Synthesis of the large pore aluminophosphate STA-1 and its application as a catalyst for the Beckmann rearrangement of cyclohexanone oxime.

The preparation of stable large pore aluminophosphate (AlPO) zeotypes offers materials for applications in adsorption and catalysis. Here we report the synthesis of the pure AlPO with the SAO topology type (AlPO STA-1) using N,N'-diethylbicyclo[2.2.2]oct-7-ene-2,3:5,6-dipyrrolidine (DEBOP) as the organic structure directing agent in the presence of fluoride. The AlPO STA-1 can be rendered microporous (pore volume 0.36 cm3 g-1) via calcination and the calcined form remains stable in the presence of moisture. The structure of the dehydrated form has been established by Rietveld refinement (tetragonal P4̄n2, a = 13.74317(10) Å, c = 21.8131(5) Å, V = 4119.94(16) Å3). Multinuclear 27Al and 31P MAS NMR, together with 2D COSY and CASTEP NMR calculations, enables resolution and assignment of the signals from all crystallographically distinct Al and P framework sites. Structural elucidation of the as-prepared aluminophosphate-fluoride is more challenging, because of the presence of partially protonated OSDA molecules in the 3D-connected channel system and in particular because the fluoride ions coordinate with positional disorder to some of the Al atoms to give 5-fold as well as tetrahedrally-coordinated framework Al species. These are postulated to occupy Al-F-Al bridging sites, where they are responsible for distortion of the framework [P4̄n2, a = 13.3148(9) Å, c = 22.0655(20) Å, V = 3911.9(7) Å3]. Calcination and removal of fluoride ions and OSDAs allows the framework to expand to its relaxed configuration. The SAO topology type aluminophosphate can also be synthesised with small amounts of Si and Ge in the framework, and these SAPO and GeAPO STA-1 materials are also stable to template removal. IR spectroscopy with CO as a probe at 123 K indicates all have weak-to-mild acidity, increasing in the order AlPO < GeAPO < SAPO. These STA-1 materials have been investigated for their activity in the Beckmann rearrangement of cyclohexanone oxime to ε-caprolactam at 598 K: while all are active, the AlPO form is favoured due to its high selectivity and slow deactivation, both of which are a consequence of its very weak acid strength, which is nevertheless sufficient to catalyse the reaction.

Impact of Zeolite Framework Composition and Flexibility on Methanol-To-Olefins Selectivity: Confinement or Diffusion?

The methanol-to-olefins reaction catalyzed by small-pore cage-based acid zeolites and zeotypes produces a mixture of short chain olefins, whose selectivity to ethene, propene and butene varies with the cavity architecture and with the framework composition. The product distribution of aluminosilicates and silicoaluminophosphates with the CHA and AEI structures (H-SSZ-13, H-SAPO-34, H-SSZ-39 and H-SAPO-18) has been experimentally determined, and the impact of acidity and framework flexibility on the stability of the key cationic intermediates involved in the mechanism and on the diffusion of the olefin products through the 8r windows of the catalysts has been evaluated by means of periodic DFT calculations and ab initio molecular dynamics simulations. The preferential stabilization by confinement of fully methylated hydrocarbon pool intermediates favoring the paring pathway is the main factor controlling the final olefin product distribution.

A Cationic Oligomer as an Organic Template for Direct Synthesis of Aluminosilicate ITH Zeolite.

There are a large number of zeolites, such as ITH, that cannot be prepared in the aluminosilicate form. Now, the successful synthesis of aluminosilicate ITH zeolite using a simple cationic oligomer as an organic template is presented. Key to the success is that the cationic oligomer has a strong complexation ability with aluminum species combined with a structural directing ability for the ITH structure similar to that of the conventional organic template. The aluminosilicate ITH zeolite has very high crystallinity, nanosheet-like crystal morphology, large surface area, fully four-coordinated Al species, and abundant acidic sites. Methanol-to-propylene (MTP) tests reveal that the Al-ITH zeolite shows much higher selectivity for propylene and longer lifetime than commercial ZSM-5. FCC tests show that Al-ITH zeolite is a good candidate as a shape-selective FCC additive for enhancing propylene and butylene selectivity.

Influence of the synthesis method on the catalytic activity of mayenite for the oxidation of gas-phase trichloroethylene.

Catalytic oxidation of trichloroethylene (TCE) in heterogeneous phase (gas-solid) is an effective strategy for the conversion of this pollutant in less harmful compounds, namely CO2, CO and HCl. In this work, we have studied the use of mayenite, a cost-effective material, as an active catalyst for the TCE conversion. In particular, we have assessed the influence of the mayenite synthesis method (hydrothermal, sol-gel and ceramic) on the reaction performance. The materials have been characterized by different techniques, such as XRD, N2-sorption (BET), TPR, Raman spectroscopy, FESEM-EDX and TEM. The analysis of the light-off curves and product distribution, has shown that the use of the hydrothermal method for the mayenite synthesis results in the most active and selective catalyst. This has been related with a higher surface area and with a higher concentration of oxygen anions in the mayenite prepared by this method. It has been found that the presence of water in the stream do not influence the catalytic performance of the material. A mechanism for the reaction and for the partial deactivation of the catalyst has been proposed.

