Deactivation of Zeolite Catalyst H-ZSM-5 during Conversion of Methanol to Gasoline: Operando Time- and Space-Resolved X-ray Diffraction

Cation-induced speciation of port-size during mordenite zeolite synthesis

Mordenite (MOR) zeolite, an important industrial catalyst exists in two, isostructural variants defined by their port-size, small and large-port. Here we show for the first time how a systematic, single-parameter variation influences the synthesis out-come on the final MOR material leading to distinctly different catalysts. The cation identity has a direct impact on the synthesis mechanism with potassium cations generating the more constrained, small-port MOR variant compared to the large-port obtained with sodium cations. This was expressed by different degrees of accessibility ascertained with a combination of toluene breakthrough and temperature programmed desorption (TPD), propylamine TPD, as well as sterically sensitive isobutane conversion. Rietveld refinement of the X-ray diffractograms elucidated the preferential siting of the smaller sodium cations in the constricted 8-ring, from which differences in Al distribution follow. Note, there are no organic structure directing agents utilized in this synthesis pointing at the important role of inorganic structure directing agents (ISDA).

Ca Cations Impact the Local Environment inside HZSM-5 Pores during the Methanol-to-Hydrocarbons Reaction

The methanol-to-hydrocarbons (MTH) process is an industrially relevant method to produce valuable light olefins such as propylene. One of the ways to enhance propylene selectivity is to modify zeolite catalysts with alkaline earth cations. The underlying mechanistic aspects of this type of promotion are not well understood. Here, we study the interaction of Ca²⁺ with reaction intermediates and products formed during the MTH reaction. Using transient kinetic and spectroscopic tools, we find strong indications that the selectivity differences between Ca/ZSM-5 and HZSM-5 are related to the different local environment inside the pores due to the presence of Ca²⁺. In particular, Ca/ZSM-5 strongly retains water, hydrocarbons, and oxygenates, which occupy as much as 10% of the micropores during the ongoing MTH reaction. This change in the effective pore geometry affects the formation of hydrocarbon pool components and in this way directs the MTH reaction toward the olefin cycle.

Tracking Structural Deactivation of H-Ferrierite Zeolite Catalyst During MTH with XRD

We used the methanol-to-hydrocarbon (MTH) reaction as a shape-selective model reaction to investigate coke formation in zeolite H-Ferrierite. Despite being a 2D topology in terms of channel propagation, the FER framework displays a lattice expansion in all three dimensions of space upon deactivation. Therefore, the volume of the unit cell is an excellent X-Ray diffraction (XRD) descriptor for the catalyst deactivation. A model with dummy atoms added, also proved to be an accurate approach to measure the amount of internal coke and/or water inside the pore network correlated with thermogravimetric analysis results. While the catalyst deactivation of the H-Ferrerite during the MTH was fast, a comparably long induction period was observed. We were able to track such fast deactivation with the aforementioned descriptors by means of an operando XRD study by a standard laboratory diffractometer.

Elucidation of radical- and oxygenate-driven paths in zeolite-catalysed conversion of methanol and methyl chloride to hydrocarbons

Understanding hydrocarbon generation in the zeolite-catalysed conversions of methanol and methyl chloride requires advanced spectroscopic approaches to distinguish the complex mechanisms governing C-C bond formation, chain growth and the deposition of carbonaceous species. Here operando photoelectron photoion coincidence (PEPICO) spectroscopy enables the isomer-selective identification of pathways to hydrocarbons of up to C₁₄ in size, providing direct experimental evidence of methyl radicals in both reactions and ketene in the methanol-to-hydrocarbons reaction. Both routes converge to C₅ molecules that transform into aromatics. Operando PEPICO highlights distinctions in the prevalence of coke precursors, which is supported by electron paramagnetic resonance measurements, providing evidence of differences in the representative molecular structure, density and distribution of accumulated carbonaceous species. Radical-driven pathways in the methyl chloride-to-hydrocarbons reaction(s) accelerate the formation of extended aromatic systems, leading to fast deactivation. By contrast, the generation of alkylated species through oxygenate-driven pathways in the methanol-to-hydrocarbons reaction extends the catalyst lifetime. The findings demonstrate the potential of the presented methods to provide valuable mechanistic insights into complex reaction networks.

Emerging Analytical Methods to Characterize Zeolite-Based Materials

Zeolites and zeolitic materials are, through their use in numerous conventional and sustainable applications, very important to our daily lives, including to foster the necessary transition to a more circular society. The characterization of zeolite-based materials has a tremendous history and a great number of applications and properties of these materials have been discovered in the past decades. This review focuses on recently developed novel as well as more conventional techniques applied with the aim of better understanding zeolite-based materials. Recently explored analytical methods, e.g. atom probe tomography, scanning transmission X-ray microscopy, confocal fluorescence microscopy and photo-induced force microscopy, are discussed on their important contributions to the better understanding of zeolites as they mainly focus on the micro- to nanoscale chemical imaging and the revelation of structure–composition–performance relationships. Some other techniques have a long and established history, e.g. nuclear magnetic resonance, infrared, neutron scattering, electron microscopy and X-ray diffraction techniques, and have gone through increasing developments allowing the techniques to discover new and important features in zeolite-based materials. Additional to the increasing application of these methods, multiple techniques are nowadays used to study zeolites under working conditions (i.e. the in situ/operando mode of analysis) providing new insights in reaction and deactivation mechanisms.

