Effects of Coke Deposits on the Catalytic Performance of Large Zeolite H‐ZSM‐5 Crystals during Alcohol‐to‐Hydrocarbon Reactions as Investigated by a Combination of Optical Spectroscopy and Microscopy

The catalytic activity of large zeolite H‐ZSM‐5 crystals in methanol (MTO) and ethanol‐to‐olefins (ETO) conversions was investigated and, using operando UV/Vis measurements, the catalytic activity and deactivation was correlated with the formation of coke. These findings were related to in situ single crystal UV/Vis and confocal fluorescence micro‐spectroscopy, allowing the observation of the spatiotemporal formation of intermediates and coke species during the MTO and ETO conversions. It was observed that rapid deactivation at elevated temperatures was due to the fast formation of aromatics at the periphery of the H‐ZSM‐5 crystals, which are transformed into more poly‐aromatic coke species at the external surface, preventing the diffusion of reactants and products into and out of the H‐ZSM‐5 crystal. Furthermore, we were able to correlate the operando UV/Vis spectroscopy results observed during catalytic testing with the single crystal in situ results.     

π‐Interactions between Cyclic Carbocations and Aromatics Cause Zeolite Deactivation in Methanol‐to‐Hydrocarbon Conversion

The understanding of catalyst deactivation represents one of the major challenges for the methanol‐to‐hydrocarbon (MTH) reaction over acidic zeolites. Here we report the critical role of intermolecular π‐interactions in catalyst deactivation in the MTH reaction on zeolites H‐SSZ‐13 and H‐ZSM‐5. π‐interaction‐induced spatial proximities between cyclopentenyl cations and aromatics in the confined channels and/or cages of zeolites are revealed by two‐dimensional solid‐state NMR spectroscopy. The formation of naphtalene as a precursor to coke species is favored due to the reaction of aromatics with the nearby cyclopentenyl cations and correlates with both acid density and zeolite topology.     

Space‐ and Time‐Resolved In‐situ Spectroscopy on the Coke Formation in Molecular Sieves: Methanol‐to‐Olefin Conversion over H‐ZSM‐5 and H‐SAPO‐34

Formation of coke in large H‐ZSM‐5 and H‐SAPO‐34 crystals during the methanol‐to‐olefin (MTO) reaction has been studied in a space‐ and time‐resolved manner. This has been made possible by applying a high‐temperature in‐situ cell in combination with micro‐spectroscopic techniques. The buildup of optically active carbonaceous species allows detection with UV/Vis microscopy, while a confocal fluorescence microscope in an upright configuration visualises the formation of coke molecules and their precursors inside the catalyst grains. In H‐ZSM‐5, coke is initially formed at the triangular crystal edges, in which straight channel openings reach directly the external crystal surface. At reaction temperatures ranging from 530 to 745 K, two absorption bands at around 415 and 550 nm were detected due to coke or its precursors. Confocal fluorescence microscopy reveals fluorescent carbonaceous species that initially form in the near‐surface area and gradually diffuse inwards the crystal in which internal intergrowth boundaries hinder a facile penetration for the more bulky aromatic compounds. In the case of H‐SAPO‐34 crystals, an absorption band at around 400 nm arises during the reaction. This band grows in intensity with time and then decreases if the reaction is carried out between 530 and 575 K, whereas at higher temperatures its intensity remains steady with time on stream. Formation of the fluorescent species during the course of the reaction is limited to the near‐surface region of the H‐SAPO‐34 crystals, thereby creating diffusion limitations for the coke front moving towards the middle of the crystal during the MTO reaction. The two applied micro‐spectroscopic techniques introduced allow us to distinguish between graphite‐like coke deposited on the external crystal surface and aromatic species formed inside the zeolite channels. The use of the methods can be extended to a wide variety of catalytic reactions and materials in which carbonaceous deposits are formed.     

