Understanding Zeolites Catalyzed Methanol‐to‐Olefins Conversion from Theoretical Calculations

Zeolites catalyzed methanol‐to‐olefins (MTO) conversion provides an alternative process to produce light olefins such as ethene and propene from nonpetroleum resources. Despite of successful industrialization of the MTO process, its detailed reaction mechanism is not yet well understood. Here we summarize our work on the hydrocarbon pool reaction mechanism based on theoretical calculations. We proposed that the olefins themselves are likely to be the dominating hydrocarbon pool species, and the distribution of cracking precursors and diffusion constraints affect the selectivity. The similarities between aromatic‐based and olefin‐based cycles are highlighted.     

New Insight into the Hydrocarbon‐Pool Chemistry of the Methanol‐to‐Olefins Conversion over Zeolite H‐ZSM‐5 from GC‐MS,Solid‐State NMR Spectroscopy,and DFT Calculations

Over zeolite H‐ZSM‐5, the aromatics‐based hydrocarbon‐pool mechanism of methanol‐to‐olefins (MTO) reaction was studied by GC‐MS, solid‐state NMR spectroscopy, and theoretical calculations. Isotopic‐labeling experimental results demonstrated that polymethylbenzenes (MBs) are intimately correlated with the formation of olefin products in the initial stage. More importantly, three types of cyclopentenyl cations (1,3‐dimethylcyclopentenyl, 1,2,3‐trimethylcyclopentenyl, and 1,3,4‐trimethylcyclopentenyl cations) and a pentamethylbenzenium ion were for the first time identified by solid‐state NMR spectroscopy and DFT calculations under both co‐feeding ([¹³C₆]benzene and methanol) conditions and typical MTO working (feeding [¹³C]methanol alone) conditions. The comparable reactivity of the MBs (from xylene to tetramethylbenzene) and the carbocations (trimethylcyclopentenyl and pentamethylbenzium ions) in the MTO reaction was revealed by ¹³C‐labeling experiments, evidencing that they work together through a paring mechanism to produce propene. The paring route in a full aromatics‐based catalytic cycle was also supported by theoretical DFT calculations.     

Initial Carbon–Carbon Bond Formation during the Early Stages of the Methanol‐to‐Olefin Process Proven by Zeolite‐Trapped Acetate and Methyl Acetate

Methanol‐to‐olefin (MTO) catalysis is a very active field of research because there is a wide variety of sometimes conflicting mechanistic proposals. An example is the ongoing discussion on the initial C?C bond formation from methanol during the induction period of the MTO process. By employing a combination of solid‐state NMR spectroscopy with UV/Vis diffuse reflectance spectroscopy and mass spectrometry on an active H‐SAPO‐34 catalyst, we provide spectroscopic evidence for the formation of surface acetate and methyl acetate, as well as dimethoxymethane during the MTO process. As a consequence, new insights in the formation of the first C?C bond are provided, suggesting a direct mechanism may be operative, at least in the early stages of the MTO reaction.     

A Dynamic Kinetic Model for Methanol to Light Olefins Reactions over a Nanohierarchical SAPO‐34 Catalyst: Catalyst Synthesis,Model Presentation,and Validation at the Bench Scale

This study includes three main parts: synthesizing the hierarchical silicoaluminophosphate (SAPO‐34) catalyst, evaluating the performance of this modified catalyst in the methanol to light olefins (MTO) process, and providing a new dynamic kinetic model for the modified catalyst. At first, a carbon nanotube (CNT) was used as a mesopore template in the sonochemical synthesis of SAPO‐34 hierarchical catalyst. By comparing the performance of this hierarchical catalyst and the common catalyst in the MTO process, it is observed that better performance is obtained on a modified catalysts for a longer period of time. Then, nine process tests were performed in differential fixed bed reactors at different temperatures and space velocities to obtain the kinetic model of the desired catalyst in the MTO process. Finally, the dynamic kinetic model of the modified SAPO‐34 catalyst was considered for main reactions in the MTO process. In this model, the rate equations were assumed elementary and lumped, and the decreasing of the catalyst activity over time on stream was also considered. The reactions constant and catalyst activity coefficient for different reactions were obtained by simultaneous connection of the code related to the reactor model and the genetic algorithm and genetic programming codes. The results obtained from the kinetic model were consistent with the experimental results.     

