Engineering Selective and Stable Methanol to Olefins Catalysts

ChemE/Catalysis Engineerin

Progress in Developing a Structure-Activity Relationship for the Direct Aromatization of Methane

To secure future supply of aromatics, methane is a commercially interesting alternative feedstock. Direct conversion of methane into aromatics combines the challenge of activating one of the strongest C-H bonds in all hydrocarbons with the selective aromatization over zeolites. To address these challenges, smart catalyst and process design are a must. And for that, understanding the most important factors leading to successful methane C-H bond activation and selective aromatization is needed. In this review, we summarize mechanistic insight that has been gained so far not only for this reaction, but also for other similar processes involving aromatization reactions over zeolites. With that, we highlight what can be learnt from similar processes. In addition, we provide an overview of characterization tools and strategies, which are useful to gain structural information about this particular metal-zeolite system at reaction conditions. Here we also aim to inspire future characterization work, by giving an outlook on characterization strategies that have not yet been applied for the methane dehydroaromatization catalyst, but are promising for this system.Accepted Author ManuscriptChemE/Catalysis Engineerin

The importance of heat effects in the Methanol to Hydrocarbons reaction over ZSM-5: on the role of mesoporosity on catalyst performance

Interpretation of catalytic performance during the MTH process is hampered by heat transport phenomena. We demonstrate that large temperature rises can occur during fixed bed labscale catalyst testing of ZSM-5, even when a large catalyst bed dilution is applied. Formation of mesopores in ZSM-5 leads to partial mitigation of these effects because of a lower generation of heat per unit catalyst volume and weakening of the zeolite acidity.ChemE/Catalysis Engineerin

Consequences of secondary zeolite growth on catalytic performance in DMTO studied over DDR and CHA

Zeolites with DDR (Sigma-1 and ZSM-58) and CHA (SSZ-13) topology were synthesized by seed assisted and direct hydrothermal synthesis in order to investigate the effects of fast crystal growth on catalytic performance. Application of small amount of seeds (0.1% wt) significantly reduced synthesis time of all the studied zeolites. XRD and NH3-TPD analyses did not reveal any difference in crystallinity and acidity. On the other hand, IR spectroscopy clearly demonstrates the presence of multiple defects, internal silanols (3729 cm-1) and silanol nests (3400 cm-1), as a result of accelerated crystal growth kinetics. Comparison of catalytic properties in the dimethyl ether to olefins (DMTO) reaction at 400°C and 450°C revealed that, despite smaller crystal sizes, zeolites prepared by secondary growth display shorter lifetimes due to faster coking rates, the latter being a result of silanols promoting hydrogen transfer reactions. Fluoride treatment of CHA removed silanols and prolonged its lifetime. This work highlights the importance of zeolite quality for catalytic application and the necessity to optimize current synthetic protocols based on secondary growth.ChemE/Catalysis Engineerin

Quantifying the impact of dispersion, acidity and porosity of Mo/HZSM-5 on the performance in methane dehydroaromatization

The catalytic performance of the bifunctional catalyst Mo/HZSM-5 for methane dehydroaromatization (MDA) depends on the Mo dispersion and on zeolite acidity. Here we separately quantify the effect of dispersion and the effect of acidity on aromatic yields and coke selectivity. Also, the effect of porosity on the same is quantitatively assessed. For that, a suite of 17 samples with varying Mo dispersion were synthesized by means of several methods, including chemical vapor deposition with MoCl 5 , MoO 2 Cl 2 and Mo(CO) 6 as precursors and the conventional methods, incipient wetness impregnation and solid ion exchange. These catalysts were characterized with pyridine IR-spectroscopy, XPS, UV–vis spectroscopy, N 2 adsorption, XRD, TGA and 27 Al MAS NMR. The combined results yielded a measure of how much Mo is anchored to the zeolite as well-defined cationic species and how much is present as bigger clusters on the outer surface of the zeolite. Through relating these characterization results to the catalytic behavior of the catalysts, it was found that the maximum instantaneous benzene and naphthalene yields as well as the integral selectivities during methane dehydroaromatization linearly increase with the amount of Mo present as mono- or dimeric species. At the same time, the selectivity to coke increases with the amount of Mo present as bigger clusters or nanoparticles on the outer surface of the zeolite. The number of Mo cationic sites is the most important factor determining the activity of Mo/HZSM-5 for low loadings of Mo. But at higher loadings, the high rate of aromatics formation requires an easily accessible pore structure as well. ChemE/Catalysis EngineeringApplied Science

Revealing Lattice Expansion of Small-Pore Zeolite Catalysts during the Methanol-to-Olefins Process Using Combined Operando X-ray Diffraction and UV-vis Spectroscopy

In small-pore zeolite catalysts, where the size of the pores is limited by eight-ring windows, aromatic hydrocarbon pool molecules that are formed inside the zeolite during the Methanol-to-Olefins (MTO) process cannot exit the pores and are retained inside the catalyst. Hydrocarbon species whose size is comparable to the size of the zeolite cage can cause the zeolite lattice to expand during the MTO process. In this work, the formation of retained hydrocarbon pool species during MTO at a reaction temperature of 400 °C was followed using operando UV-vis spectroscopy. During the same experiment, using operando X-ray Diffraction (XRD), the expansion of the zeolite framework was assessed, and the activity of the catalyst was measured using online gas chromatography (GC). Three different small-pore zeolite frameworks, i.e., CHA, DDR, and LEV, were compared. It was shown using operando XRD that the formation of retained aromatic species causes the zeolite lattice of all three frameworks to expand. Because of the differences in the zeolite framework dimensions, the nature of the retained hydrocarbons as measured by operando UV-vis spectroscopy is different for each of the three zeolite frameworks. Consequently, the magnitude and direction of the zeolite lattice expansion as measured by operando XRD also depends on the specific combination of the hydrocarbon species and the zeolite framework. The catalyst with the CHA framework, i.e., H-SSZ-13, showed the biggest expansion: 0.9% in the direction along the c-axis of the zeolite lattice. For all three zeolite frameworks, based on the combination of operando XRD and operando UV-vis spectroscopy, the hydrocarbon species that are likely to cause the expansion of the zeolite cages are presented; methylated naphthalene and pyrene in CHA, 1-methylnaphthalene and phenalene in DDR, and methylated benzene and naphthalene in LEV. Filling of the zeolite cages and, as a consequence, the zeolite lattice expansion causes the deactivation of these small-pore zeolite catalysts during the MTO process.ChemE/Catalysis Engineerin

