to improved properties for target aplications. We present a short review of the advances that have been reported recently, highlight promising work and important studies, and give a perspective of potential future endeavours.

Memory Effect on a LDH/zeolite A Composite: An XRD In Situ Study

In this memory effect study, hydrotalcite-type compounds in the lamellar double hydroxide-like (LDH)/zeolite A composite material were analyzed using X-Ray Diffration XRD) in situ experiments. Three samples were analyzed: Al,Mg-LDH, Al,Mg-LDH/ZA composite, and a physical mixture (50/50 wt%) of zeolite A and Al,Mg-LDH. The Al,Mg-LDH sample was treated at 500 °C in an O₂ atmosphere and subsequently rehydrated. The Al,Mg-LDH/ZA composites had three treatments: one was performed at 300 °C in a He atmosphere, and two treatments were performed with an O₂ atmosphere at 300 and 500 °C. In the physical mixture, two treatments were carried out under O₂ flow at 500 °C and under He flow at 300 °C. Both went through the rehydration process. All samples were also analyzed by energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM). The results show that the LDH phase in the Al,Mg-LDH/ZA compounds has memory effects, and thus, the compound can be calcined and rehydrated. For the LDH in the composite, the best heat treatment system is a temperature of 300 °C in an inert atmosphere.

Direct Ink Writing of Metal Oxide/H-ZSM-5 Catalysts for n-Hexane Cracking: A New Method of Additive Manufacturing with High Metal Oxide Loading

Previously, 3D printing of porous materials and metal oxides was limited to low loading metal loadings, as increasing the nitrate salt concentrations, which are used to generate the oxide component, gave rise to poor rheological properties beyond 10 wt %. In this study, we addressed this problem by directly printing insoluble oxides alongside H-ZSM-5 zeolite, which allowed for increased oxide loadings. Various metal oxides such as V₂O₅, ZrO₂, Cr₂O₃, and Ga₂O₃ were doped onto H-ZSM-5 through the additive manufacturing method. Characterization and correlation between the X-ray diffraction, NH₃-temperature-programmed desorption, O₂-temperature programmed oxidation, temperature-programmed reduction, scanning electron microscopy-energy dispersive spectroscopy, and in situ CO₂ DRIFTS experiments revealed that directly 3D printing metal oxides/H-ZSM-5 inks leads to significant modification in the surface properties and oxide bulk dispersion, thereby enhancing the composites' reducibility and giving rise to widely differing product distributions in n-hexane cracking reaction. The obtained metal oxide/zeolite structured materials were used as bifunctional structured catalysts for the selective formation of light olefins from hexane at 550-600 °C and GHSV = 9000 mL/g_catalst·h in a packed-bed reactor. Among the various compositions of metal oxides/H-ZSM-5 examined (i.e., 15 wt % Ga₂O₃, 15 wt % ZrO₂, 15 wt % V₂O₅, 15 wt % Cr₂O₃, or 5 wt % Cr/10 wt % ZrO₂/10 wt % V₂O₅/10 wt % Ga₂O₃ balanced with H-ZSM-5), the 15 wt % Cr/ZSM-5 monolith displayed the best n-hexane cracking performance, as it achieved 80-85% conversion of hexane with a 40% selectivity toward propylene, 30% selectivity toward ethylene, and 10% selectivity toward butene at 550 °C. The sample also showed zero benzene/toluene/xylene selectivity and no deactivation after 6 h. This study represents a proof-of-concept for tailoring customizable heterogeneous structured catalysts by directly 3D printing high loading of metal oxides/porous zeolite and is a breakthrough in material science.

Mo-Modified ZSM-5 zeolite with intergrowth crystals for high-efficiency catalytic xylene isomerization

Mo/ZSM-5 catalysts of xylene isomerization were prepared on the intergrowth ZSM-5 support by an impregnation–calcination–reduction procedure.

