Silicalite-1 Layer Secures the Bifunctional Nature of a CO2 Hydrogenation Catalyst

Close proximity usually shortens the travel distance of reaction intermediates, thus able to promote the catalytic performance of CO₂ hydrogenation by a bifunctional catalyst, such as the widely reported In₂O₃/H-ZSM-5. However, nanoscale proximity (e.g., powder mixing, PM) more likely causes the fast deactivation of the catalyst, probably due to the migration of metals (e.g., In) that not only neutralizes the acid sites of zeolites but also leads to the reconstruction of the In₂O₃ surface, thus resulting in catalyst deactivation. Additionally, zeolite coking is another potential deactivation factor when dealing with this methanol-mediated CO₂ hydrogenation process. Herein, we reported a facile approach to overcome these three challenges by coating a layer of silicalite-1 (S-1) shell outside a zeolite H-ZSM-5 crystal for the In₂O₃/H-ZSM-5-catalyzed CO₂ hydrogenation. More specifically, the S-1 layer (1) restrains the migration of indium that preserved the acidity of H-ZSM-5 and at the same time (2) prevents the over-reduction of the In₂O₃ phase and (3) improves the catalyst lifetime by suppressing the aromatic cycle in a methanol-to-hydrocarbon conversion step. As such, the activity for the synthesis of C₂ ⁺ hydrocarbons under nanoscale proximity (PM) was successfully obtained. Moreover, an enhanced performance was observed for the S-1-coated catalyst under microscale proximity (e.g., granule mixing, GM) in comparison to the S-1-coating-free counterpart. This work highlights an effective shielding strategy to secure the bifunctional nature of a CO₂ hydrogenation catalyst.

Detecting Cage Crossing and Filling Clusters of Magnesium and Carbon Atoms in Zeolite SSZ-13 with Atom Probe Tomography

The conversion of methanol to valuable hydrocarbon molecules is of great commercial interest, as the process serves as a sustainable alternative for the production of, for instance, the base chemicals for plastics. The reaction is catalyzed by zeolite materials. By the introduction of magnesium as a cationic metal, the properties of the zeolite, and thereby the catalytic performance, are changed. With atom probe tomography (APT), nanoscale relations within zeolite materials can be revealed: i.e., crucial information for a fundamental mechanistic understanding. We show that magnesium forms clusters within the cages of zeolite SSZ-13, while the framework elements are homogeneously distributed. These clusters of just a few nanometers were analyzed and visualized in 3-D. Magnesium atoms seem to initially be directed to the aluminum sites, after which they aggregate and fill one or two cages in the zeolite SSZ-13 structure. The presence of magnesium in zeolite SSZ-13 increases the lifetime as well as the propylene selectivity. By using operando UV-vis spectroscopy and X-ray diffraction techniques, we are able to show that these findings are related to the suppression of aromatic intermediate products, while maintaining the formation of polyaromatic compounds. Further nanoscale analysis of the spent catalysts showed indications of magnesium redistribution after catalysis. Unlike zeolite H-SSZ-13, for which only a homogeneous distribution of carbon was found, carbon can be either homogeneously or heterogeneously distributed within zeolite Mg-SSZ-13 crystals as the magnesium decreases the coking rate. Carbon clusters were isolated, visualized, and analyzed and were assumed to be polyaromatic compounds. Small one-cage-filling polyaromatic compounds were identified; furthermore, large-cage-crossing aromatic molecules were found by isolating large coke clusters, demonstrating the unique coking mechanism in zeolite SSZ-13. Short-length-scale evidence for the formation of polyaromatic compounds at acid sites is discovered, as clear nanoscale relations between aluminum and carbon atoms exist.

