The porosity, acidity, and reactivity of dealuminated zeolite ZSM-5 at the single particle level: the influence of the zeolite architecture

A combination of atomic force microscopy (AFM), high‐resolution scanning electron microscopy (HR‐SEM), focused‐ion‐beam scanning electron microscopy (FIB‐SEM), X‐ray photoelectron spectroscopy (XPS), confocal fluorescence microscopy (CFM), and UV/Vis and synchrotron‐based IR microspectroscopy was used to investigate the dealumination processes of zeolite ZSM‐5 at the individual crystal level. It was shown that steaming has a significant impact on the porosity, acidity, and reactivity of the zeolite materials. The catalytic performance, tested by the styrene oligomerization and methanol‐to‐olefin reactions, led to the conclusion that mild steaming conditions resulted in greatly enhanced acidity and reactivity of dealuminated zeolite ZSM‐5. Interestingly, only residual surface mesoporosity was generated in the mildly steamed ZSM‐5 zeolite, leading to rapid crystal coloration and coking upon catalytic testing and indicating an enhanced deactivation of the zeolites. In contrast, harsh steaming conditions generated 5–50 nm mesopores, extensively improving the accessibility of the zeolites. However, severe dealumination decreased the strength of the Brønsted acid sites, causing a depletion of the overall acidity, which resulted in a major drop in catalytic activity.     

Staining of fluid-catalytic-cracking catalysts: localising Brønsted acidity within a single catalyst particle

A time‐resolved in situ micro‐spectroscopic approach has been used to investigate the Brønsted acidic properties of fluid‐catalytic‐cracking (FCC) catalysts at the single particle level by applying the acid‐catalysed styrene oligomerisation probe reaction. The reactivity of individual FCC components (zeolite, clay, alumina and silica) was monitored by UV/Vis micro‐spectroscopy and showed that only clay and zeolites (Y and ZSM‐5) contain Brønsted acid sites that are strong enough to catalyse the conversion of 4‐fluorostyrene into carbocationic species. By applying the same approach to complete FCC catalyst particles, it has been found that the fingerprint of the zeolitic UV/Vis spectra is clearly recognisable. This almost exclusive zeolitic activity is confirmed by the fact that hardly any reactivity is observed for FCC particles that contain no zeolite. Confocal fluorescence microscopy images of FCC catalyst particles reveal inhomogeneously distributed micron‐sized zeolite domains with a highly fluorescent signal upon reaction. By examining laboratory deactivated FCC catalyst particles in a statistical approach, a clear trend of decreasing fluorescence intensity, and thus Brønsted acidity, of the zeolite domains is observed with increasing severity of the deactivation method. By comparing the average fluorescence intensities obtained with two styrenes that differ in reactivity, it has been found that the Brønsted acid site strength within FCC catalyst particles containing ZSM‐5 is more uniform than within those containing zeolite Y, as confirmed with temperature‐programmed desorption of ammonia.     

Steam‐Induced Coarsening of Single‐Unit‐Cell MFI Zeolite Nanosheets and Its Effect on External Surface Brønsted Acid Catalysis

Commonly used methods to assess crystallinity, micro‐/mesoporosity, Brønsted acid site density and distribution (in micro‐ vs. mesopores), and catalytic activity suggest nearly invariant structure and function for aluminosilicate zeolite MFI two‐dimensional nanosheets before and after superheated steam treatment. Yet, pronounced reaction rate decrease for benzyl alcohol alkylation with mesitylene, a reaction that cannot take place in the zeolite micropores, is observed. Transmission electron microscopy images reveal pronounced changes in nanosheet thickness, aspect ratio and roughness indicating that nanosheet coarsening and the associated changes in the external (mesoporous) surface structure are responsible for the changes in the external surface catalytic activity. Superheated steam treatment of hierarchical zeolites can be used to alter nanosheet morphology and regulate external surface catalytic activity while preserving micro‐ and mesoporosity, and micropore reaction rates.     