Making Nanosized CHA Zeolites with Controlled Al Distribution for Optimizing Methanol-to-Olefin Performance.

From theoretical calculations and a rational synthesis methodology, it has been possible to prepare nanocrystalline (60-80 nm) chabazite with an optimized framework Al distribution that has a positive impact on its catalytic properties. This is exemplified for the methanol-to-olefin (MTO) process. The nanosized material with the predicted Al distribution maximizes the formation of the required MTO hydrocarbon pool intermediates, while better precluding excessive diffusion pathways that favor the rapid catalyst deactivation by coke formation.

Simple organic structure directing agents for synthesizing nanocrystalline zeolites.

The synthesis of the ZSM-5 and beta zeolites in their nanosized form has been achieved by using simple alkyl-substituted mono-cationic cyclic ammonium cations as OSDA molecules. The particular combination of a cyclic fragment and a short linear alkyl-chain group (preferentially C4) within the monocationic OSDA molecules allows directing the crystallization of nanosized zeolites with excellent solid yields (above 90%). Interestingly, the formation of the nanosized ZSM-5 and beta zeolites mostly depends on the size and nature of the cyclic fragment of the OSDA molecule, resulting in all cases in nanocrystalline solids with homogeneous distributions of particle sizes (∼10-25 nm) and controlled Si/Al molar ratios (∼15-30). The achieved nanosized ZSM-5 and beta zeolites have been extensively characterized by different techniques to study their physico-chemical properties, such as chemical composition, pore accessibility or Brønsted acidity, among others. Moreover, the catalytic properties of the nanosized ZSM-5 and beta zeolites have been evaluated for different chemical reactions, including methanol-to-olefins (MTO) in the case of ZSM-5, and alkylation of benzene with propylene to obtain cumene and oligomerization of light olefins to liquid fuels in the case of beta, observing in all cases improved catalytic activity and product selectivity towards target products when compared to related catalysts.

Nanocrystalline SSZ-39 zeolite as an efficient catalyst for the methanol-to-olefin (MTO) process.

The synthesis of nanosized SSZ-39 zeolite has been achieved using a high silica FAU zeolite as the Si and Al source and tetraethylphosphonium (TEP) cations as OSDAs. The obtained SSZ-39 material shows a remarkably high catalyst lifetime compared to conventional SSZ-13 and SSZ-39 materials.

Methanol to olefins: activity and stability of nanosized SAPO-34 molecular sieves and control of selectivity by silicon distribution.

Nano-SAPO-34 molecular sieves synthesized in a microwave environment with 20 nm crystal size showed a longer lifetime than SAPO-34 prepared by the conventional hydrothermal method in the reaction of methanol to olefins. It has been found that silicon distribution strongly affects the lifetime and selectivity. Thus, silicon at the border of the silicon islands gives a higher lifetime and lower C2/C3 ratio. This change in activity and selectivity is better explained in terms of different silicon distribution than by preferential diffusion of ethene through the 8MR pores and agrees with transition-state selectivity. The effects of equilibrium of olefins and deactivation by coke were isolated, showing that after full formation of the hydrocarbon pool, selectivity is independent of deactivation by coke.

A large-cavity zeolite with wide pore windows and potential as an oil refining catalyst.

Crude oil is an important feedstock for the petrochemical industry and the dominant energy source driving the world economy, but known oil reserves will cover demand for no more than 50 years at the current rate of consumption. This situation calls for more efficient strategies for converting crude oil into fuel and petrochemical products. At present, more than 40% of oil conversion is achieved using catalysts based on faujasite; this zeolite requires extensive post-synthesis treatment to produce an ultrastable form, and has a large cavity accessible through four 0.74-nm-wide windows and thus limits the access of oil molecules to the catalytically active sites. The use of zeolites with better accessibility to their active sites should result in improved catalyst efficiency. To date, two zeolites with effective pore diameters exceeding that of faujasite have been reported, but their one-dimensional pore topology excludes use in oil refining. Similarly, zeolites with large pores and a three-dimensional pore topology have been reported, but in all these materials the pore openings are smaller than in faujasite. Here we report the synthesis of ITQ-21, a zeolite with a three-dimensional pore network containing 1.18-nm-wide cavities, each of which is accessible through six circular and 0.74-nm-wide windows. As expected for a zeolite with this structure, ITQ-21 exhibits high catalytic activity and selectivity for valuable products in preliminary oil refining tests.