Facile manufacture of porous organic framework membranes for precombustion CO₂ capture

The development of new membranes with high H2 separation performance under industrially relevant conditions (high temperatures and pressures) is of primary importance. For instance, these membranes may facilitate the implementation of energy-efficient precombustion CO2 capture or reduce energy intensity in other industrial processes such as ammonia synthesis. We report a facile synthetic protocol based on interfacial polymerization for the fabrication of supported benzimidazole-linked polymer membranes that display an unprecedented H2/CO2 selectivity (up to 40) at 423 K together with high-pressure resistance and long-term stability (>800 hours in the presence of water vapor).ChemE/Catalysis EngineeringChemE/Transport Phenomen

Insights into the Activity and Deactivation of the Methanol-to-Olefins Process over Different Small-Pore Zeolites As Studied with Operando UV-vis Spectroscopy

The nature and evolution of the hydrocarbon pool (HP) species during the Methanol-to-Olefins (MTO) process for three small-pore zeolite catalysts, with a different framework consisting of large cages interconnected by small eight-ring windows (CHA, DDR, and LEV) was studied at reaction temperatures between 350 and 450 °C using a combination of operando UV-vis spectroscopy and online gas chromatography. It was found that small differences in cage size, shape, and pore structure of the zeolite frameworks result in the generation of different hydrocarbon pool species. More specifically, it was found that the large cage of CHA results in the formation of a wide variety of hydrocarbon pool species, mostly alkylated benzenes and naphthalenes. In the DDR cage, 1-methylnaphthalene is preferentially formed, while the small LEV cage generally contains fewer hydrocarbon pool species. The nature and evolution of these hydrocarbon pool species was linked with the stage of the reaction using a multivariate analysis of the operando UV-vis spectra. In the 3-D pore network of CHA, the reaction temperature has only a minor effect on the performance of the MTO catalyst. However, for the 2-D pore networks of DDR and LEV, an increase in the applied reaction temperature resulted in a dramatic increase in catalytic activity. For all zeolites in this study, the role of the hydrocarbon species changes with reaction temperature. This effect is most clear in DDR, in which diamantane and 1-methylnaphthalene are deactivating species at a reaction temperature of 350 °C, whereas at higher temperatures diamantane formation is not observed and 1-methylnaphthalene is an active species. This results in a different amount and nature of coke species in the deactivated catalyst, depending on zeolite framework and reaction temperature.ChemE/Catalysis Engineerin

Relevance of the Mo-precursor state in H-ZSM-5 for methane dehydroaromatization

Although the local geometry of Mo in Mo/HZSM-5 has been characterized before, we present a systematic way to manipulate the configuration of Mo and link it to its catalytic properties. The location and geometry of cationic Mo-complexes, the precursor of the active metal site for methane dehydroaromatization, are altered by directing the way they anchor to the framework of the zeolite. The feature used to direct the anchoring of Mo is the location of Al in the zeolite framework. According to DFT calculations, the local geometry of Mo should change, while UV-vis and pyridine FTIR spectroscopy indicated differences in the dispersion of Mo. Both aspects, however, did not influence the catalytic behavior of Mo/HZSM-5, indicating that as long as enough isolated Mo species are present inside the pores of the zeolite, the catalytic behavior is unaffected. This paves the way to better understand how the Mo oxo precursor transforms into the active phase under the reaction conditions.Accepted Author ManuscriptChemE/Catalysis Engineerin

Benzimidazole linked polymers (BILPs) in mixed-matrix membranes: Influence of filler porosity on the CO₂/N₂ separation performance

The performance of mixed-matrix membranes (MMMs) based on Matrimid® and benzimidazole-linked polymers (BILPs) have been investigated for the separation CO2/N2 and the dependency on the filler porosity. BILPs with two different porosities (BILP-101 and RT-BILP-101) were synthesized through controlling the initial polymerization rate and further characterized by several techniques (DRIFTs, 13C CP/MAS NMR, SEM, TEM, N2 and CO2 adsorption). To investigate the influence of porosity, the two types of fillers were incorporated into Matrimid® to prepare MMMs at varied loadings (8, 16 and 24 wt%). SEM confirmed that both BILP-101 and RT-BILP-101 are well dispered, indicating their good compatibility with the polymeric matrix. The partial pore blockage in the membrane was verified by CO2 adsorption isotherms on the prepared membranes. In the separation of CO2 from a 15:85 CO2:N2 mixture at 308 K, the incorporation of both BILPs fillers resulted in an enhancement in gas permeability together with constant selectivity owing to the fast transport pathways introduced by the porous network. It was noteworthy that the initial porosity of the filler had a large impact in separation permeability. The best improvement was achieved by 24 wt% RT-BILP-101 MMMs, for which the CO2 permeability increases up to 2.8-fold (from 9.6 to 27 Barrer) compared to the bare Matrimid®.Accepted Author ManuscriptChemE/Catalysis EngineeringChemE/Transport Phenomen