High‐Resolution Single‐Molecule Fluorescence Imaging of Zeolite Aggregates within Real‐Life Fluid Catalytic Cracking Particles

Fluid catalytic cracking (FCC) is a major process in oil refineries to produce gasoline and base chemicals from crude oil fractions. The spatial distribution and acidity of zeolite aggregates embedded within the 50–150 μm‐sized FCC spheres heavily influence their catalytic performance. Single‐molecule fluorescence‐based imaging methods, namely nanometer accuracy by stochastic chemical reactions (NASCA) and super‐resolution optical fluctuation imaging (SOFI) were used to study the catalytic activity of sub‐micrometer zeolite ZSM‐5 domains within real‐life FCC catalyst particles. The formation of fluorescent product molecules taking place at Brønsted acid sites was monitored with single turnover sensitivity and high spatiotemporal resolution, providing detailed insight in dispersion and catalytic activity of zeolite ZSM‐5 aggregates. The results point towards substantial differences in turnover frequencies between the zeolite aggregates, revealing significant intraparticle heterogeneities in Brønsted reactivity.     

Hierarchical ZSM‐5 Zeolites in Shape‐Selective Xylene Isomerization: Role of Mesoporosity and Acid Site Speciation

The isomerization of o‐xylene, a prototypical example of shape‐selective catalysis by zeolites, was investigated on hierarchical porous ZSM‐5. Extensive intracrystalline mesoporosity in ZSM‐5 was introduced by controlled silicon leaching with NaOH. In addition to the development of secondary porosity, the treatment also induced substantial aluminum redistribution, increasing the density of Lewis acid sites located at the external surface of the crystals. However, the strength of the remaining Brønsted sites was not changed. The mesoporous zeolite displayed a higher o‐xylene conversion than its parent, owing to the reduced diffusion limitations. However, the selectivity to p‐xylene decreased, and fast deactivation due to coking occurred. This is mainly due to the deleterious effect of acidity at the substantially increased external surface and near the pore mouths. A consecutive mild HCl washing of the hierarchical zeolite proved effective to increase the p‐xylene selectivity and reduce the deactivation rate. The HCl‐washed hierarchical ZSM‐5 displayed an approximately twofold increase in p‐xylene yield compared to the purely microporous zeolite. The reaction was followed by operando infrared spectroscopy to simultaneously monitor the catalytic performance and the buildup of carbonaceous deposits on the surface. Our results show that the interplay between activity, selectivity, and stability in modified zeolites can be optimized by relatively simple post‐synthesis treatments, such as base leaching (introduction of mesoporosity) and acid washing (surface acidity modification).     

Exploring meso-/microporous composite molecular sieves with core-shell structures

A series of core–shell‐structured composite molecular sieves comprising zeolite single crystals (i.e., ZSM‐5) as a core and ordered mesoporous silica as a shell were synthesized by means of a surfactant‐directed sol–gel process in basic medium by using cetyltrimethylammonium bromide (CTAB) as a template and tetraethylorthosilicate (TEOS) as silica precursor. Through this coating method, uniform mesoporous silica shells closely grow around the anisotropic zeolite single crystals, the shell thickness of which can easily be tuned in the range of 15–100 nm by changing the ratio of TEOS/zeolite. The obtained composite molecular sieves have compact meso‐/micropore junctions that form a hierarchical pore structure from ordered mesopore channels (2.4–3.0 nm in diameter) to zeolite micropores (≈0.51 nm). The short‐time kinetic diffusion efficiency of benzene molecules within pristine ZSM‐5 (≈7.88×10^?19 m² s^?1) is almost retainable after covering with 75 nm‐thick mesoporous silica shells (≈7.25×10^?19 m² s^?1), which reflects the greatly opened junctions between closely connected mesopores (shell) and micropores (core). The core–shell composite shows greatly enhanced adsorption capacity (≈1.35 mmol g^?1) for large molecules such as 1,3,5‐triisopropylbenzene relative to that of pristine ZSM‐5 (≈0.4 mmol g^?1) owing to the mesoporous silica shells. When Al species are introduced during the coating process, the core–shell composite molecular sieves demonstrate a graded acidity distribution from weak acidity of mesopores (predominant Lewis acid sites) to accessible strong acidity of zeolite cores (Lewis and Brønsted acid sites). The probe catalytic cracking reaction of n‐dodecane shows the superiority of the unique core–shell structure over pristine ZSM‐5. Insight into the core–shell composite structure with hierarchical pore and graded acidity distribution show great potential for petroleum catalytic processes.     

Aluminum Redistribution during the Preparation of Hierarchical Zeolites by Desilication

A literature survey reveals a prominent reduction in the concentration of Brønsted acid sites in hierarchically organized zeolites with increasing mesoporous or external surface area independent of the framework type or synthesis route; this suggests a common fundamental explanation. To determine the cause, nature, and impact of the underlying changes in aluminum speciation, this study combines a multitechnique analysis that integrates basic characterization, a detailed synchrotron XRD and multiple‐quantum NMR spectroscopy assessment, and catalytic tests to correlate evolution of the properties with performance during successive steps in the preparation of hierarchical MFI‐type zeolites by desilication. The findings, subsequently generalized to FAU‐ and BEA‐type materials, identify the crucial impact of calcination on the protonic form, which is an integral step in the synthesis and regeneration of zeolite catalysts; on aluminum coordination; and the associated acidity trends.     

