Designed Synthesis of Nanostructured Materials as the Heterogeneous Catalysts.

The development of nanoscale syntheses and innovative characterization tools resulted in the tailored design of nanostructured materials with versatile abilities in many applications [...].

Controlled Metal-Support Interactions in Au/CeO2-Mg(OH)2 Catalysts Activating the Direct Oxidative Esterification of Methacrolein with Methanol to Methyl Methacrylate.

The strong metal-support interaction (SMSI) between the three components in Au/CeO2-Mg(OH)2 can be controlled by the relative composition of CeO2 and Mg(OH)2 and by the calcination temperature for the direct oxidative esterification of methacrolein (MACR) with methanol to methyl methacrylate (MMA). The composition ratio of CeO2 and Mg(OH)2 in the catalyst affects the catalytic performance dramatically. An Au/CeO2 catalyst without Mg(OH)2 esterified MACR to a hemiacetal species without MMA production, which confirmed that Mg(OH)2 is a prerequisite for successful oxidative esterification. When Au/Mg(OH)2 was used without CeO2, the direct oxidative esterification of MACR was successful and produced MMA, the desired product. However, the MMA selectivity was much lower (72.5%) than that with Au/CeO2-Mg(OH)2 catalysts, which have an MMA selectivity of 93.9-99.8%, depending on the relative composition of CeO2 and Mg(OH)2. In addition, depending on the calcination temperature, the crystallinity of the CeO2-Mg(OH)2 and the surface acidity/basicity can be remarkably changed. Consequently, the Au-nanoparticle-supported catalysts exhibited different MACR conversions and MMA selectivities. The catalytic behavior can be explained by the different metal-support interactions between the three components depending on the composition ratio of CeO2 and Mg(OH)2 and the calcination temperature. These differences were evidenced by X-ray diffraction, X-ray photoelectron spectroscopy, and CO2 temperature-programmed desorption. The present study provides new insights into the design of SMSI-induced supported metal catalysts for the development of multifunctional heterogeneous catalysts.

A Multifunctional Au/CeO2-Mg(OH)2 Catalyst for One-Pot Aerobic Oxidative Esterification of Aldehydes with Alcohols to Alkyl Esters.

Au nanoparticles bound to crystalline CeO2 nanograins that were dispersed on the nanoplate-like Mg(OH)2, denoted as Au/CeO2-Mg(OH)2, were developed as the highly active and selective multifunctional heterogeneous catalyst for direct oxidative esterification of aldehydes with alcohols to produce alkyl esters under base-free aerobic conditions using oxygen or air as the green oxidants. Au/CeO2-Mg(OH)2 converted 93.3% of methacrylaldehyde (MACR) to methyl methacrylate (MMA, monomer of poly(methyl methacrylate)) with 98.2% selectivity within 1 h, and was repeatedly used over eight recycle runs without regeneration. The catalyst was extensively applied to other aldehydes and alcohols to produce desirable alkyl esters. Comprehensive characterization analyses revealed that the strong metal-support interaction (SMSI) among the three catalytic components (Au, CeO2, and Mg(OH)2), and the proximity and strong contact between Au/CeO2 and the Mg(OH)2 surface were prominent factors that accelerated the reaction toward a desirable oxidative esterification pathway. During the reaction, MACR was adsorbed on the surface of CeO2-Mg(OH)2, upon which methanol was simultaneously activated for esterifying the adsorbed MACR. Hemiacetal-form intermediate species were subsequently produced and oxidized to MMA on the surface of the electron-rich Au nanoparticles bound to partially reduced CeO2-x with electron-donating properties. The present study provides new insights into the design of SMSI-induced supported-metal-nanoparticles for the development of novel, multifunctional, and heterogeneous catalysts.

Catalytic Effects of Zeolite Socony Mobil-5 (ZSM-5) on the Oxidation of Acoustically Levitated exo-Tetrahydrodicyclopentadiene (JP-10) Droplets.

