Direct visualization of spatiotemporal evolution of molecules and active sites during chemical transformation in individual catalyst crystal will accelerate the intuitive understanding of heterogeneous catalysis. So far, widespread imaging techniques can only provide limited information either with large probe molecules or in model catalyst of large size, which are beyond the interests of industrial catalysis. Herein, we demonstrate a feasible deep data approach via synergy of multiscale reaction-diffusion simulation and super-resolution structured illumination microscopy to  illustrate the dynamical evolution of spatiotemporal distributions of gas molecules, carbonaceous species and acid sites in SAPO-34 zeolite crystals of several micrometers that are typically used in industrial methanol-to-olefins process. The profound insights into the inadequate utilization of activated acid sites and rapid deactivation are unveiled. The notable elucidation of molecular reaction-diffusion process  at the scale of single catalyst crystal via this approach opens an interesting method for mechanism study in materials synthesis and catalysis.

Methanol-to-olefins (MTO), the most important catalytic process producing ethylene and propylene from non-oil feedstocks (coal, natural gas, biomass, CO2, etc.), is hindered by rapid catalyst deactivation due to coke deposition. Common practice to recover catalyst activity, i.e. removing coke via air combustion or steam gasification, unavoidably eliminates the active hydrocarbon pool species (HCPs) favoring light olefins formation. Density functional theory calculations and structured illumination microscopy reveal that naphthalenic cations, active HCPs enhancing ethylene production, are highly stable within SAPO-34 zeolites at high temperature. Here, we demonstrate a strategy of directly transforming coke to naphthalenic species in SAPO-34 zeolites via steam cracking. Fluidized bed reactor-regenerator pilot experiments show that an unexpectedly high light olefins selectivity of 85% is achieved in MTO reaction with 88% valuable CO and H2 and negligible CO2 as byproducts from regeneration under industrial-alike continuous operations. This strategy significantly boosts the economics and sustainability of MTO process.

Mass transfer of guest molecules in nanoporous crystalline materials has gained attention in catalysis, separation, electrochemistry, and other fields. Two mechanisms, surface barriers and intracrystalline diffusion, dominate the mass transport process. Lack of methods to separately quantify these two mechanisms restricts further understanding and thus rational design and efficient application of nanoporous materials. Here we derive an approximate expression of uptake rate relying solely on surface permeability, offering an approach to directly quantify surface barriers and intracrystalline diffusion. By use of this approach, we study the diffusion in zeolitic materials, and find that the intracrystalline diffusivity is intrinsic to the topological structure of host materials at low molecular loading for the given guest molecules, while the surface permeability is sensitive to the non-ideality of a crystalline surface owing to the physical and chemical properties of the crystalline surface, host-guest interaction at the surface, and change of the environment.

As a commercial MTO catalyst, SAPO-34 zeolite exhibits excellent recyclability probably due to its intrinsic good hydrothermal stability. However, the structural dynamic changes of SAPO-34 catalyst induced by hydrocarbon pool (HP) species and the water formed during the MTO conversion as well as its long-term stability after continuous regenerations are rarely investigated and poorly understood. Herein, the dynamic changes of SAPO-34 framework during the MTO conversion were identified by 1D 27Al, 31P MAS NMR, and 2D 31P-27Al HETCOR NMR spectroscopy. The breakage of T-O-T bonds in SAPO-34 catalyst during long-term continuous regenerations in the MTO conversion could be efficiently suppressed by pre-coking. The combination of catalyst pre-coking and water co-feeding is established to be an efficient strategy to promote the catalytic efficiency and long-term stability of SAPO-34 catalysts in the commercial MTO processes, also sheds light on the development of other high stable zeolite catalyst in the commercial catalysis.

Mass transfer of guest molecules has a significant impact on the applications of nanoporous crystalline materials and particularly shape-selective catalysis over zeolites. Control of mass transfer to alter reaction over zeolites, however, remains an open challenge. Recent studies show that, in addition to intracrystalline diffusion, surface barriers represent another transport mechanism that may dominate the overall mass transport rate in zeolites. We demonstrate that the methanol-to-olefins (MTO) reaction can be modulated by regulating surface permeability in SAPO-34 zeolites with improved chemical liquid deposition and acid etching. Our results explicitly show that the reduction of surface barriers can prolong catalyst lifetime and promote light olefins selectivity, which opens a potential avenue for improving reaction performance by controlling the mass transport of guest molecules in zeolite catalysis.

No abstract

Conversion of methanol to olefins (MTO) is an important non-oil alternative route for ethylene and propylene production, which has been industrialized based on a fluidized-bed process with a small-pore SAPO-34 (CHA topology) molecular sieve as the active catalyst component. However, it remains a challenge to effectively regulate the selectivity toward single ethylene or propylene due to the limited catalyst selection and insufficient understanding of the selectivity control principle. Herein, we report the synthesis of a small-pore SAPO-14 molecular sieve (AFN topology) with an ultra-small cage structure and a narrow 8-membered ring (8-MR) channel system, over which the propylene selectivity can rise to as high as 77.3%, representing the highest record of one-pass propylene selectivity in the MTO reaction. The influence of reaction conditions on the catalytic performance was investigated, and the olefin formation mechanism was revealed by combining the analyses of 12C/13C-methanol isotopic switch experiments, confined organics analysis, and reaction-diffusion simulations. This work provides a possibility to subtly control the MTO product distribution by the design and synthesis of the molecular sieve catalyst.

No abstract