Operando Laboratory-Based Multi-Edge X-Ray Absorption Near-Edge Spectroscopy of Solid Catalysts

Laboratory-based X-ray absorption spectroscopy (XAS) and especially X-ray absorption near-edge structure (XANES) offers new opportunities in catalyst characterization and presents not only an alternative, but also a complementary approach to precious beamtime at synchrotron facilities. We successfully designed a laboratory-based setup for performing operando, quasi-simultaneous XANES analysis at multiple K-edges, more specifically, operando XANES of mono-, bi-, and trimetallic CO₂ hydrogenation catalysts containing Ni, Fe, and Cu. Detailed operando XANES studies of the multielement solid catalysts revealed metal-dependent differences in the reducibility and re-oxidation behavior and their influence on the catalytic performance in CO₂ hydrogenation. The applicability of operando laboratory-based XANES at multiple K-edges paves the way for advanced multielement catalyst characterization complementing detailed studies at synchrotron facilities.

Favoring the Methane Oxychlorination Reaction over EuOCl by Synergistic Effects with Lanthanum

The direct conversion of CH4 into fuels and chemicals produces less waste, requires smaller capital investments, and has improved energy efficiency compared to multistep processes. While the methane oxychlorination (MOC) reaction has been given little attention, it offers the potential to achieve high CH4 conversion levels at high selectivities. In a continuing effort to design commercially interesting MOC catalysts, we have improved the catalyst design of EuOCl by the partial replacement of Eu3+ by La3+. A set of catalytic solid solutions of La3+ and Eu3+ (i.e., La x Eu1-x OCl, where x = 0, 0.25, 0.50, 0.75, and 1) were synthesized and tested in the MOC reaction. The La3+-Eu3+ catalysts exhibit an increased CH3Cl selectivity (i.e., 54-66 vs 41-52%), a lower CH2Cl2 selectivity (i.e., 8-24 vs 18-34%), and a comparable CO selectivity (i.e., 11-28 vs 14-28%) compared to EuOCl under the same reaction conditions and varying HCl concentrations in the feed. The La3+-Eu3+ catalysts possessed a higher CH4 conversion rate than when the individual activities of LaOCl and EuOCl are summed with a similar La3+/Eu3+ ratio (i.e., the linear combination). In the solid solution, La3+ is readily chlorinated and acts as a chlorine buffer that can transfer chlorine to the active Eu3+ phase, thereby enhancing the activity. The improved catalyst design enhances the CH3Cl yield and selectivity and reduces the catalyst cost and the separation cost of the unreacted HCl. These results showcase that, by matching intrinsic material properties, catalyst design can be altered to overcome reaction bottlenecks.

New insights into the NH3-selective catalytic reduction of NO over Cu-ZSM-5 as revealed by operando spectroscopy

To control diesel vehicle NO _x emissions, Cu-exchanged zeolites have been applied in the selective catalytic reduction (SCR) of NO using NH₃ as reductant. However, the harsh hydrothermal environment of tailpipe conditions causes irreversible catalyst deactivation. The aggregation of isolated Cu²⁺ brings about unselective ammonia oxidation along with the main NH₃-SCR reaction. An unusual 'dip' shaped NO conversion curve was observed in the steamed zeolite Cu-ZSM-5, resulting from the undesired NH₃ oxidation that produced NO. Here we gain further insights into the NH₃-SCR reaction and its deactivation by employing operando UV-vis diffuse reflectance spectroscopy (DRS) and diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) on fresh and steamed zeolite Cu-ZSM-5. We found that tetragonally distorted octahedral Cu²⁺ with associated NH₃ preferentially forms during low temperature NH₃-SCR (<250 °C) in fresh Cu-ZSM-5. The high coordination number of Cu²⁺ ensures the availability for high coverage of nitrate intermediates. Whilst in the steamed Cu-ZSM-5, [Cu _x (OH)_2x-1]⁺ oligomers/clusters in pseudo-tetrahedral symmetry with coordinated NH₃ accumulated during the low-temperature NH₃-SCR reaction. These clusters presented a strong adsorption of surface NH₃ and nitrates/nitric acid at low temperatures and therefore limited the reaction between surface species in the steamed Cu-ZSM-5. Further release of NH₃ with increased reaction temperature favors NH₃ oxidation that causes the drop of NO conversion at ∼275 °C. Moreover, competitive adsorption of NH₃ and nitrates/nitric acid occurs on shared Lewis-acidic adsorption sites. Prompt removal of surface nitrates/nitric acid by NO avoids the surface blockage and tunes the selectivity by alternating nitrate-nitrite equilibrium. The formation of adsorbed NO₂ and HNO _x points to the necessity of an acid adsorbent in practical applications. The structural similarity under the NH₃-SCR reaction and unselective NH₃ oxidation confirmed the entanglement of these two reactions above 250 °C.