Quantum‐Chemical Study of the FeNCN Conversion‐Reaction Mechanism in Lithium‐ and Sodium‐Ion Batteries

We report a computational study on 3d transition‐metal (Cr, Mn, Fe, and Co) carbodiimides in Li‐ and Na‐ion batteries. The obtained cell voltages semi‐quantitatively fit the experiments, highlighting the practicality of PBE+U as an approach for modeling the conversion‐reaction mechanism of the FeNCN archetype with lithium and sodium. Also, the calculated voltage profiles agree satisfactorily with experiment both for full (Li‐ion battery) and partial (Na‐ion battery) discharge, even though experimental atomistic knowledge is missing up to now. Moreover, we rationalize the structural preference of intermediate ternaries and their characteristic lowering in the voltage profile using chemical‐bonding and Mulliken‐charge analysis. The formation of such ternary intermediates for the lithiation of FeNCN and the contribution of at least one ternary intermediate is also confirmed experimentally. This theoretical approach, aided by experimental findings, supports the atomistic exploration of electrode materials governed by conversion reactions.     

Single‐Particle Spectroscopy on Large SAPO‐34 Crystals at Work: Methanol‐to‐Olefin versus Ethanol‐to‐Olefin Processes

The formation of hydrocarbon pool (HCP) species during methanol‐to‐olefin (MTO) and ethanol‐to‐olefin (ETO) processes have been studied on individual micron‐sized SAPO‐34 crystals with a combination of in situ UV/Vis, confocal fluorescence, and synchrotron‐based IR microspectroscopic techniques. With in situ UV/Vis microspectroscopy, the intensity changes of the λ=400 nm absorption band, ascribed to polyalkylated benzene (PAB) carbocations, have been monitored and fitted with a first‐order kinetics at low reaction temperatures. The calculated activation energy (E_a) for MTO, approximately 98 kJ mol^?1, shows a strong correlation with the theoretical values for the methylation of aromatics. This provides evidence that methylation reactions are the rate‐determining steps for the formation of PAB. In contrast for ETO, the E_a value is approximately 60 kJ mol^?1, which is comparable to the E_a values for the condensation of light olefins into aromatics. Confocal fluorescence microscopy demonstrates that during MTO the formation of the initial HCP species are concentrated in the outer rim of the SAPO‐34 crystal when the reaction temperature is at 600 K or lower, whereas larger HCP species are gradually formed inwards the crystal at higher temperatures. In the case of ETO, the observed egg‐white distribution of HCP at 509 K suggests that the ETO process is kinetically controlled, whereas the square‐shaped HCP distribution at 650 K is indicative of a diffusion‐controlled process. Finally, synchrotron‐based IR microspectroscopy revealed a higher degree of alkylation for aromatics for MTO as compared to ETO, whereas high reaction temperatures favor dealkylation processes for both the MTO and ETO processes.     

Ortho‐Alkylation of Phenol with Methanol Using Pb‐Cr Promoted Magnesium Oxide Catalysts

In this study, Pb‐Cr promoted magnesium oxide catalysts were used to catalyze the ortho‐alkylation of phenol in the presence of excess methanol. The Cr/MgO catalyst exhibited a high conversion of phenol and a relatively high selectivity for the ortho‐alkylation of phenol. The catalytic activity and the stability of Cr/MgO were improved by the addition of a fairly small amount of Pb. The Pb‐Cr/MgO catalyst showed specificity for the ortho‐alkylation of phenol, which was proved by a series of phenol derivative reactions with methanol.     

Fabrication of SAPO‐34 with Tuned Mesopore Structure

Crystalline SAPO‐34 molecular sieves with hierarchical network were synthesized employing polyethylene glycol (PEG) as the meso‐generating agent via a self‐assembly strategy. XRD, FESEM, N₂ adsorption‐desorption and FT‐IR spectroscopic analyses showed that PEG co‐template has a decisive role in tailoring the pore structure and producing a tuned structure from microporous towards the mesoporous structure. Also, addition of PEG favored the formation of more uniform and smaller crystals than the conventional SAPO‐34. In fact, PEG did not only control the size of crystals due to its crystal growth inhibiting (CGI) effect but also modified the morphology of the crystals and improved CSD (crystal size distribution) along with induction of mesopores into the porous structure. The modified SAPO‐34 would be recommended for selective formation of light olefins through the acid‐catalyzed reactions, such as the conversion of methanol to olefins/propylene (MTO/MTP) and propane dehydrogenation (PDH) to produce olefins with higher selectivity and catalyst stability than the conventional SAPO‐34.     

