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‐Al₂O₃ 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.     

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 NO_x 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 Cu^II to Cu^I and Cu_xO_y 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 Cu^I 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 Cu^II sites trumps that of Brønsted acid sites for NH₃‐SCR activity.     

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.     

Rapid Synthesis of an Aluminum‐Rich MSE‐Type Zeolite by the Hydrothermal Conversion of an FAU‐Type Zeolite

An aluminum‐rich MSE‐type zeolite (Si/Al is as small as 7) has been successfully synthesized in a remarkably short crystallization period of only 3 days by the hydrothermal conversion of an FAU‐type zeolite, presumably by the assembly of four‐membered‐ring (4‐R) aluminosilicate oligomers supplied by the double 6‐R (D6R) components of the FAU framework with the aid of the structure‐directing agents and seed crystals. The dealuminated version of the aluminum‐rich MSE‐type zeolite showed a high level of coke durability in addition to a significant yield of propylene, which indicates that this novel zeolitic material is suitable for industrial applications as a highly selective and long‐lived catalyst.     

Phosphatation of Zeolite H‐ZSM‐5: A Combined Microscopy and Spectroscopy Study

A variety of phosphated zeolite H‐ZSM‐5 samples are investigated by using a combination of Fourier transfer infrared (FTIR) spectroscopy, single pulse ²⁷Al, ²⁹Si, ³¹P, ¹H‐³¹P cross polarization (CP), ²⁷Al‐³¹P CP, and ²⁷Al 3Q magic angle spinning nuclear magnetic resonance (MAS NMR) spectroscopy, scanning transmission X‐ray microscopy (STXM) and N₂ physisorption. This approach leads to insights into the physicochemical processes that take place during phosphatation. Direct phosphatation of H‐ZSM‐5 promotes zeolite aggregation, as phosphorus does not penetrate deep into the zeolite material and is mostly found on and close to the outer surface of the zeolite, acting as a glue. Phosphatation of pre‐steamed H‐ZSM‐5 gives rise to the formation of a crystalline tridymite AlPO₄ phase, which is found in the mesopores of dealuminated H‐ZSM‐5. Framework aluminum species interacting with phosphorus are not affected by hydrothermal treatment. Dealuminated H‐ZSM‐5, containing AlPO₄, retains relatively more framework Al atoms and acid sites during hydrothermal treatment than directly phosphated H‐ZSM‐5.     

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.     

Integrated Transmission Electron and Single‐Molecule Fluorescence Microscopy Correlates Reactivity with Ultrastructure in a Single Catalyst Particle

Establishing structure–activity relationships in complex, hierarchically structured nanomaterials, such as fluid catalytic cracking (FCC) catalysts, requires characterization with complementary, correlated analysis techniques. An integrated setup has been developed to perform transmission electron microscopy (TEM) and single‐molecule fluorescence (SMF) microscopy on such nanostructured samples. Correlated structure–reactivity information was obtained for 100 nm thin, microtomed sections of a single FCC catalyst particle using this novel SMF‐TEM high‐resolution combination. High reactivity in a thiophene oligomerization probe reaction correlated well with TEM‐derived zeolite locations, while matrix components, such as clay and amorphous binder material, were found not to display activity. Differences in fluorescence intensity were also observed within and between distinct zeolite aggregate domains, indicating that not all zeolite domains are equally active.     

Hexane Cracking over Steamed Phosphated Zeolite H‐ZSM‐5: Promotional Effect on Catalyst Performance and Stability

The nature behind the promotional effect of phosphorus on the catalytic performance and hydrothermal stability of zeolite H‐ZSM‐5 has been studied using a combination of ²⁷Al and ³¹P MAS NMR spectroscopy, soft X‐ray absorption tomography and n‐hexane catalytic cracking, complemented with NH₃ temperature‐programmed desorption and N₂ physisorption. Phosphated H‐ZSM‐5 retains more acid sites and catalytic cracking activity after steam treatment than its non‐phosphated counterpart, while the selectivity towards propylene is improved. It was established that the stabilization effect is twofold. First, the local framework silico‐aluminophosphate (SAPO) interfaces, which form after phosphatation, are not affected by steam and hold aluminum atoms fixed in the zeolite lattice, preserving the pore structure of zeolite H‐ZSM‐5. Second, the four‐coordinate framework aluminum can be forced into a reversible sixfold coordination by phosphate. These species remain stationary in the framework under hydrothermal conditions as well. Removal of physically coordinated phosphate after steam‐treatment leads to an increase in the number of strong acid sites and increased catalytic activity. We propose that the improved selectivity towards propylene during catalytic cracking can be attributed to local SAPO interfaces located at channel intersections, where they act as impediments in the formation of bulky carbenium ions and therefore suppress the bimolecular cracking mechanism.     