Nano-scale insights regarding coke formation in zeolite SSZ-13 subject to the methanol-to-hydrocarbons reaction

The methanol-to-hydrocarbons (MTH) process, commonly catalyzed by zeolites, is of great commercial interest and therefore widely studied both in industry and academia. However, zeolite-based catalyst materials are notoriously hard to study at the nano-scale. Atom probe tomography (APT) is uniquely positioned among the suite of characterization techniques, as it can provide 3D chemical information with sub-nm resolution. In this work, we have used APT to study the nano-scale coking behavior of zeolite SSZ-13 and its relation to bulk coke formation on the macro-/micro-scale studied with operando and in situ UV-vis spectroscopy and microscopy. Radial distribution function analysis (RDF) of the APT data revealed short carbon–carbon length scale affinities, consistent with the formation of larger aromatic molecules (coke species). Using nearest neighbor distribution (NND) analysis, an increase in the homogeneity of carbon was found with increasing time-on-stream. However, carbon clusters could not be isolated due to spatial noise and limited clustering. Therefore, it was found that the coke formation in zeolite SSZ-13 (CHA) is reasonably homogeneous on the nano-scale, and is rather similar to the silicoaluminophosphate analogue SAPO-34 (CHA) but different in nano-scale coking behavior compared to previously studied zeolite ZSM-5 (MFI).

A correlation between the micro- and nano-scale coking behavior of SSZ-13 was discovered with in situ/operando spectroscopy and atom probe tomography (APT), which allows for spatial reconstruction and analysis of relations between framework elements and carbon atoms.

Mechanistic Insights into the Lanthanide-Catalyzed Oxychlorination of Methane as Revealed by Operando Spectroscopy

Commercialization of CH₄ valorization processes is currently hampered by the lack of suitable catalysts, which should be active, selective, and stable. CH₄ oxychlorination is one of the promising routes to directly functionalize CH₄, and lanthanide-based catalysts show great potential for this reaction, although relatively little is known about their functioning. In this work, a set of lanthanide oxychlorides (i.e., LnOCl with Ln = La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, and Ho) and Er- and Yb-based catalysts were synthesized, characterized, and tested. All lanthanide-based catalysts can directly activate CH₄ into chloromethanes, but their catalytic properties differ significantly. EuOCl shows the most promising catalytic activity and selectivity, as very high conversion levels (>30%) and chloromethane selectivity values (>50%) can be reached at moderate reaction temperatures (∼425 °C). Operando Raman spectroscopy revealed that the chlorination of the EuOCl catalyst surface is rate-limiting; hence, increasing the HCl concentration improves the catalytic performance. The CO selectivity could be suppressed from 30 to 15%, while the CH₄ conversion more than doubled from 11 to 24%, solely by increasing the HCl concentration from 10 to 60% at 450 °C. Even though more catalysts reported in this study and in the literature show a negative correlation between the S _CO and HCl concentration, this effect was never as substantial as observed for EuOCl. EuOCl has promising properties to bring the oxychlorination one step closer to an economically viable CH₄ valorization process.

On the Cobalt Carbide Formation in a Co/TiO2 Fischer-Tropsch Synthesis Catalyst as Studied by High-Pressure, Long-Term Operando X-ray Absorption and Diffraction

Operando X-ray absorption spectroscopy (XAS) and X-ray diffraction (XRD) were performed on a Co/TiO2 Fischer-Tropsch synthesis (FTS) catalyst at 16 bar for (at least) 48 h time-on-stream in both a synchrotron facility and a laboratory-based X-ray diffractometer. Cobalt carbide formation was observed earlier during FTS with operando XAS than with XRD. This apparent discrepancy is due to the higher sensitivity of XAS to a short-range order. Interestingly, in both cases, the product formation does not noticeably change when cobalt carbide formation is detected. This suggests that cobalt carbide formation is not a major deactivation mechanism, as is often suggested for FTS. Moreover, no cobalt oxide formation was detected by XAS or XRD. In other words, one of the classical proposals invoked to explain Co/TiO2 catalyst deactivation could not be supported by our operando X-ray characterization data obtained at close to industrially relevant reaction conditions. Furthermore, a bimodal cobalt particle distribution was observed by high-angle annular dark-field scanning transmission electron microscopy and energy-dispersive X-ray analysis, while product formation remained relatively stable. The bimodal distribution is most probably due to the mobility and migration of the cobalt nanoparticles during FTS conditions.