Conversion of methane to C2 and C3 hydrocarbons over TiO2/ZSM-5 core–shell particles in an electric field

Catalytic conversion of methane (CH₄) to light olefins is motivated by increasing recoverable reserves of methane resources, abundantly available in natural gas, shale gas, and gas hydrates. The development of effective processes for conversion of CH₄ to light olefins is still a great challenge. The interface of ZSM-5 zeolite and TiO₂ nanoparticles is successfully constructed in their core–shell particles via mechanochemical treatment with high shear stress. The oxidative coupling of methane at a low temperature under application of an electric field may be induced by the O₂ activation via electrons running through the surface of TiO₂ located at the interface of TiO₂ and zeolite particles. Moreover, C₃H₆ was also produced by the ethylene to propylene (ETP) reaction catalyzed by Brønsted acid sites in the ZSM-5 zeolite within core–shell particles.

A TiO₂/ZSM-5 composite catalyst efficiently works for the oxidative coupling of methane and the subsequent ethylene-to-propylene reactions in an electric field.

Interconnected Hierarchical ZSM-5 with Tunable Acidity Prepared by a Dealumination-Realumination Process: A Superior MTP Catalyst

ZSM-5 that uses TPAOH as a template has an Al-rich exterior and defective Si-rich interior; thus, a simple base leaching selectively removed the Si-rich interior while the Al-rich exterior was protected. This catalyst showed no change in stability comparing with parent ZSM-5 during the MTP reaction that was attributed to the enclosed hollow structure and richly acidic outer shell. A preliminary fluorination, however, both removed defective Si-sites and caused distortion in tetrahedral aluminum that made the outer shell susceptible to alkaline treatment. These distorted tetrahedral Al were mostly leached out by NaOH in 1 min. Furthermore, aluminum in the filtrate was slowly redeposited onto the zeolite, serving as external pore-directing agents to control silicon dissolution from the Si-rich interior. This dealumination-realumination alkaline treatment process led to a higher solid yield and a uniform opened-mesopore structure with mesopores around 13 nm in diameter. This material was characterized by SEM, TEM, N₂ adsorption, and mercury porosimetry. In addition, NH₃-TPD, OH-IR, ²⁷Al MAS NMR, and ¹H MAS NMR results demonstrated that the reinserted Al were unlike the framework Al, contributing less to acidity. The dealumination-realumination process, therefore, was also capable of tuning the acidity of the mesoporous ZSM-5. This mesoporous catalyst exhibited a longer lifetime and a higher propylene selectivity than other catalysts with an enclosed mesopore structure.

Location, distribution and acidity of Al substitution in ZSM-5 with different Si/Al ratios – a periodic DFT computation

Systematic periodic density functional theory computations including dispersion correction (GGA-PBE-D3) have been carried out to characterize the location, distribution and acidity of Al substitution in ZSM-5 with different Si/Al ratios (up to 8 Al atoms).

Catalytic conversion of methanol to aromatics over nano-sized HZSM-5 zeolite modified by ZnSiF6·6H2O

ZnSiF₆-modified nano-sized HZSM-5 zeolites (NZ2, NZ3 and NZ4 catalysts) were prepared and investigated as catalysts for the conversion of methanol to aromatics.

Development of AEI type germanoaluminophosphate (GeAPO-18) with ultra-weak acid sites and its catalytic properties for the methanol to olefin (MTO) reaction

Incorporating Ge into the aluminophosphate framework generated weakened Brønsted acid sites, leading to prolonged catalyst lifetimes in the MTO reaction.

Improvement in the catalytic properties of ZSM-5 zeolite nanoparticles via mechanochemical and chemical modifications

A combination of bead-milling, subsequent recrystallization and acid treatment of micron-sized ZSM-5 zeolite can provide a highly efficient ZSM-5 nanoparticle catalyst.

Simultaneous realization of high catalytic activity and stability for catalytic cracking of n-heptane on highly exposed (010) crystal planes of nanosheet ZSM-5 zeolite

Nanosheet ZSM-5 zeolite exhibits outstanding reactivity and anti-coking stability for catalytic cracking of n-heptane.