Coke formation during the methanol-to-olefin conversion: in situ microspectroscopy on individual H-ZSM-5 crystals with different Brønsted acidity

Coke formation during the methanol‐to‐olefin (MTO) conversion has been studied at the single‐particle level with in situ UV/Vis and confocal fluorescence microscopy. For this purpose, large H‐ZSM‐5 crystals differing in their Si/Al molar ratio have been investigated. During MTO, performed at 623 and 773 K, three major UV/Vis bands assigned to different carbonaceous deposits and their precursors are observed. The absorption at 420 nm, assigned to methyl‐substituted aromatic compounds, initiates the buildup of the optically active coke species. With time‐on‐stream, these carbonaceous compounds expand in size, resulting in the gradual development of a second absorption band at around 500 nm. An additional broad absorption band in the 600 nm region indicates the enhanced formation of extended carbonaceous compounds that form as the reaction temperature is raised. Overall, the rate of coke formation decreases with decreasing aluminum content. Analysis of the reaction kinetics indicates that an increased Brønsted acid site density facilitates the formation of larger coke species and enhances their formation rate. The use of multiple excitation wavelengths in confocal fluorescence microscopy enables the localization of coke compounds with different molecular dimensions in an individual H‐ZSM‐5 crystal. It demonstrates that small coke species evenly spread throughout the entire H‐ZSM‐5 crystal, whereas extended coke deposits primarily form near the crystal edges and surfaces. Polarization‐dependent UV/Vis spectroscopy measurements illustrate that extended coke species are predominantly formed in the straight channels of H‐ZSM‐5. In addition, at higher temperatures, fast deactivation leads to the formation of large aromatic compounds within channel intersections and at the external zeolite surface, where the lack of spatial restrictions allows the formation of graphite‐like coke.     

Unraveling the Homologation Reaction Sequence of the Zeolite‐Catalyzed Ethanol‐to‐Hydrocarbons Process

Although industrialized, the mechanism for catalytic upgrading of bioethanol over solid‐acid catalysts (that is, the ethanol‐to‐hydrocarbons (ETH) reaction) has not yet been fully resolved. Moreover, mechanistic understanding of the ETH reaction relies heavily on its well‐known “sister‐reaction” the methanol‐to‐hydrocarbons (MTH) process. However, the MTH process possesses a C₁‐entity reactant and cannot, therefore, shed any light on the homologation reaction sequence. The reaction and deactivation mechanism of the zeolite H‐ZSM‐5‐catalyzed ETH process was elucidated using a combination of complementary solid‐state NMR and operando UV/Vis diffuse reflectance spectroscopy, coupled with on‐line mass spectrometry. This approach establishes the existence of a homologation reaction sequence through analysis of the pattern of the identified reactive and deactivated species. Furthermore, and in contrast to the MTH process, the deficiency of any olefinic‐hydrocarbon pool species (that is, the olefin cycle) during the ETH process is also noted.     

Disentangling Reaction Processes of Zeolites within Single‐Oriented Channels

Establishing structure–reactivity relationships for specific channel orientations of zeolites is vital to developing new, superior materials for various applications, including oil and gas conversion processes. Herein, a well‐defined model system was developed to build structure–reactivity relationships for specific zeolite‐channel orientations during various catalytic reaction processes, for example, the methanol‐ and ethanol‐to‐hydrocarbons (MTH and ETH) process as well as oligomerization reactions. The entrapped and effluent hydrocarbons from single‐oriented zeolite ZSM‐5 channels during the MTH process were monitored by using operando UV/Vis diffuse reflectance spectroscopy (DRS) and on‐line mass spectrometry (MS), respectively. The results reveal that the straight channels favor the formation of internal coke, promoting the aromatic cycle. Furthermore, the sinusoidal channels produce aromatics, (e.g., toluene) that further grow into larger polyaromatics (e.g., graphitic coke) leading to deactivation of the zeolites. This underscores the importance of careful engineering of materials to suppress coke formation and tune product distribution by rational control of the location of zeolite acid sites and crystallographic orientations.     