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.     

Steam-Induced Coarsening of Single-Unit-Cell MFI Zeolite Nanosheets and Its Effect on External Surface Brønsted Acid Catalysis

Commonly used methods to assess crystallinity, micro-/mesoporosity, Brønsted acid site density and distribution (in micro- vs. mesopores), and catalytic activity suggest nearly invariant structure and function for aluminosilicate zeolite MFI two-dimensional nanosheets before and after superheated steam treatment. Yet, pronounced reaction rate decrease for benzyl alcohol alkylation with mesitylene, a reaction that cannot take place in the zeolite micropores, is observed. Transmission electron microscopy images reveal pronounced changes in nanosheet thickness, aspect ratio and roughness indicating that nanosheet coarsening and the associated changes in the external (mesoporous) surface structure are responsible for the changes in the external surface catalytic activity. Superheated steam treatment of hierarchical zeolites can be used to alter nanosheet morphology and regulate external surface catalytic activity while preserving micro- and mesoporosity, and micropore reaction rates.     

Elucidation of Adsorbate Structures and Interactions on Brønsted Acid Sites in H‐ZSM‐5 by Synchrotron X‐ray Powder Diffraction

Microporous H‐ZSM‐5 containing one Brønsted acid site per asymmetric unit is deliberately chosen to host pyridine, methanol, and ammonia as guest molecules. By using new‐generation in situ synchrotron X‐ray powder diffraction combined with Rietveld refinement, the slight but significant alteration in scattering parameters of framework atoms modified by the guest molecules enables the user to elucidate their adsorption geometries and interactions with the Brønsted acid sites in H‐ZSM‐5 in terms of atomic distances and angles within experimental errors. The conclusion, although demonstrated in the H‐ZSM‐5, is expected to be transferable to other zeolites. This approach provides a stepping stone towards the rational engineering of molecular interaction(s) with acid sites in zeolitic catalysis.     

Cascade Reactions in Tunable Lamellar Micro‐ and Mesopores for C=C Bond Coupling and Hydrocarbon Synthesis

Two‐dimensional MFI zeolite nanosheets contain Brønsted acid sites partially confined at the intercept between micro‐ and mesopores. These acid sites exhibit exceptional reactivities and stabilities for C=C bond coupling and ring‐closure reactions that transform light aldehydes to aromatics. These sites are much more effective than those confined within the micropores of MFI crystallites and those unconfined on H₄SiW₁₂O₄₀ clusters or mesoporous aluminosilicate Al‐MCM‐41. The partially confined site environment solvates and stabilizes the transition states of the kinetically relevant steps during aromatization.     

A New Family of Two‐Dimensional Zeolites Prepared from the Intermediate Layered Precursor IPC‐3P Obtained during the Synthesis of TUN Zeolite

The crystallization of zeolite TUN with 1,4‐bis(N‐methylpyrrolidinium)butane as template proceeds through an intermediate, designated IPC‐3P, following the Ostwald rule of successive transformations. This apparently layered transient product has been thoroughly investigated and found to consist of MWW monolayers stacked without alignment in register, that is, disordered compared with MCM‐22P. The structure was confirmed based on X‐ray diffraction and high‐resolution (HR)TEM analysis. The layered zeolite precursor IPC‐3P can be swollen and pillared affording a combined micro‐ and mesoporous material with enhanced Brunauer–Emmett–Teller (BET) surface area (685 m²g^?1) and greater accessibility of Brønsted acid sites for bulky molecules. This mesoporous material was probed with 2,6‐di‐tert‐butylpyridine (DTBP). IPC‐3P and its modification create a new layered zeolite sub‐family belonging to the MWW family. FTIR data indicate that (Al)MWW materials MCM‐22 and IPC‐3 with Si/Al ratios greater than 20 exhibit a lower relative ratio of Brønsted to Lewis acid sites than MCM‐22 (with Si/Al ratios of around 13), that is, less than 2 versus more than 3, respectively. This is maintained even upon pillaring and warrants further exploration of materials like IPC‐3P with a higher Al content. The unique XRD features of IPC‐3P indicating misaligned stacking of layers and distinct from MCM‐22P, are also seen in other MWW materials such as EMM‐10P, hexamethonium‐templated (HM)‐MCM‐22, ITQ‐30, and UZM‐8 suggesting the need for more detailed study of their identity and properties.     