Deactivation of Cu-Exchanged Automotive-Emission NH3 -SCR Catalysts Elucidated with Nanoscale Resolution Using Scanning Transmission X-ray Microscopy

To gain insight into the underlying mechanisms of catalyst durability for the selective catalytic reduction (SCR) of NOx with an ammonia reductant, we employed scanning transmission X-ray microscopy (STXM) to study Cu-exchanged zeolites with the CHA and MFI framework structures before and after simulated 135 000-mile aging. X-ray absorption near-edge structure (XANES) measurements were performed at the Al K- and Cu L-edges. The local environment of framework Al, the oxidation state of Cu, and geometric changes were analyzed, showing a multi-factor-induced catalytic deactivation. In Cu-exchanged MFI, a transformation of CuII to CuI and Cux Oy was observed. We also found a spatial correlation between extra-framework Al and deactivated Cu species near the surface of the zeolite as well as a weak positive correlation between the amount of CuI and tri-coordinated Al. By inspecting both Al and Cu in fresh and aged Cu-exchanged zeolites, we conclude that the importance of the preservation of isolated CuII sites trumps that of Brønsted acid sites for NH3 -SCR activity.

Nickel Poisoning of a Cracking Catalyst Unravelled by Single-Particle X-ray Fluorescence-Diffraction-Absorption Tomography

Ni contamination from crude oil in the fluid catalytic cracking (FCC) process is one of the primary sources of catalyst deactivation, thereby promoting dehydrogenation-hydrogenation and speeding up coke growth. Herein, single-particle X-ray fluorescence, diffraction and absorption (μXRF-μXRD-μXAS) tomography is used in combination with confocal fluorescence microscopy (CFM) after thiophene staining to spatially resolve Ni interaction with catalyst components and study zeolite degradation, including the processes of dealumination and Brønsted acid sites distribution changes. The comparison between a Ni-lean particle, exposed to hydrotreated feedstock, and a Ni-rich one, exposed to non-hydrotreated feedstock, reveals a preferential interaction of Ni, found in co-localization with Fe, with the γ-Al₂ O₃ matrix, leading to the formation of spinel-type hotspots. Although both particles show similar surface zeolite degradation, the Ni-rich particle displays higher dealumination and a clear Brønsted acidity drop.

Probing the Location and Speciation of Elements in Zeolites with Correlated Atom Probe Tomography and Scanning Transmission X-Ray Microscopy

Characterizing materials at nanoscale resolution to provide new insights into structure property performance relationships continues to be a challenging research target due to the inherently low signal from small sample volumes, and is even more difficult for nonconductive materials, such as zeolites. Herein, we present the characterization of a single Cu-exchanged zeolite crystal, namely Cu-SSZ-13, used for NOX reduction in automotive emissions, that was subject to a simulated 135,000-mile aging. By correlating Atom Probe Tomography (APT), a single atom microscopy method, and Scanning Transmission X-ray Microscopy (STXM), which produces high spatial resolution X-ray Absorption Near Edge Spectroscopy (XANES) maps, we show that a spatially non-uniform proportion of the Al was removed from the zeolite framework. The techniques reveal that this degradation is heterogeneous at length scales from micrometers to tens of nanometers, providing complementary insight into the long-term deactivation of this catalyst system.

Methane-to-methanol conversion over zeolite Cu-SSZ-13, and its comparison with the selective catalytic reduction of NOx with NH3

Using in situ FT-IR and operando UV-vis-NIR DRS, performed on a series of different Cu–ion-exchanged SSZ-13 zeolites, both a mono-nuclear site or a dimeric copper active site are consistent for methane-to-methanol activation.

