Unsaturated Penta-Coordinated Mo5c5+ Sites Enabled Low-Temperature Oxidation of C-H Bonds in Ethers

Selective oxidation of C-H bonds under mild conditions is one of the most important and challenging issues in utilization of energy-related molecules. Molybdenum oxide nanostructures containing Mo5+ species are effective for these reactions, but the accurate identification of the structure of active Mo5+ species and the catalytic mechanism remain unclear. Herein, unsaturated penta-coordinated Mo5c5+ with a high fraction in MoOx fabricated by the hydrothermal method were identified as the active sites for low-temperature oxidation of dimethyl ether (DME) by the deep correlation of characterizations, density functional theory calculations, and activity results, giving a methyl formate selectivity of 96.3% and DME conversion of 12.5% at unreported 110 °C. Low-temperature electron spin resonance (ESR) and quasi in situ X-ray photoelectron spectra (XPS) with the designed experiments confirm that the Mo5c5+ species can be formed in situ. Molybdenum located at the pentachronic site is preferable to significantly promote the oxidation of the C-H bond in CH3O* at lower temperatures.

A Review and Experimental Revisit of Alternative Catalysts for Selective Oxidation of Methanol to Formaldehyde

The selective oxidation of methanol to formaldehyde is a growing million-dollar industry, and has been commercial for close to a century. The Formox process, which is the largest production process today, utilizes an iron molybdate catalyst, which is highly selective, but has a short lifetime of 6 months due to volatilization of the active molybdenum oxide. Improvements of the process’s lifetime is, thus, desirable. This paper provides an overview of the efforts reported in the scientific literature to find alternative catalysts for the Formox process and critically assess these alternatives for their industrial potential. The catalysts can be grouped into three main categories: Mo containing, V containing, and those not containing Mo or V. Furthermore, selected interesting catalysts were synthesized, tested for their performance in the title reaction, and the results critically compared with previously published results. Lastly, an outlook on the progress for finding new catalytic materials is provided as well as suggestions for the future focus of Formox catalyst research.

Methanol to Formaldehyde: An Overview of Surface Studies and Performance of an Iron Molybdate Catalyst

Formaldehyde is a primary chemical in the manufacturing of various consumer products. It is synthesized via partial oxidation of methanol using a mixed oxide iron molybdate catalyst (Fe2(MoO4)3–MoO3). This is one of the standard energy-efficient processes. The mixed oxide iron molybdate catalyst is an attractive commercial catalyst for converting methanol to formaldehyde. However, a detailed phase analysis of each oxide phase and a complete understanding of the catalyst formulation and deactivation studies is required. It is crucial to correctly formulate each oxide phase and influence the synthesis methods precisely. A better tradeoff between support and catalyst and oxygen revival on the catalyst surface is vital to enhance the catalyst’s selectivity, stability, and lifetime. This review presents recent advances on iron molybdate’s catalytic behaviour for formaldehyde production—a deep recognition of the catalyst and its critical role in the processes are highlighted. Finally, the conclusion and prospects are presented at the end.

Hydroxyapatite supported molybdenum oxide catalyst for selective oxidation of methanol to formaldehyde: studies of industrial sized catalyst pellets

Promising alternative catalysts for the Formox process as industrial sized pellets and the influence of pellet density on catalyst performance.

Investigation of MoOx/Al2O3 under Cyclic Operation for Oxidative and Non-Oxidative Dehydrogenation of Propane

A MoOx/Al2O3 catalyst was synthesised and tested for oxidative (ODP) and non-oxidative (DP) dehydrogenation of propane in a reaction cycle of ODP followed by DP and a second ODP run. Characterisation results show that the fresh catalyst contains highly dispersed Mo oxide species in the +6 oxidation state with tetrahedral coordination as [MoVIO4]2− moieties. In situ X-ray Absorption Spectroscopy (XAS) shows that [MoVIO4]2− is present during the first ODP run of the reaction cycle and is reduced to MoIVO2 in the following DP run. The reduced species are partly re-oxidised in the subsequent second ODP run of the reaction cycle. The partly re-oxidised species exhibit oxidation and coordination states that are lower than 6 but higher than 4 and are referred to as MoxOy. These species significantly improved propene formation (relatively 27% higher) in the second ODP run at similar propane conversion activity. Accordingly, the initial tetrahedral [MoVIO4]2− present during the first ODP run of the reaction cycle is active for propane conversion; however, it is unselective for propene. The reduced MoIVO2 species are relatively less active and selective for DP. It is suggested that the MoxOy species generated by the reaction cycle are active and selective for ODP. The vibrational spectroscopic data indicate that the retained surface species are amorphous carbon deposits with a higher proportion of aromatic/olefinic like species.

Synthesis of High Dimensionally Structured Mo-Fe Mixed Metal Oxide and Its Catalytic Activity for Selective Oxidation of Methanol

High-dimensionally structured Mo-Fe oxide (HDS-MoFeO) was synthesized through an assembly of structural units supplied from Keplerate-type polyoxometalate, {Mo₇₂Fe₃₀}, under an appropriate hydrothermal condition. HDS-MoFeO showed excellent catalytic activity for the selective oxidation of methanol with slightly lower selectivity for formaldehyde than that of a conventional Mo-Fe oxide catalyst.

Structural dynamics of an iron molybdate catalyst under redox cycling conditions studied with in situ multi edge XAS and XRD

Combination of in situ multi-edge X-ray absorption spectroscopy at the Mo K- and Fe K-edges in combination with X-ray diffraction successfully uncovered structural dynamics and phase transformations of an iron molybdate catalyst during redox cycling.

Design and stabilisation of a high area iron molybdate surface for the selective oxidation of methanol to formaldehyde

The performance of Mo-enriched, bulk ferric molybdate, employed commercially for the industrially important reaction of the selective oxidation of methanol to formaldehyde, is limited by a low surface area, typically 5-8 m(2) g(-1). Recent advances in the understanding of the iron molybdate catalyst have focused on the study of MoOx@Fe2O3 (MoOx shell, Fe2O3 core) systems, where only a few overlayers of Mo are present on the surface. This method of preparing MoOx@Fe2O3 catalysts was shown to support an iron molybdate surface of higher surface area than the industrially-favoured bulk phase. In this research, a MoOx@Fe2O3 catalyst of even higher surface area was stabilised by modifying a haematite support containing 5 wt% Al dopant. The addition of Al was an important factor for stabilising the haematite surface area and resulted in an iron molybdate surface area of ∼35 m(2) g(-1), around a 5 fold increase on the bulk catalyst. XPS confirmed Mo surface-enrichment, whilst Mo XANES resolved an amorphous MoOx surface monolayer supported on a sublayer of Fe2(MoO4)3 that became increasingly extensive with initial Mo surface loading. The high surface area MoOx@Fe2O3 catalyst proved amenable to bulk characterisation techniques; contributions from Fe2(MoO4)3 were detectable by Raman, XAFS, ATR-IR and XRD spectroscopies. The temperature-programmed pulsed flow reaction of methanol showed that this novel, high surface area catalyst (3ML-HSA) outperformed the undoped analogue (3ML-ISA), and a peak yield of 94% formaldehyde was obtained at ∼40 °C below that for the bulk Fe2(MoO4)3 phase. This work demonstrates how core-shell, multi-component oxides offer new routes for improving catalytic performance and understanding catalytic activity.