New Insights into the Nature of Co‐components and Their Impact on Pd Structure: X‐ray Absorption Studies on Toluene Acetoxylation Catalysts

Co‐components are a powerful tool to tune the performance of catalysts, but their nature and their impact on the catalysts is often controversially discussed. In this study X‐ray absorption spectroscopy (XAS) was employed to elucidate the nature of co‐components and their impact on the catalytic reaction. In anatase‐supported Pd‐based catalysts for the gas‐phase acetoxylation of toluene, less noble co‐components (e.g., Mn, Co, and Sb) spread over the support in their oxidic form and changed their valence state on stream. Incorporated atoms such as C or a small part of the Sb affect the electronic structure of Pd. For the noble Au, only a weak interaction with the support and Pd was observed during time on stream. Only XAS at the K‐edges together with investigations of the Pd L‐edge for a better understanding of the electronic structure, supplemented by STEM for elemental mapping, allow such detailed insights.     

Nanoscale Chemical Imaging of the Reduction Behavior of a Single Catalyst Particle

A closer look : Investigation of the reduction properties of a single Fischer–Tropsch catalyst particle, using in situ scanning transmission X‐ray microscopy with spatial resolution of 35 nm, reveals a heterogeneous distribution of Fe⁰, Fe²⁺, and Fe³⁺ species. Regions of different reduction properties are defined and explained on the basis of local chemical interactions and catalyst morphology.

     

Large Zeolite H‐ZSM‐5 Crystals as Models for the Methanol‐to‐Hydrocarbons Process: Bridging the Gap between Single‐Particle Examination and Bulk Catalyst Analysis

The catalytic, deactivation, and regeneration characteristics of large coffin‐shaped H‐ZSM‐5 crystals were investigated during the methanol‐to‐hydrocarbons (MTH) reaction at 350 and 500 °C. Online gas‐phase effluent analysis and examination of retained material thereof were used to explore the bulk properties of large coffin‐shaped zeolite H‐ZSM‐5 crystals in a fixed‐bed reactor to introduce them as model catalysts for the MTH reaction. These findings were related to observations made at the individual particle level by using polarization‐dependent UV‐visible microspectroscopy and mass spectrometric techniques after reaction in an in situ microspectroscopy reaction cell. Excellent agreement between the spectroscopic measurements and the analysis of hydrocarbon deposits by means of retained hydrocarbon analysis and time‐of‐flight secondary‐ion mass spectrometry of spent catalyst materials was observed. The obtained data reveal a shift towards more condensed coke deposits on the outer zeolite surface at higher reaction temperatures. Zeolites in the fixed‐bed reactor setup underwent more coke deposition than those reacted in the in situ microspectroscopy reaction cell. Regeneration studies of the large zeolite crystals were performed by oxidation in O₂/inert gas mixtures at 550 °C. UV‐visible microspectroscopic measurements using the oligomerization of styrene derivatives as probe reaction indicated that the fraction of strong acid sites decreased during regeneration. This change was accompanied by a slight decrease in the initial conversion obtained after regeneration. H‐ZSM‐5 deactivated more rapidly at higher reaction temperature.     

High‐Silica Zeolite SSZ‐61 with Dumbbell‐Shaped Extra‐Large‐Pore Channels

The synthesis of the high‐silica zeolite SSZ‐61 using a particularly bulky polycyclic structure‐directing agent and the subsequent elucidation of its unusual framework structure with extra‐large dumbbell‐shaped pore openings are described. By using information derived from a variety of X‐ray powder diffraction and electron microscopy techniques, the complex framework structure, with 20 Si atoms in the asymmetric unit, could be determined and the full structure refined. The Si atoms at the waist of the dumbbell are only three‐connected and are bonded to terminal O atoms pointing into the channel. Unlike the six previously reported extra‐large‐pore zeolites, SSZ‐61 contains no heteroatoms in the framework and can be calcined easily. This, coupled with the possibility of inserting a catalytically active center in the channel between the terminal O atoms in place of H⁺, afford SSZ‐61 intriguing potential for catalytic applications.     

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.