Jet propulsion 10 (JP-10) droplets with and without aluminum nanoparticles in conjunction with HZSM-5 zeolite and surfactants were ultrasonically levitated, and their oxidation processes were explored to identify how the oxidation process of JP-10 is catalytically affected by the HZSM-5 zeolites and how the surfactant and Al NPs in the system impacted the key experimental parameters of the ignition such as ignition delay time, burn rate, and the maximum temperatures. Singly levitated droplets were ignited using a carbon dioxide laser under an oxygen-argon atmosphere. Pure JP-10 droplets and JP-10 droplets with silicon dioxide of an identical size distribution as the zeolite HZSM-5 did not ignite in strong contrast to HZSM-5-doped droplets. Acidic sites were found to be critical in the ignition of the JP-10. With the addition of the surfactant, the characteristic features of the JP-10 ignition were improved, so the ignition delay time of the zeolite-JP-10 samples were decreased by 2-3 ms and the burn rates were increased by 1.3 to 1.6 × 105 K s-1. The addition of Al NPs increased the maximum temperatures during the combustion of the systems by 300-400 K. Intermediates and end products of the JP-10 oxidation over HZSM-5 were characterized by UV-vis emission and Fourier-transform infrared transmission spectroscopies, revealing key reactive intermediates (OH, CH, C2, O2, and HCO) along with the H2O molecules in highly excited rovibrational states. Overall, this work revealed that acetic sites in HZSM-5 are critical in the catalytic ignition of JP-10 droplets with the addition of the surfactant and Al NPs, enhancing the oxidation process of JP-10 over HZSM-5 zeolites.

Non-Topotactic Transformation of Silicate Nanolayers into Mesostructured MFI Zeolite Frameworks During Crystallization.

Mesostructured MFI zeolite nanosheets are established to crystallize non-topotactically through a nanolayered silicate intermediate during hydrothermal synthesis. Solid-state 2D NMR analyses, with sensitivity enhanced by dynamic nuclear polarization (DNP), provide direct evidence of shared covalent 29 Si-O-29 Si bonds between intermediate nanolayered silicate moieties and the crystallizing MFI zeolite nanosheet framework.

Mesoporous Aluminosilicate Catalysts for the Selective Isomerization of n-Hexane: The Roles of Surface Acidity and Platinum Metal.

Several types of mesoporous aluminosilicates were synthesized and evaluated in the catalytic isomerization of n-hexane, both with and without Pt nanoparticles loaded into the mesopores. The materials investigated included mesoporous MFI and BEA type zeolites, MCF-17 mesoporous silica, and an aluminum modified MCF-17. The acidity of the materials was investigated through pyridine adsorption and Fourier Transform-Infrared Spectroscopy (FT-IR). It was found that the strong Brönsted acid sites in the micropores of the zeolite catalysts facilitated the cracking of hexane. However, the medium strength acid sites on the Al modified MCF-17 mesoporous silica greatly enhanced the isomerization reaction. Through the loading of different amounts of Pt into the mesopores of the Al modified MCF-17, the relationship between the metal nanoparticles and acidic sites on the support was revealed.

Chemical Environment Control and Enhanced Catalytic Performance of Platinum Nanoparticles Embedded in Nanocrystalline Metal-Organic Frameworks.

Chemical environment control of the metal nanoparticles (NPs) embedded in nanocrystalline metal-organic frameworks (nMOFs) is useful in controlling the activity and selectivity of catalytic reactions. In this report, organic linkers with two functional groups, sulfonic acid (-SO3H, S) and ammonium (-NH3(+), N), are chosen as strong and weak acidic functionalities, respectively, and then incorporated into a MOF [Zr6O4(OH)4(BDC)6 (BDC = 1,4-benzenedicarboxylate), termed UiO-66] separately or together in the presence of 2.5 nm Pt NPs to build a series of Pt NPs-embedded in UiO-66 (Pt⊂nUiO-66). We find that these chemical functionalities play a critical role in product selectivity and activity in the gas-phase conversion of methylcyclopentane (MCP) to acyclic isomer, olefins, cyclohexane, and benzene. Pt⊂nUiO-66-S gives the highest selectivity to C6-cyclic products (62.4% and 28.6% for cyclohexane and benzene, respectively) without acyclic isomers products. Moreover, its catalytic activity was doubled relative to the nonfunctionalized Pt⊂nUiO-66. In contrast, Pt⊂nUiO-66-N decreases selectivity for C6-cyclic products to <50% while increases the acyclic isomer selectivity to 38.6%. Interestingly, the Pt⊂nUiO-66-SN containing both functional groups gave different product selectivity than their constituents; no cyclohexane was produced, while benzene was the dominant product with olefins and acyclic isomers as minor products. All Pt⊂nUiO-66 catalysts with different functionalities remain intact and maintain their crystal structure, morphology, and chemical functionalities without catalytic deactivation after reactions over 8 h.

Co-development of crystalline and mesoscopic order in mesostructured zeolite nanosheets.