Nanoscale tomography reveals the deactivation of automotive copper-exchanged zeolite catalysts

Copper-exchanged zeolite chabazite (Cu-SSZ-13) was recently commercialized for the selective catalytic reduction of NO _X with ammonia in vehicle emissions as it exhibits superior reaction performance and stability compared to all other catalysts, notably Cu-ZSM-5. Herein, the 3D distributions of Cu as well as framework elements (Al, O, Si) in both fresh and aged Cu-SSZ-13 and Cu-ZSM-5 are determined with nanometer resolution using atom probe tomography (APT), and correlated with catalytic activity and other characterizations. Both fresh catalysts contain a heterogeneous Cu distribution, which is only identified due to the single atom sensitivity of APT. After the industry standard 135,000 mile simulation, Cu-SSZ-13 shows Cu and Al clustering, whereas Cu-ZSM-5 is characterized by severe Cu and Al aggregation into a copper aluminate phase (CuAl₂O₄ spinel). The application of APT as a sensitive and local characterization method provides identification of nanometer scale heterogeneities that lead to catalytic activity and material deactivation.

Enhanced activity of desilicated Cu-SSZ-13 for the selective catalytic reduction of NOx and its comparison with steamed Cu-SSZ-13

Mesoporous Cu-SSZ-13 was created by first synthesizing zeolite H-SSZ-13 and subsequently desilicating the material by base leaching using NaOH in different concentrations.

Molybdenum Speciation and its Impact on Catalytic Activity during Methane Dehydroaromatization in Zeolite ZSM-5 as Revealed by Operando X-Ray Methods

Combined high‐resolution fluorescence detection X‐ray absorption near‐edge spectroscopy, X‐ray diffraction, and X‐ray emission spectroscopy have been employed under operando conditions to obtain detailed new insight into the nature of the Mo species on zeolite ZSM‐5 during methane dehydroaromatization. The results show that isolated Mo–oxo species present after calcination are converted by CH₄ into metastable MoC_xO_y species, which are primarily responsible for C₂H_x/C₃H_x formation. Further carburization leads to MoC₃ clusters, whose presence coincides with benzene formation. Both sintering of MoC₃ and accumulation of large hydrocarbons on the external surface, evidenced by fluorescence‐lifetime imaging microscopy, are principally responsible for the decrease in catalytic performance. These results show the importance of controlling Mo speciation to achieve the desired product formation, which has important implications for realizing the impact of CH₄ as a source for platform chemicals.

The curious case of zeolite–clay/binder interactions and their consequences for catalyst preparation

Zeolite-based catalyst bodies are commonly employed in a range of important industrial processes. Depending on the binder and shaping method chosen, vast differences in the reactivity, selectivity and stability are obtained. Here, three highly complementary micro-spectroscopic techniques were employed to study zeolite ZSM-5–binder interactions in SiO₂-, Al₂O₃-, SiO₂ : Al₂O₃- (2 : 1 mix) and kaolinite-bound catalyst pellets. We establish how their preparation influences the zeolite–clay/binder interactions. Using thiophene as an acid-catalyzed staining reaction, light absorbing oligomers produced in each sample were followed. To our surprise, kaolinite decreased the overall reactivity of the sample due to the phase change of the binder, creating a hard impenetrable outer layer. Aluminum migration to the zeolite was observed when Al₂O₃ was selected as a binder, creating additional Brønsted acid sites, which favored the formation of ring-opened thiophene oligomers compared to the larger oligomer species produced when SiO₂ was used as a binder. In the latter case, the interaction of the Si–OH groups in the binder with thiophene was revealed to have a large impact in creating such large oligomer species. Furthermore, the combination of a SiO₂ : Al₂O₃ mix as a binder enhanced the reactivity, possibly due to the creation of additional Brønsted acid sites between the two binder components during pellet preparation. It is evident that, independent of the shaping method, the intimate contact between the zeolite and binder heavily impacts the reactivity and product selectivity, with the type of binder playing a vital role.