Theoretical Insights on Methylbenzene Side‐Chain Growth in ZSM‐5 Zeolites for Methanol‐to‐Olefin Conversion

The key step in the conversion of methane to polyolefins is the catalytic conversion of methanol to light olefins. The most recent formulations of a reaction mechanism for this process are based on the idea of a complex hydrocarbon‐pool network, in which certain organic species in the zeolite pores are methylated and from which light olefins are eliminated. Two major mechanisms have been proposed to date—the paring mechanism and the side‐chain mechanism—recently joined by a third, the alkene mechanism. Recently we succeeded in simulating a full catalytic cycle for the first of these in ZSM‐5, with inclusion of the zeolite framework and contents. In this paper, we will investigate crucial reaction steps of the second proposal (the side‐chain route) using both small and large zeolite cluster models of ZSM‐5. The deprotonation step, which forms an exocyclic double bond, depends crucially on the number and positioning of the other methyl groups but also on steric effects that are typical for the zeolite lattice. Because of steric considerations, we find exocyclic bond formation in the ortho position to the geminal methyl group to be more favourable than exocyclic bond formation in the para position. The side‐chain growth proceeds relatively easily but the major bottleneck is identified as subsequent de‐alkylation to produce ethene. These results suggest that the current formulation of the side‐chain route in ZSM‐5 may actually be a deactivating route to coke precursors rather than an active ethene‐producing hydrocarbon‐pool route. Other routes may be operating in alternative zeotype materials like the silico‐aluminophosphate SAPO‐34.     

Study of the grafting reaction of SnMe4 on the surface of ZSM‐5 zeolite

The grafting reaction of tetramethyltin on the surface of ZSM‐5 zeolite (Si:Al = 55.0) was studied under vacuum conditions, and the chemical compositions, structure and properties of the resulting solid were characterized by in situ FTIR, ICP, XRD, XPS, UV–vis DRS, temperature programmed decomposition (TPD) and N₂ adsorption. The results show that the reaction occurs on the surface of ZSM‐5 zeolite at 223 K without destroying the zeolite framework. The BET surface area and the pore volume of the zeolite decrease and the surface properties change; however, the microporous structure is retained during the reaction and post treatment. Copyright © 2006 John Wiley & Sons, Ltd.     

Catalytic Para‐Xylene Maximization. V. Toluene Methylation with Methanol and Disproportionation of Toluene Using Pt/ZSM‐5 and Pt/Mordenite Catalysts

Toluene was methylated with methanol and disproportionated using catalysts containing different Pt contents (0.2, 0.4 and 0.6%) supported on H‐ZSM‐5 or H‐mordenite (H‐M) zeolites in a fixed‐bed flow‐reactor operated atmospherically at temperatures of 300–500 °C in a flow of hydrogen. Platinum dispersion in the zeolite supports and acid sites strength distribution were evaluated using hydrogen chemisorption (1:1 stoichiometry) and ammonia temperature programmed desorption (TPD) in a differential scanning calorimeter (DSC). Toluene methylation was much faster on all catalysts than toluene disproportionation (DISP). Both reactions were more accelerated using H‐ZSM‐5 containing catalysts than H‐M containing catalysts. The yield of xylenes, and in particular para‐xylene, was significantly influenced by the yield of trimethylbenzenes (TMBs) in product. The selectivities for para‐, ortho‐ and meta‐xylenes production were found largely dependent on the Pt content in the catalysts, particularly when supported on H‐ZSM5‐zeolite. However, using Pt/H‐M catalysts, these selectivities were not strictly controlled by Pt content in the catalysts.     