Mesoporous zeolites are a new and technologically important class of materials that exhibit improved diffusion and catalytic reaction properties compared to conventional zeolites with sub-nanometer pore dimensions. During their syntheses, the transient developments of crystalline and mesoscopic order are closely coupled and challenging to control. Correlated solid-state NMR, X-ray, and electron microscopy analyses yield new molecular-level insights on the interactions and distributions of complicated organic structure-directing agents with respect to crystallizing zeolite frameworks. The analyses reveal the formation of an intermediate layered silicate phase, which subsequently transforms into zeolite nanosheets with uniform nano- and mesoscale porosities. Such materials result from coupled surfactant self-assembly and inorganic crystallization processes, the interplay between which governs the onset and development of framework structural order on different length and time scales.

The pathway to total isomer selectivity: n-hexane conversion (reforming) on platinum nanoparticles supported on aluminum modified mesoporous silica (MCF-17).

When pure mesoporous silica (MCF-17) was modified with aluminum (Al modified MCF-17), Lewis acid sites were created, but this material was inactive for the catalytic conversion (reforming) of n-hexane to isomers. When colloidally synthesized platinum nanoparticles were loaded onto traditional MCF-17, the catalyst showed very low activity toward isomer production. However, when Pt nanoparticles were loaded onto Al modified MCF-17, isomerization became the dominant catalytic pathway, with extremely high activity and selectivity (>90%), even at high temperatures (240-360 °C). This highly efficient catalytic chemistry was credited to the tandem effect between the acidic Al modified MCF-17 and the Pt metal.

Effect of acidic properties of mesoporous zeolites supporting pt nanoparticles on hydrogenative conversion of methylcyclopentane.

The effect of acidic properties of mesoporous zeolites on the control of product selectivity during the hydrogenative isomerization of methylcyclopentane has been investigated. A series of mesoporous zeolites with controlled acidic properties were prepared by postdealumination process with hydrochloric acid under hydrothermal conditions, and the resultant zeolites used for supporting colloidal Pt nanoparticles (NPs) with a mean size of 2.5 nm (± 0.6 nm). As compared to the pure Pt NPs supported on catalytically inert mesoporous silica (MCF-17) as the reference catalyst that can produce isomers most selectively (∼80%), the Pt NPs supported on mesoporous zeolites produced C6-cyclic hydrocarbons (i.e., cyclohexane and benzene) most dominantly. The type and strength of the Brönsted (B) and Lewis (L) acid sites of those zeolites with a controlled Al amount are analyzed by using FT-IR after the adsorption of pyridine and NH3 temperature-programmed desorption measurements, and they are correlated with the selectivity change between cyclohexane and benzene. From this investigation, we found a linear relationship between the number of Brönsted acid sites and the formation rate for cyclohexane. In addition, we revealed that more Lewis acidic zeolite having relatively smaller B/L ratio is effective for the cyclohexane formation, whereas more Brönsted acidic zeolite having relatively larger B/L ratio is effective for the benzene formation.

Metal nanocrystals embedded in single nanocrystals of MOFs give unusual selectivity as heterogeneous catalysts.

The growth of nanocrystalline metal-organic frameworks (nMOFs) around metal nanocrystals (NCs) is useful in controlling the chemistry and metric of metal NCs. In this Letter, we show rare examples of nMOFs grown in monocrystalline form around metal NCs. Specifically, Pt NCs were subjected to reactions yielding Zr(IV) nMOFs [Zr6O4(OH)4(fumarate)6, MOF-801; Zr6O4(OH)4(BDC)6 (BDC = 1,4-benzenedicarboxylate), UiO-66; Zr6O4(OH)4(BPDC)6 (BPDC = 4,4'-biphenyldicarboxylate), UiO-67] as a single crystal within which the Pt NCs are embedded. These constructs (Pt⊂nMOF)nanocrystal are found to be active in gas-phase hydrogenative conversion of methylcyclopentane (MCP) and give unusual product selectivity. The Pt⊂nUiO-66 shows selectivity to C6-cyclic hydrocarbons such as cyclohexane and benzene that takes place with 100 °C lower temperature than the standard reaction (Pt-on-SiO2). We observe a pore size effect in the nMOF series where the small pore of Pt⊂nMOF-801 does not produce the same products, while the larger pore Pt⊂nUiO-67 catalyst provides the same products but with different selectivity. The (Pt⊂nMOF)nanocrystal spent catalyst is found to maintain the original crystallinity, and be recyclable without any byproduct residues.

Superacidity in sulfated metal-organic framework-808.