Cover Picture: Understanding Zeolites Catalyzed Methanol‐to‐Olefins Conversion from Theoretical Calculations (Chin. J. Chem. 5/2018)

The cover picture shows the complexity of the reaction mechanism of zeolites catalyzed methanol‐to‐olefins (MTO) conversion. The MTO process plays a vital role in the production of light olefins from nonpetroleum resources. Despite of the successful industrialization of the MTO process in China, the detailed reaction mechanism is not yet well understood. The theoretical studies on the MTO hydrocarbon pool mechanism by the Group of Xie are summarized in the Chemistry Author Up Close by Xie et al. on page 381–386.

     

High Ethylene Selectivity in Methanol‐to‐Olefin (MTO) Reaction over MOR‐Zeolite Nanosheets

Precisely controlled crystal growth endows zeolites with special textural and catalytic properties. A nanosheet mordenite zeolite with a thickness of ca. 11 nm, named as MOR‐NS, has been prepared using a well‐designed gemini‐type amphiphilic surfactant as bifunctional structure‐directing agent (SDA). Its benzyl diquarternary ammonium cations structurally directed the formation of MOR topology, whereas the long and hydrophobic hexadecyl tailing group prevented the extensive crystal growth along b axis. This kind of orientated crystallization took place through the inorganic–organic interaction between silica species and SDA molecules present in the whole process. The thin MOR nanosheets, with highly exposed (010) planes and 8‐membered ring (MR) windows, exhibited a much improved ethylene selectivity (42.1 %) for methanol‐to‐olefin (MTO) reactions when compared with conventional bulk MOR crystals (3.3 %).     

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.     

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.     

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.     

CO2‐to‐Methanol Hydrogenation on Zirconia‐Supported Copper Nanoparticles: Reaction Intermediates and the Role of the Metal–Support Interface

Methanol synthesis by CO₂ hydrogenation is a key process in a methanol‐based economy. This reaction is catalyzed by supported copper nanoparticles and displays strong support or promoter effects. Zirconia is known to enhance both the methanol production rate and the selectivity. Nevertheless, the origin of this observation and the reaction mechanisms associated with the conversion of CO₂ to methanol still remain unknown. A mechanistic study of the hydrogenation of CO₂ on Cu/ZrO₂ is presented. Using kinetics, in situ IR and NMR spectroscopies, and isotopic labeling strategies, surface intermediates evolved during CO₂ hydrogenation were observed at different pressures. Combined with DFT calculations, it is shown that a formate species is the reaction intermediate and that the zirconia/copper interface is crucial for the conversion of this intermediate to methanol.     

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.     

Formation Mechanism of the First Carbon–Carbon Bond and the First Olefin in the Methanol Conversion into Hydrocarbons

The elementary reactions leading to the formation of the first carbon–carbon bond during early stages of the zeolite‐catalyzed methanol conversion into hydrocarbons were identified by combining kinetics, spectroscopy, and DFT calculations. The first intermediates containing a C?C bond are acetic acid and methyl acetate, which are formed through carbonylation of methanol or dimethyl ether even in presence of water. A series of acid‐catalyzed reactions including acetylation, decarboxylation, aldol condensation, and cracking convert those intermediates into a mixture of surface bounded hydrocarbons, the hydrocarbon pool, as well as into the first olefin leaving the catalyst. This carbonylation based mechanism has an energy barrier of 80 kJ mol^?1 for the formation of the first C?C bond, in line with a broad range of experiments, and significantly lower than the barriers associated with earlier proposed mechanisms.     

Atom transfer radical polymerization of n‐butyl acrylate catalyzed by CuBr/N‐(n‐hexyl)‐2‐pyridylmethanimine

The homogeneous atom transfer radical polymerization (ATRP) of n‐butyl acrylate with CuBr/N‐(n‐hexyl)‐2‐pyridylmethanimine as a catalyst and ethyl 2‐bromoisobutyrate as an initiator was investigated. The kinetic plots of ln([M]₀/[M]) versus the reaction time for the ATRP systems in different solvents such as toluene, anisole, N,N‐dimethylformamide, and 1‐butanol were linear throughout the reactions, and the experimental molecular weights increased linearly with increasing monomer conversion and were very close to the theoretical values. These, together with the relatively narrow molecular weight distributions (polydispersity index ～ 1.40 in most cases with monomer conversion > 50%), indicated that the polymerization was living and controlled. Toluene appeared to be the best solvent for the studied ATRP system in terms of the polymerization rate and molecular weight distribution among the solvents used. The polymerization showed zero order with respect to both the initiator and the catalyst, probably because of the presence of a self‐regulation process at the beginning of the reaction. The reaction temperature had a positive effect on the polymerization rate, and the optimum reaction temperature was found to be 100 °C. An apparent enthalpy of activation of 81.2 kJ/mol was determined for the ATRP of n‐butyl acrylate, corresponding to an enthalpy of equilibrium of 63.6 kJ/mol. An apparent enthalpy of activation of 52.8 kJ/mol was also obtained for the ATRP of methyl methacrylate under similar reaction conditions. Moreover, the CuBr/N‐(n‐hexyl)‐2‐pyridylmethanimine‐based system was proven to be applicable to living block copolymerization and living random copolymerization of n‐butyl acrylate with methyl methacrylate. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3549–3561, 2002     