Hierarchical Porous ZSM‐5 Zeolite Synthesized by in situ Zeolitization and Its Coke Deposition Resistance in Aromatization Reaction

Hierarchical ZSM‐5 zeolites with micro‐, meso‐ and macroporosity were prepared from diatomite zeolitization through a vapor‐phase transport process on solid surfaces. The aromatization performance of the catalysts was investigated on a fixed bed reactor by using FCC gasoline as feedstock. The crystal phase, morphology, pore structures, acidity and coke depositions of the hierarchical ZSM‐5 zeolites were characterized by means of X‐ray diffraction (XRD), scanning electron microscope (SEM), N₂ adsorption/desorption, Fourier transform infrared (FT‐IR) and thermogravimetry‐mass spectrogram (TG‐MS), respectively. The results show that the prepared hierarchical ZSM‐5 zeolite possesses excellent porosity and high crystallinity, displaying an improved aromatization performance and carbon deposition resistance due to its meso‐ and macroporous structures.     

A Simple Route to Synthesize Mesoporous ZSM‐5 Templated by Ammonium‐Modified Chitosan

Uniform mesoporous zeolite ZSM‐5 crystals have been successfully fabricated through a simple hydrothermal synthetic method by utilizing ammonium‐modified chitosan and tetrapropylammonium hydroxide (TPAOH) as the meso‐ and microscale template, respectively. It was revealed that mesopores with diameters of 5–20 nm coexisted with microporous network within mesoporous ZSM‐5 crystals. Ammonium‐modified chitosan was demonstrated to serve as a mesoporogen, self‐assembling with the zeolite precursor through strong static interactions. As expected, the prepared mesoporous ZSM‐5 exhibited greatly enhanced catalytic activities compared with conventional ZSM‐5 and Al‐MCM‐41 in reactions involving bulky molecules, such as the Claisen–Schmidt condensation of 2‐hydroxyacetophenone with benzaldehyde and the esterification reaction of dodecanoic acid and 2‐ethylhexanol.     

Differences Between Individual ZSM‐5 Crystals in Forming Hollow Single Crystals and Mesopores During Base Leaching

After base treatment of ZSM‐5 crystals below 100 nm in size, TEM shows hollow single crystals with a 10 nm shell. SEM images confirm that the shell is well‐ preserved even after prolonged treatment. Determination of the Si/Al ratios with AAS and XPS in combination with argon sputtering reveals aluminum zoning of the parent zeolite, and the total pore volume increases in the first two hours of base treatment. In corresponding TEM images, the amount of hollow crystals are observed to increase during the first two hours of base treatment, and intact crystals are visible even after 10 h of leaching; these observations indicate different dissolution rates between individual crystals. TEM of large, commercially available ZSM‐5 crystals shows inhomogeneous distribution of mesopores among different crystals, which points to the existence of structural differences between individual crystals. Only tetrahedrally coordinated aluminum is detected with ²⁷Al MAS NMR after the base leaching of nano‐sized ZSM‐5.     

Enthalpy and Entropy Barriers Explain the Effects of Topology on the Kinetics of Zeolite‐Catalyzed Reactions

The methylation of ethene, propene, and trans‐2‐butene on zeolites H‐ZSM‐58 (DDR), H‐ZSM‐22 (TON), and H‐ZSM‐5 (MFI) is studied to elucidate the particular influence of topology on the kinetics of zeolite‐catalyzed reactions. H‐ZSM‐58 and H‐ZSM‐22 are found to display overall lower methylation rates compared to H‐ZSM‐5 and also different trends in methylation rates with increasing alkene size. These variations may be rationalized based on a decomposition of the free‐energy barriers into enthalpic and entropic contributions, which reveals that the lower methylation rates on H‐ZSM‐58 and H‐ZSM‐22 have virtually opposite reasons. On H‐ZSM‐58, the lower methylation rates are caused by higher enthalpy barriers, owing to inefficient stabilization of the reaction intermediates in the large cage‐like pores. On the other hand, on H‐ZSM‐22, the methylation rates mostly suffer from higher entropy barriers, because excessive entropy losses are incurred inside the narrow‐channel structure. These results show that the kinetics of crucial elementary steps hinge on the balance between proper stabilization of the reaction intermediates inside the zeolite pores and the resulting entropy losses. These fundamental insights into their inner workings are indispensable for ultimately selecting or designing better zeolite catalysts.     