Superacids, defined as acids with a Hammett acidity function H0 ≤ -12, are useful materials, but a need exists for new, designable solid state systems. Here, we report superacidity in a sulfated metal-organic framework (MOF) obtained by treating the microcrystalline form of MOF-808 [MOF-808-P: Zr6O5(OH)3(BTC)2(HCOO)5(H2O)2, BTC = 1,3,5-benzenetricarboxylate] with aqueous sulfuric acid to generate its sulfated analogue, MOF-808-2.5SO4 [Zr6O5(OH)3(BTC)2(SO4)2.5(H2O)2.5]. This material has a Hammett acidity function H0 ≤ -14.5 and is thus identified as a superacid, providing the first evidence for superacidity in MOFs. The superacidity is attributed to the presence of zirconium-bound sulfate groups structurally characterized using single-crystal X-ray diffraction analysis.

Designed catalysts from Pt nanoparticles supported on macroporous oxides for selective isomerization of n-hexane.

Selective isomerization toward branched hydrocarbons is an important catalytic process in oil refining to obtain high-octane gasoline with minimal content of aromatic compounds. Colloidal Pt nanoparticles with controlled sizes of 1.7, 2.7, and 5.5 nm were deposited onto ordered macroporous oxides of SiO2, Al2O3, TiO2, Nb2O5, Ta2O5, and ZrO2 to investigate Pt size- and support-dependent catalytic selectivity in n-hexane isomerization. Among the macroporous oxides, Nb2O5 and Ta2O5 exhibited the highest product selectivity, yielding predominantly branched C6 isomers, including 2- or 3-methylpentane, as desired products of n-hexane isomerization (140 Torr n-hexane and 620 Torr H2 at 360 °C). In situ characterizations including X-ray diffraction and ambient-pressure X-ray photoelectron spectroscopy showed that the crystal structures of the oxides in Pt/oxide catalysts were not changed during the reaction and oxidation states of Nb2O5 were maintained under both H2 and O2 conditions. Fourier transform infrared spectra of pyridine adsorbed on the oxides showed that Lewis sites were the dominant acidic site of the oxides. Macroporous Nb2O5 and Ta2O5 were identified to play key roles in the selective isomerization by charge transfer at Pt-oxide interfaces. The selectivity was revealed to be Pt size-dependent, with improved isomer production as Pt sizes increased from 1.7 to 5.5 nm. When 5.5 nm Pt nanoparticles were supported on Nb2O5 or Ta2O5, the selectivity toward branched C6 isomers was further increased, reaching ca. 97% with a minimum content of benzene, due to the combined effects of the Pt size and the strong metal-support interaction.

Promotional effects of mesoporous zeolites with Pt nanoparticle catalysts during reforming of methylcyclopentane.

Selective C-C and C-H bond activations are an important catalytic process to produce various value-added hydrocarbons via reforming processes. For producing desired product with a high yield, control of reaction pathway through the design of catalyst and fundamental understanding and clarification of reaction mechanism are prerequisite. In this work, we designed heterogeneous catalysts by combining Pt nanoparticles and two different mesoporous zeolites with microporous frameworks of BEA and MFI for the hydrogenative model reforming reaction of hydrocarbon (i.e., methylcyclopentane). Depending on the catalyst combination, the reaction pathways of (i) dehydrogenation, (ii) ring-opening with isomerization, and ring-enlargement with (iii) hydrogenation and (iv) dehydrogenation of C5-cyclic ring to C6-cyclic ring (i.e., cyclohexane and benzene) can be controlled to produce various products with high yields. Furthermore, we revealed a reaction intermediate formed at the interface of Pt and zeolite by real-time surface vibrational sum-frequency generation spectroscopic studies. This study would provide practical and fundamental insights for design of heterogeneous catalyst for controlling reaction pathways.

A membrane-integrated fermentation reactor system: its effects in reducing the amount of sub-raw materials for D-lactic acid continuous fermentation by Sporolactobacillus laevolacticus.

Continuous fermentation by retaining cells with a membrane-integrated fermentation reactor (MFR) system was found to reduce the amount of supplied sub-raw material. If the amount of sub-raw material can be reduced, continuous fermentation with the MFR system should become a more attractive process for industrialization, due to decreased material costs and loads during the refinement process. Our findings indicate that the production rate decreased when the amount of the sub-raw material was reduced in batch fermentation, but did not decrease during continuous fermentation with Sporolactobacillus laevolacticus. Moreover, continuous fermentation with a reduced amount of sub-raw material resulted in a productivity of 11.2 g/L/h over 800 h. In addition, the index of industrial process applicability used in the MFR system increased by 6.3-fold as compared with the conventional membrane-based fermentation reactor previously reported, suggesting a potential for the industrialization of this D-lactic acid continuous fermentation process.

Membrane-integrated fermentation system for improving the optical purity of D-lactic acid produced during continuous fermentation.

