A systematic investigation has been carried out, aiming at elucidating several aspects of the gas/solid methylation of phenol over high Si/Al ratio BEA-structured zeolite in protonated form. The catalysts have been characterized by several techniques, such as XRD, SEM, BET, ICP, FT-IR, TGA, micro-calorimetry and modelling by ab initio calculations. The correlation between these characteristics and kinetics and mechanistic features of the catalytic reaction, as well as of catalyst deactivation, showed that these zeolites are very active for the present reaction, leading to cresols and anisole as primary products. As catalyst deactivation proceeds, the selectivity to cresols and anisole increases substantially, together with a rapid decrease of selectivity to poly-alkylated species. Catalyst surface acidity is prevalently made of medium-to-low-strength silanolsbased acid sites of Brønsted type. High-strength Lewis acid sites are either almost absent, especially when metal cations partially substitute for protons, or play a role essentially in catalyst deactivation. Stacking faults in the zeolite framework, generated by the 2 intergrowth of at least two BEA polymorphs, lead to an increase of the concentration of silanols-based acid sites. Deactivation is essentially due to the interaction of phenol and oxygenated products with the strong Lewis acid sites. For time-on stream values longer than a few hours, self oligomerisation-cyclisation of methanol to olefins and aromatics, followed by further alkylation to aromatic C atoms, contributes more significantly to catalyst deactivation. At higher temperature all the zeolites deactivate at a comparable rate, whereas at lower temperature initial catalytic activity is higher for larger crystal size zeolite, due to the longer diffusion time of bulkier coke precursors within zeolite pores. At any conversion level and at any temperature the anisole/cresols ratio is systematically lower for the larger crystal size zeolite, since the secondary transformations of anisole to cresols, by both intra-molecular rearrangement and inter-molecular alkylation of phenol, is favoured by the longer residence time of anisole within the zeolite pores.
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