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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 (mandator...

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In this study, we have developed a method to predict the steady-state rate and Cu oxidation state during ethylene oxychlorination from a reaction rate diagram of the individual steps involved in the catalytic oxychlorination cycle. The steady state of the redox cycle is represented by a cross point of the reaction rates of the reduction and oxidation steps as a function of the Cu2+ in the rate diagram. Transient kinetics of elementary reactions and steady-state kinetics of the overall catalytic cycle were investigated in an operando study using combined mass and UV–vis-NIR spectrophotometry. The catalytic consequence of the promoters was then evaluated in terms of reduction and oxidation activity as well as number of active sites, site activity, and the catalyst oxidation state at steady state. Results revealed that the neat CuCl2 catalysts operated at low Cu2+ at the steady-state conditions with stoichiometric feed composition, as a result of relatively low oxidation rate of Cu1+. As a consequence of a high content of Cu1+, ethylene conversion and selectivity are low, and the catalyst deactivates rapidly. By the promotion of the CuCl2 catalyst by K, the reactor operates at a high Cu2+ concentration with much improved stability as a result of enhanced oxidation rate, but the catalyst has low activity due to significantly reduced reduction rate. Therefore, the rate diagram has been applied as a tool for a rational design of the CuCl2-based oxychlorination catalysts, and Ce was proposed as the promoter due to its high promotion to the oxidation and low reactivity with Cu ions. It was found that the activity of the Ce-promoted catalysts increased 8 times compared to the neat CuCl2 catalyst and moreover significantly improved the stability for the oxychlorination catalyst at steady state, due to the enhancement of both the rates of the reduction and oxidation. It is anticipated that the methodology developed here paves the way for a general method for catalyst design of heterogeneous catalysts where the catalyst undergoes oxidation state changes, in particular in redox reactions.