Quantification of copper phases, their reducibility and dispersion in doped-CuCl2/Al2O3 catalysts for ethylene oxychlorination.

The comprehensive understanding of the composition, behaviour and reactivity of a catalyst used inside industrial plants is an extremely hard task that is rarely achieved. It requires the use of different spectroscopic techniques, applied under in situ or in operando conditions, and combined with the investigation of the catalyst activity. Often the operating experimental conditions are different from technique to technique and the different results must be compared with care. In the present contribution, we combined in situ XANES/EXAFS, IR spectroscopy of adsorbed CO, CO chemisorption and catalytic tests performed using a pulse reactor in depletive mode. This multitechnical approach resulted in the understanding of the role that dopants (LiCl, KCl, CsCl, MgCl(2) LaCl(3)) have in the nature, relative fraction, reducibility and dispersion of Cu-phases on CuCl(2)/gamma-Al(2)O(3) catalysts for oxychlorination reaction, a key step of the PVC chemistry. In the undoped catalyst two Cu phases coexist: Cu-aluminate and supported CuCl(2), being the latter the only active one [J. Catal., 2000, 189, 91]. EXAFS and XANES highlighted that all dopants contribute more or less efficiently in increasing the fraction of the active copper species, that reaches a value of almost 100% in the case of MgCl(2) or LaCl(3). EXAFS directly, and IR indirectly, proved that the addition of KCl or CsCl (and less efficiently of LiCl) results in the formation of mixed CuK(x)Cl(2+x) or CuCs(x)Cl(2+x) phases, so altering the chemical nature of the active phase. XANES spectroscopy indicates that addition of MgCl(2) or LaCl(3) does not affect the reducibility by ethylene (under static conditions) of the active CuCl(2) phase and that the reducibilility of the new copper-dopant mixed chloride are in the order CuCl(2) > CuLi(x)Cl(2+x) > CuK(x)Cl(2+x) > CuCs(x)Cl(2+x). However, when reduction is done inside a pulse reactor, a more informative picture comes out. The last technique is able to differentiate all samples, and their ability to be reduced by ethylene resulted in the order: La- > Mg- > Li-doped > undoped > K- > Cs-doped catalyst. To understand this apparent discrepancy the dispersion of the active phase, measured by CO chemisorption, was needed: it has been found that addition of LiCl increases enormously the dispersion of the active phase, LaCl(3) significantly and MgCl(2) barely, while addition of both KCl and CsCl results in a decrease of the surface area of the active phase. The mechanism of the enhancing effect of La and Mg on catalytic activity is still not clear, but it could be associated to the modification that they induce to the support surface: the Cu is so highly dispersed that almost all is in direct contact with support surface. It is finally worth noticing that the previous EXAFS and XANES study allowed us to refer the chemisorption data to the active phase only, while the IR study allowed us to fix the Cu(+)/CO surface stoichiometry. Summarizing the use of a multidisciplinary approach has been the conditio sine qua non (mandatory condition) to understand the complex role that the different additives have on the active phase of the CuCl(2)/gamma-Al(2)O(3) catalysts for ethylene oxychlorination.

Influence of additives in defining the active phase of the ethylene oxychlorination catalyst.

The understanding, at the atomic level, of the role played by additives (dopants or promoters) in the chemistry of an industrial catalyst is a very complex and difficult task. We succeeded in this goal for the ethylene oxychlorination catalyst (CuCl(2)/gamma-Al(2)O(3)), used to produce dichloroethane, a key intermediate of the polyvinyl chloride chemistry (PVC). Among the most used additives for both fluid and fixed beds technologies (LiCl, KCl, CsCl, MgCl(2), LaCl(3), CeCl(4)) we have been able to highlight that KCl, and CsCl, forming in reaction conditions a mixed phase with CuCl(2), strongly modify the catalyst behaviour. In particular, these additives are able to displace the rate determining step from the CuCl oxidation (undoped catalyst) to the CuCl(2) reduction. This results from the decrease of the rate of the latter reaction, thus the overall activity of the system. For all remaining additives the rate determining step remains the CuCl oxidation, as for the undoped catalyst. These results have been obtained coupling the catalyst activity monitored with a pulse reactor working in both non-depletive and depletive modes with time resolved XANES spectroscopy performed under in operando conditions (i.e. coupled with mass spectrometry). Formation of CuK(x)Cl(2+x) and CuCs(x)Cl(2+x) mixed phases has been proved monitoring the Cu(II) d-d transitions with UV-Vis spectrometer and the CO stretching frequency of carbon monoxide adsorbed on reduced catalyst by in situ IR spectroscopy. Finally, of high relevance is the observation that the fully oxidized catalyst is inactive. This unexpected evidence highlight the role of coordinatively unsaturated Cu(I) species in adsorbing ethylene on the catalyst surface indicating that copper, in the working catalyst, exhibits a (I)/(II) mixed valence state.

Pd-supported catalysts: evolution of support porous texture along Pd deposition and alkali-metal doping.

Adsorption of N2 at 77 K and scanning electron microscopy have been used to measure the changes in the support morphology, at nano- and microscale level, along the processes involved in the preparation of a supported Pd catalyst: Pd deposition, doping, and thermal treatments. Among the investigated supports, viz., activated carbons, gamma-Al2O3, SiO2, and SiO2-Al2O3 (SA), the SA one was found particularly sensitive to these processes, as a result of its high plasticity and reactivity. Involved processes can be summarized as follows: (i) During the Pd deposition, the support itself is partially dissolved and removed as a result of both the basicity of the precipitating agent and the final washing. (ii) When the undoped sample is thermally treated up to 823 K, only modest phenomena are observed. (iii) Upon doping with potassium carbonate, the support dissolution continues, and the greater the carbonate concentration, the greater the dissolution extent. In this case the dissolved material is not removed, but reprecipitates (partially outside the pores), during the subsequent drying at 393 K. (iv) When doped samples are thermally treated, the reaction between carbonate and support causes the mobilization of the support itself, with sintering phenomena that can reach the total collapse of the porous structure. The starting temperature of the pore collapse decreases with increasing potassium carbonate concentration. The modification of the support influences, directly or indirectly, the surface properties and the availability of Pd particles that can be doped or even covered by materials from support and made more or less accessible or even inaccessible by pore narrowing, widening, or blocking.

Direct IR observation of vibrational properties of carbonyl species formed on Pd nano-particles supported on amorphous carbon: comparison with Pd/SiO2-Al2O3.

By diluting optically opaque carbon-supported Pd particles in silica Aerosil we succeeded in observing the IR bands of adsorbed carbonyls and extracting information on the particle dispersion. Comparison with literature single crystal data and with silica-alumina supported Pd allowed us to make an assignment in terms of linear and 2-fold bridged carbonyls formed on Pd(111) and Pd(100) faces. Two Pd/C samples have been investigated. The relative intensities of the two carbonyl families observed on the two samples are consistent with the Pd dispersion independently measured with CO chemisorption, TEM and EXAFS analysis.