调变 MTO反应中双循环机理的比重：ZSM-5分子筛上不同接触时间的作用

低碳烯烃(乙烯、丙烯和丁烯)是重要的有机化工原料,是现代石油化工的基础,主要通过石脑油裂解和烷烃脱氢制备。现阶段我国原油对外依存度已超过60%,“多煤、缺油、少气”的能源现状决定了以煤或天然气为原料经甲醇制取石化产品成为一种重要的替代途径。甲醇制取低碳烯烃(MTO)过程成为连接煤化工和石油化工的桥梁。 ZSM-5分子筛以其高效的甲醇转化能力、优异的低碳烯烃选择性和出色的抗积碳性能成为非常理想的 MTO反应催化剂。研究发现 ZSM-5分子筛催化 MTO反应过程中,乙烯的生成规律与其它 C3–C7链状烯烃不一致,认为乙烯主要来源于芳烃缩环/扩环循环,而 C3–C7链状烯烃主要来源于烯烃甲基化/裂解循环,两种循环同时存在。本文于300°C在 ZSM-5分子筛上进行 MTO反应,通过考察不同空速(WHSV)条件下的 MTO反应性能和分析催化剂内留存物种的生成和所起的作用,研究甲醇转化机理。气相流出物种和催化剂内留存物种的分析表明, ZSM-5分子筛催化 MTO反应时遵循双循环机理——以多甲基苯和多甲基环戊二烯为主要活性物种的芳烃循环机理和以链状烯烃为主要活性物种的烯烃循环机理。在双循环机理中,芳烃循环和烯烃循环并不是简单叠加,而是相互影响,芳烃循环产生的烯烃可以作为烯烃循环的活性物种促进烯烃循环,烯烃循环中较高级的烯烃经过环化、氢转移作用,能够转化成富氢的烷烃和贫氢的芳烃、环戊二烯物种,贫氢的芳烃和环戊二烯物种又可以作为芳烃循环的主要物种促进芳烃循环的进行。氢转移反应是联系烯烃循环和芳烃循环的重要过程,与反应过程中原料甲醇与催化剂床层的接触时间有关,12C/13C甲醇切换实验揭示了双循环机理与氢转移反应的相关性,通过调变原料甲醇与催化剂床层的接触时间,可以调变氢转移反应的剧烈程度,进而对催化剂上芳烃循环和烯烃循环的甲醇转化能力产生不同的影响。当空速较低时,进料甲醇与催化剂床层的接触时间较长,有利于产物烯烃的氢转移反应,加速了分子筛催化剂上芳烃物种和环戊二烯物种的生成和累积,促进了芳烃循环,主要由芳烃循环生成的乙烯和多甲基苯的气相选择性提高;反之,当空速较高时,进料甲醇与催化剂床层的接触时间减少,产物烯烃的氢转移反应受到抑制,氢转移反应的产物——芳烃和环戊二烯物种的生成数量和累积速率降低,芳烃循环活性不高,使得烯烃循环成为甲醇转化的主要途径, C3–C7烯烃显示出更高的活性,在气相流出物种中的选择性也更高。总之,原料甲醇与催化剂床层的接触时间能够显著影响催化剂内留存物种的生成和累积,进而改变两种循环的比重。这些发现对于实现 ZSM-5分子筛催化 MTO反应过程中的产物烯烃和芳烃的选择性调控具有重要意义。     

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.     

Structured catalysts for methanol-to-olefins conversion: a review

Conversion of methanol to light olefins is a promising alternative for the conversion of new feed-stocks such as gas, coal or biomass to ethylene and propylene via the methanol-to-olefins (MTO) process. During the last decade, the use of structured catalysts in this reaction has received increasing attention. The effect of such structured catalysts on the stability and selectivity is discussed in this review. The reaction and coking mechanism show the importance of good mass transfer properties of the catalyst in the MTO reaction. Important aspects such as thickness of the coating, crystal size of the zeolite and architecture of the support on the mass transfer properties of the final catalyst are highlighted. An overview of the results of structured catalysts used in the MTO reaction is presented.