Revealing shape selectivity and catalytic activity trends within the pores of H-ZSM-5 crystals by time- and space-resolved optical and fluorescence microspectroscopy

A combination of in-situ optical and fluorescence microspectroscopy has been employed to investigate the oligomerization of styrene derivatives occurring in the micropores of coffin-shaped H-ZSM-5 zeolite crystals in a space- and time-resolved manner. The carbocationic intermediates in this reaction act as reporter molecules for catalytic activity, since they exhibit strong optical absorption and fluorescence. In this way, reactant selectivity and restricted transition-state selectivity for 14 substituted styrene molecules can be visualized and quantified. Based on a thorough analysis of the time- and space-resolved UV/Vis spectra, it has been revealed that two main parameters affect the reaction rates, namely, the carbocation stabilization effect and the diffusion hindrance. The stabilization effect was tested by comparison of the reaction rates for 4-methoxystyrene versus 4-methylstyrene and in the series 4-bromo-, 4-chloro and 4-fluorostyrene; in both cases less electronegative substituents were found to accelerate the reaction. As to the steric effect, bulkier chemical groups bring down the reaction rate, as evident from the observation that 4-methoxystyrene is more reactive than 4-ethoxystyrene due to differences in their diffusivity, while heavily substituted styrenes, such as 3,4-dichlorostyrene and 2,3,4,5,6-pentafluorostyrene, cannot enter the zeolite pore system and therefore do not display any reactivity. Furthermore, beta-methoxystyrene and trans-beta-methylstyrene show limited reactivity as well as restricted reaction-product formation due to steric constraints imposed by the H-ZSM-5 channel system. Finally, polarized-light optical microspectroscopy and fluorescence microscopy demonstrate that dimeric styrene compounds are predominantly formed and aligned within the straight channels at the edges of the crystals, whereas a large fraction of trimeric carbocations along with dimeric compounds are present in the straight channels of the main body of the H-ZSM-5 crystals. Our results reinforce the observation of a non-uniform catalytic behavior within zeolite crystals, with specific parts of the zeolite grains being less accessible and reactive towards reactant molecules. The prospects and potential of this combined in-situ approach for studying large zeolite crystals in the act will be discussed.     

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.     

Probing the Different Life Stages of a Fluid Catalytic Cracking Particle with Integrated Laser and Electron Microscopy

While cycling through a fluid catalytic cracking (FCC) unit, the structure and performance of FCC catalyst particles are severely affected. In this study, we set out to characterize the damage to commercial equilibrium catalyst particles, further denoted as ECat samples, and map the different pathways involved in their deactivation in a practical unit. The degradation was studied on a structural and a functional level. Transmission electron microscopy (TEM) of ECat samples revealed several structural features; including zeolite crystals that were partly or fully severed, mesoporous, macroporous, and/or amorphous. These defects were then correlated to structural features observed in FCC particles that were treated with different levels of hydrothermal deactivation. This allowed us not only to identify which features observed in ECat samples were a result of hydrothermal deactivation, but also to determine the severity of treatments resulting in these defects. For functional characterization of the ECat sample, the Brønsted acidity within individual FCC particles was studied by a selective fluorescent probe reaction with 4‐fluorostyrene. Integrated laser and electron microscopy (iLEM) allowed correlating this Brønsted acidity to structural features by combining a fluorescence and a transmission electron microscope in a single set‐up. Together, these analyses allowed us to postulate a plausible model for the degradation of zeolite crystals in FCC particles in the ECat sample. Furthermore, the distribution of the various deactivation processes within particles of different ages was studied. A rim of completely deactivated zeolites surrounding each particle in the ECat sample was identified by using iLEM. These zeolites, which were never observed in fresh or steam‐deactivated samples, contained clots of dense structures. The structures are proposed to be carbonaceous deposits formed during the cracking process, and seem resistant towards burning off during catalyst regeneration.     