This report describes the production of highly optically pure D-lactic acid by the continuous fermentation of Sporolactobacillus laevolacticus and S. inulinus, using a membrane-integrated fermentation (MFR) system. The optical purity of D-lactic acid produced by the continuous fermentation system was greater than that produced by batch fermentation; the maximum value for the optical purity of D-lactic acid reached 99.8% enantiomeric excess by continuous fermentation when S. leavolacticus was used. The volumetric productivity of the optically pure D-lactic acid was about 12 g/L/h, this being approximately 11-fold higher than that obtained by batch fermentation. An enzymatic analysis indicated that both S. laevolacticus and S. inulinus could convert L-lactic acid to D-lactic acid by isomerization after the late-log phase. These results provide evidence for an effective bio-process to produce D-lactic acid of greater optical purity than has conventionally been achieved to date.

Directing zeolite structures into hierarchically nanoporous architectures.

Crystalline mesoporous molecular sieves have long been sought as solid acid catalysts for organic reactions involving large molecules. We synthesized a series of mesoporous molecular sieves that possess crystalline microporous walls with zeolitelike frameworks, extending the application of zeolites to the mesoporous range of 2 to 50 nanometers. Hexagonally ordered or disordered mesopores are generated by surfactant aggregates, whereas multiple cationic moieties in the surfactant head groups direct the crystallization of microporous aluminosilicate frameworks. The wall thicknesses, framework topologies, and mesopore sizes can be controlled with different surfactants. The molecular sieves are highly active as catalysts for various acid-catalyzed reactions of bulky molecular substrates, compared with conventional zeolites and ordered mesoporous amorphous materials.

Pillared MFI zeolite nanosheets of a single-unit-cell thickness.

Zeolite MFI nanosheets of 2-nm thickness have been hydrothermally synthesized via cooperative assembly between silica and an organic surfactant, which is functionalized with a diquaternary ammonium group. The zeolite nanosheets have been further assembled into their ordered multilamellar mesostructure through hydrophobic interactions between the surfactant tails located outside the zeolite nanosheet. This assembly process involves successive transformations from an initially hexagonal mesophase to a multilamellar mesophase without crystallinity and then to a lamellar mesophase with a crystalline zeolite framework. The mesopore volume in the interlamellar space could be retained by supporting the zeolite nanosheets with silica pillars, as in pillared clays, even after surfactant removal by calcination. The mesopore diameters could be controlled according to the surfactant tail lengths. Due to the interlamellar structural coherence, the hierarchically mesoporous/microporous zeolite could exhibit small-angle X-ray diffraction peaks up to the fourth-order reflections corresponding to the interlayer distance. In addition, an Ar adsorption analysis and transmission electron microscopic investigation indicated that the pillars were highly likely to be built with an MFI structure. The present approach using a zeolite structure-directing functional group contained in a surfactant would be suitable for the synthesis of other related nanomorphous zeolites in the future.

Stable single-unit-cell nanosheets of zeolite MFI as active and long-lived catalysts.

Zeolites-microporous crystalline aluminosilicates-are widely used in petrochemistry and fine-chemical synthesis because strong acid sites within their uniform micropores enable size- and shape-selective catalysis. But the very presence of the micropores, with aperture diameters below 1 nm, often goes hand-in-hand with diffusion limitations that adversely affect catalytic activity. The problem can be overcome by reducing the thickness of the zeolite crystals, which reduces diffusion path lengths and thus improves molecular diffusion. This has been realized by synthesizing zeolite nanocrystals, by exfoliating layered zeolites, and by introducing mesopores in the microporous material through templating strategies or demetallation processes. But except for the exfoliation, none of these strategies has produced 'ultrathin' zeolites with thicknesses below 5 nm. Here we show that appropriately designed bifunctional surfactants can direct the formation of zeolite structures on the mesoporous and microporous length scales simultaneously and thus yield MFI (ZSM-5, one of the most important catalysts in the petrochemical industry) zeolite nanosheets that are only 2 nm thick, which corresponds to the b-axis dimension of a single MFI unit cell. The large number of acid sites on the external surface of these zeolites renders them highly active for the catalytic conversion of large organic molecules, and the reduced crystal thickness facilitates diffusion and thereby dramatically suppresses catalyst deactivation through coke deposition during methanol-to-gasoline conversion. We expect that our synthesis approach could be applied to other zeolites to improve their performance in a range of important catalytic applications.

The synthesis of a hierarchically porous BEA zeolite via pseudomorphic crystallization.

A synthesis route to a hierarchically meso-/microporous BEA zeolite has been developed with a cyclic diammonium as a structure-directing agent (SDA), which leads to pseudomorphic crystallization of the zeolite by suppressing the mobility of silicates during crystallization.