Direct Detection of Supramolecular Reaction Centers in the Methanol‐to‐Olefins Conversion over Zeolite H‐ZSM‐5 by 13C–27Al Solid‐State NMR Spectroscopy

Hydrocarbon‐pool chemistry is important in methanol to olefins (MTO) conversion on acidic zeolite catalysts. The hydrocarbon‐pool (HP) species, such as methylbenzenes and cyclic carbocations, confined in zeolite channels during the reaction are essential in determining the reaction pathway. Herein, we experimentally demonstrate the formation of supramolecular reaction centers composed of organic hydrocarbon species and the inorganic zeolite framework in H‐ZSM‐5 zeolite by advanced ¹³C–²⁷Al double‐resonance solid‐state NMR spectroscopy. Methylbenzenes and cyclic carbocations located near Brønsted acid/base sites form the supramolecular reaction centers in the zeolite channel. The internuclear spatial interaction/proximity between the ¹³C nuclei (associated with HP species) and the ²⁷Al nuclei (associated with Brønsted acid/base sites) determines the reactivity of the HP species. The closer the HP species are to the zeolite framework Al, the higher their reactivity in the MTO reaction.     

Reversible Nature of Coke Formation on Mo/ZSM‐5 Methane Dehydroaromatization Catalysts

Non‐oxidative dehydroaromatization of methane over Mo/ZSM‐5 zeolite catalysts is a promising reaction for the direct conversion of abundant natural gas into liquid aromatics. Rapid coking deactivation hinders the practical implementation of this technology. Herein, we show that catalyst productivity can be improved by nearly an order of magnitude by raising the reaction pressure to 15 bar. The beneficial effect of pressure was found for different Mo/ZSM‐5 catalysts and a wide range of reaction temperatures and space velocities. High‐pressure operando X‐ray absorption spectroscopy demonstrated that the structure of the active Mo‐phase was not affected by operation at elevated pressure. Isotope labeling experiments, supported by mass‐spectrometry and ¹³C nuclear magnetic resonance spectroscopy, indicated the reversible nature of coke formation. The improved performance can be attributed to faster coke hydrogenation at increased pressure, overall resulting in a lower coke selectivity and better utilization of the zeolite micropore space.     

Monitoring the Location,Amount, and Nature of Carbonaceous Deposits on Aged Zeolite Ferrierite Crystals by Using STEM‐EELS

By the use of electron energy‐loss spectroscopy performed in a scanning transmission electron microscope (STEM‐EELS), detailed spatial information is obtained concerning the amount and nature of carbonaceous deposits formed inside the crystals of the zeolite ferrierite (FER) during the reaction of n‐butene to isobutene. In all cases, gradients in coke concentration over the crystal have been observed and quantified. An extensive accumulation of coke is observed at the entrance of the eight‐membered‐ring (MR) pores, while less coke is present at the entrances of the ten‐MR channels. At a higher coke content, further filling up of the complete micropore system occurs and the eight‐MR pores become fully blocked. The ten‐MR channels remain partially accessible for n‐butene, with alkyl‐aromatic species deposited near the inlets of these channels. With regard to the selective transformation of n‐butene into isobutene, this supports the view that the catalytic action takes place in the pore mouths of the ten‐MR channels. Overall it is demonstrated that the major benefit of STEM‐EELS is the possibility to simultaneously determine the position‐resolved amount and nature of carbonaceous deposits on intact zeolite crystals.     