X‐ray Excited Optical Fluorescence and Diffraction Imaging of Reactivity and Crystallinity in a Zeolite Crystal: Crystallography and Molecular Spectroscopy in One

Structure–activity relationships in heterogeneous catalysis are challenging to be measured on a single‐particle level. For the first time, one X‐ray beam is used to determine the crystallographic structure and reactivity of a single zeolite crystal. The method generates μm‐resolved X‐ray diffraction (μ‐XRD) and X‐ray excited optical fluorescence (μ‐XEOF) maps of the crystallinity and Brønsted reactivity of a zeolite crystal previously reacted with a styrene probe molecule. The local gradients in chemical reactivity (derived from μ‐XEOF) were correlated with local crystallinity and framework Al content, determined by μ‐XRD. Two distinctly different types of fluorescent species formed selectively, depending on the local zeolite crystallinity. The results illustrate the potential of this approach to resolve the crystallographic structure of a porous material and its reactivity in one experiment via X‐ray induced fluorescence of organic molecules formed at the reactive centers.     

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.     

Insight into Three‐Coordinate Aluminum Species on Ethanol‐to‐Olefin Conversion over ZSM‐5 Zeolites

Commercial bioethanol can be readily converted into ethylene by a dehydration process using solid acids, such as Brønsted acidic H‐ZSM‐5 zeolites, and thus, it is an ideal candidate to replace petroleum and coal for the sustainable production of ethylene. Now, strong Lewis acidic extra‐framework three‐coordinate Al³⁺ species were introduced into H‐ZSM‐5 zeolites to improve their catalytic activity. Remarkably, Al³⁺ species working with Brønsted acid sites can accelerate ethanol dehydration at a much lower reaction temperature and shorten the unsteady‐state period within 1–2 h, compared to >9 h for those without Al³⁺ species, which can significantly enhance the ethanol dehydration efficiency and reduce the cost. The reaction mechanism, studied by solid‐state NMR, shows that strong Lewis acidic EFAl‐Al³⁺ species can collaborate with Brønsted acid sites and promote ethanol dehydration either directly or indirectly via an aromatics‐based cycle to produce ethylene.     

Brønsted Acid Catalyzed Friedel–Crafts‐Type Coupling and Dedinitrogenation Reactions of Vinyldiazo Compounds

The direct Friedel–Crafts‐type coupling and dedinitrogenation reactions of vinyldiazo compounds with aromatic compounds using a metal‐free strategy are described. This Brønsted acid catalyzed method is efficient for the formation of α‐diazo β‐carbocations (vinyldiazonium ions), vinyl carbocations, and allylic or homoallylic carbocation species via vinyldiazo compounds. By choosing suitable nucleophilic reagents to selectively capture these intermediates, both trisubstituted α,β‐unsaturated esters, β‐indole‐substituted diazo esters, and dienes are obtained with good to high yields and selectivity. Experimental insights implicate a reaction mechanism involving the selective protonation of vinyldiazo compounds and the subsequent release of dinitrogen to form vinyl cations that undergo intramolecular 1,3‐ and 1,4‐ hydride transfer processes as well as fragmentation.     

Dispersion and Orientation of Zeolite ZSM‐5 Crystallites within a Fluid Catalytic Cracking Catalyst Particle

Confocal fluorescence microscopy was employed to selectively visualize the dispersion and orientation of zeolite ZSM‐5 domains inside a single industrially applied fluid catalytic cracking (FCC) catalyst particle. Large ZSM‐5 crystals served as a model system together with the acid‐catalyzed fluorostyrene oligomerization reaction to study the interaction of plane‐polarized light with these anisotropic zeolite crystals. The distinction between zeolite and binder material, such as alumina, silica, and clay, within an individual FCC particle was achieved by utilizing the anisotropic nature of emitted fluorescence light arising from the entrapped fluorostyrene‐derived carbocations inside the zeolite channels. This characterization approach provides a non‐invasive way for post‐synthesis characterization of an individual FCC catalyst particle in which the size, distribution, orientation, and amount of zeolite ZSM‐5 aggregates can be determined. It was found that the amount of detected fluorescence light originating from the stained ZSM‐5 aggregates corresponds to about 15 wt %. Furthermore, a statistical analysis of the emitted fluorescence light indicated that a large number of the ZSM‐5 domains appeared in small sizes of about 0.015–0.25 μm², representing single zeolite crystallites or small aggregates thereof. This observation illustrated a fairly high degree of zeolite dispersion within the FCC binder material. However, the highest amount of crystalline material was aggregated into larger domains (ca. 1–5 μm²) with more or less similarly oriented zeolite crystallites. It is clear that this visualization approach may serve as a post‐synthesis quality control on the dispersion of zeolite ZSM‐5 crystallites within FCC particles.