Real-time regeneration of a working zeolite monitored via operando X-ray diffraction and crystallographic imaging: how coke flees the MFI framework

X-ray diffraction is used to investigate regeneration of an H-ZSM-5 zeolite catalyst used in the conversion of methanol to hydrocarbons.

Understanding the Preparation and Reactivity of Mo/ZSM-5 Methane Dehydroaromatization Catalysts

Methane dehydroaromatization is a promising reaction for the direct conversion of methane to liquid hydrocarbons. The active sites and the mechanism of this reaction remain controversial. This work is focused on the operando X‐ray absorption near edge structure spectroscopy analysis of conventional Mo/ZSM‐5 catalysts during their whole lifetime. Complemented by other characterization techniques, we derived spectroscopic descriptors of molybdenum precursor decomposition and its exchange with zeolite Brønsted acid sites. We found that the reduction of Mo‐species proceeds in two steps and the active sites are of similar nature, regardless of the Mo content. Furthermore, the ZSM‐5 unit cell contracts at the beginning of the reaction, which coincides with benzene formation and it is likely related to the formation of hydrocarbon pool intermediates. Finally, although reductive regeneration of used catalysts via methanation is less effective as compared to combustion of coke, it does not affect the structure of the catalysts.

High-Impact Promotional Effect of Mo Impregnation on Aluminum-Rich and Alkali-Treated Hierarchical Zeolite Catalysts on Methanol Aromatization

A systematic change of HZSM-5 (HZ5) as a catalyst of the methanol to aromatics (MTA) reaction was undertaken by employing a fixed-bed tubular-type reactor under ambient pressure, applying a weight hourly space velocity (WHSV) of 2 h^-1 at 375 °C, as the first report on the application of low-Si/Al-ratio alkaline-[Mo,Na]-HZSM-5 in the MTA process. To characterize the surface and textural properties of the catalysts, powder X-ray diffraction (PXRD), nitrogen adsorption/desorption, temperature-programmed desorption of ammonia (NH₃-TPD), pyridine-infrared spectroscopy (Py-IR), thermogravimetric analysis (TGA), and energy-dispersive X-ray (EDX) methods were employed. Gas chromatography (GC) and gas chromatography-mass spectrometry (GC-MS) measurements demonstrated a selectivity of up to 86 wt % (65.7 wt % for benzene, toluene, and xylene (BTX)) over 2[Mo]HZ5. NH₃-TPD and Py-IR results indicated a sensible decrease of strong acid sites on the impregnated samples, while the surface analyses revealed the highest Lewis acid sites (LAS) together with the largest mesopore surface area for 2[Mo]alk-HZ5, supporting the migration of Mo species to the bulk of the catalysts. Mo impregnation had a minor effect on the observed coke formation in the promoted catalyst.

Hierarchical H-ZSM5 zeolites based on natural kaolinite as a high-performance catalyst for methanol to aromatic hydrocarbons conversion

The present work introduces a good prospect for the development of hierarchical catalysts with excellent catalytic performance in the methanol to aromatic hydrocarbons conversion (MTA) process. Hierarchical H-ZSM5 zeolites, with a tailored pore size and different Si/Al ratios, were synthesized directly using natural kaolin clay as a low-cost silica and aluminium resource. Further explored for the direct synthesis of hierarchical HZSM-5 structures was the steam assisted conversion (SAC) with a cost-effective and green affordable saccharide source of high fructose corn syrup (HFCS), as a secondary mesopore agent. The fabricated zeolites exhibiting good crystallinity, 2D and 3D nanostructures, high specific surface area, tailored pore size, and tunable acidity. Finally, the catalyst performance in the conversion of methanol to aromatic hydrocarbons was tested in a fixed bed reactor. The synthesized H-ZSM5 catalysts exhibited superior methanol conversion (over 100 h up to 90%) and selectivity (over 85%) in the methanol conversion to aromatic hydrocarbon products.

Topology-dependent hydrocarbon transformations in the methanol-to-hydrocarbons reaction studied by operando UV-Raman spectroscopy

The methanol-to-hydrocarbons (MTH) reaction represents a versatile, industrially viable alternative to crude-oil based processes for the production of chemicals and fuels. In the MTH reaction, the shape selectivity of acidic zeolites is exploited to direct the synthesis towards the desired product. However, due to unavoidable side reactions occurring under processing conditions, all MTH catalysts suffer deactivation due to coke formation. Though it is likely that some common characteristics for carbon formation exist for all zeolite topologies, it has been proposed that the differences in shape selectivity among the different catalysts will also influence the individual deactivation mechanisms. As deactivating species are mostly aromatic compounds, highly methylated benzenes and/or polycyclic aromatic hydrocarbons (PAHs) have been discussed. In some cases, these can further grow to extended carbon structures. Here, we have investigated the hydrocarbon reactivities and carbon formation for five topologically different zeolite catalysts through an operando UV-Raman approach, taking advantage of the high sensitivity of this technique towards aromatic and other carbonaceous species. The combination of the spectroscopic tool with activity measurements allowed us to obtain valuable details and some general trends on the deactivation paths during MTH. This approach made accessible unique insight on the complex chemistry of MTH by allowing the real-time observation of hydrocarbon transformations typical for the peculiar topology of each catalyst, usually inaccessible by ex situ techniques.