Bridging the Gap between the Direct and Hydrocarbon Pool Mechanisms of the Methanol‐to‐Hydrocarbons Process

After a prolonged effort over many years, the route for the formation of a direct carbon?carbon (C?C) bond during the methanol‐to‐hydrocarbon (MTH) process has very recently been unveiled. However, the relevance of the “direct mechanism”‐derived molecules (that is, methyl acetate) during MTH, and subsequent transformation routes to the conventional hydrocarbon pool (HCP) species, are yet to be established. This important piece of the MTH chemistry puzzle is not only essential from a fundamental perspective, but is also important to maximize catalytic performance. The MTH process was probed over a commercially relevant H‐SAPO‐34 catalyst, using a combination of advanced solid‐state NMR spectroscopy and operando UV/Vis diffuse reflectance spectroscopy coupled to an on‐line mass spectrometer. Spectroscopic evidence is provided for the formation of (olefinic and aromatic) HCP species, which are indeed derived exclusively from the direct C?C bond‐containing acetyl group of methyl acetate. New mechanistic insights have been obtained from the MTH process, including the identification of hydrocarbon‐based co‐catalytic organic reaction centers.     

Experimental Evidence on the Formation of Ethene through Carbocations in Methanol Conversion over H‐ZSM‐5 Zeolite

The methanol to olefins conversion over zeolite catalysts is a commercialized process to produce light olefins like ethene and propene but its mechanism is not well understood. We herein investigated the formation of ethene in the methanol to olefins reaction over the H‐ZSM‐5 zeolite. Three types of ethylcyclopentenyl carbocations, that is, the 1‐methyl‐3‐ethylcyclopentenyl, the 1,4‐dimethyl‐3‐ethylcyclopentenyl, and the 1,5‐dimethyl‐3‐ethylcyclopentenyl cation were unambiguously identified under working conditions by both solid‐state and liquid‐state NMR spectroscopy as well as GC‐MS analysis. These carbocations were found to be well correlated to ethene and lower methylbenzenes (xylene and trimethylbenzene). An aromatics‐based paring route provides rationale for the transformation of lower methylbenzenes to ethene through ethylcyclopentenyl cations as the key hydrocarbon‐pool intermediates.     

Graphene Oxide Facilitates Solvent‐Free Synthesis of Well‐Dispersed,Faceted Zeolite Crystals

Zeolites with molecular dimension pores are widely used in petrochemical and fine‐chemical industries. While traditional solvothermal syntheses suffer from environmental, safety, and efficiency issues, the newly developed solvent‐free synthesis is limited by zeolite crystal aggregation. Herein, we report well‐dispersed and faceted silicalite ZSM‐5 zeolite crystals obtained using a solvent‐free synthesis facilitated by graphene oxide (GO). The selective interactions between the GO sheets and different facets, which are confirmed by molecular dynamics simulations, result in oriented growth of the ZSM‐5 crystals along the c‐axis. More importantly, the incorporation of GO sheets into the ZSM‐5 crystals leads to the formation of mesopores. Consequently, the faceted ZSM‐5 crystals exhibit hierarchical pore structures. This synthetic method is superior to conventional approaches because of the features of the ZSM‐5 zeolite.     

Graphene Oxide Facilitates Solvent‐Free Synthesis of Well‐Dispersed,Faceted Zeolite Crystals

Zeolites with molecular dimension pores are widely used in petrochemical and fine‐chemical industries. While traditional solvothermal syntheses suffer from environmental, safety, and efficiency issues, the newly developed solvent‐free synthesis is limited by zeolite crystal aggregation. Herein, we report well‐dispersed and faceted silicalite ZSM‐5 zeolite crystals obtained using a solvent‐free synthesis facilitated by graphene oxide (GO). The selective interactions between the GO sheets and different facets, which are confirmed by molecular dynamics simulations, result in oriented growth of the ZSM‐5 crystals along the c‐axis. More importantly, the incorporation of GO sheets into the ZSM‐5 crystals leads to the formation of mesopores. Consequently, the faceted ZSM‐5 crystals exhibit hierarchical pore structures. This synthetic method is superior to conventional approaches because of the features of the ZSM‐5 zeolite.