Ethylbenzene to chemicals: Catalytic conversion of ethylbenzene into styrene over metal-containing MCM-41

Isomorphously substituted (MeDM) and impregnated metal-containing MCM-41 (MeO_x/IM) catalysts, in which Me = Co, Cu, Cr, Fe or Ni, have been prepared. Structural and textural characterizations of the catalysts were performed by means of X-ray diffraction (XRD), chemical analysis, Raman spectroscopy, electron paramagnetic resonance (EPR), N₂ adsorption isotherms and temperature programmed reduction (TPR). Cu²⁺, Co²⁺, and Cr⁴⁺/Cr³⁺ species were found over the catalysts as cations incorporated in the MCM-41 structure (MeDM) or highly dispersed oxides on the surface (MeO_x/IM). The MeDM catalysts exhibited a good performance in the dehydrogenation of ethylbenzene with CO₂. However, MeO_x/IM catalysts had a low performance in styrene production (activity less than 15 × 10^?3 mmol h^?1 and selectivity for styrene less than 80%) due to the high reducibility of the metals species. However, Ni²⁺ or Fe³⁺ coordinated with the MCM-41 framework, as well as NiO_x and Fe₂O₃ extra-framework species, is continuously oxidized by the CO₂ to maintain the active sites for dehydrogenating ethylbenzene. Deactivation studies on the FeDM sample showed that Fe³⁺ species produced active sp² carbon compounds, which are removed by CO₂; the referred sample is catalytically selective for styrene and stable over 24 h of reaction. In contrast, highly active Ni²⁺ and Ni⁰ species produced a large amount of polyaromatic carbonaceous deposits from styrene, as identified by TPO, TG and Raman spectroscopy. An acid–base mechanism is proposed to operate to adsorb ethylbenzene and abstract the β-hydrogen. CO₂ plays a role in furnishing the lattice oxygen to maintain the Fe³⁺ active sites in the dehydrogenation of ethylbenzene to form styrene.