The most studied catalysts for methane dehydroaromatization (MDA)Mo/ZSM-5are not commercialized yet due to the rapid deactivation and insufficient activity. Catalytic systems based on Fe and Re are potential alternatives to Mo-containing zeolites. Here, we compare the catalytic performance of these catalysts as a function of metal type and its loading in ZSM-5 zeolite. The results show that the catalytic activity decreases in the order of Re/ZSM-5 > Mo/ZSM-5 > Fe/ZSM-5, while the catalyst stability decreases in the opposite order: Fe/ZSM-5 > Mo/ZSM-5 > Re/ZSM-5. The active metal species in the working catalysts were determined by operando X-ray absorption near-edge structure spectroscopy combined with mass spectrometry. We found that Re0 and Fe2+ species are the most likely active species for the catalytic dehydroaromatization of CH4 to aromatics in respective catalysts. Combining the pulse reaction technique with operando thermogravimetry analysis–mass spectrometry experiments, we demonstrate that the length of the induction period strongly correlates to the activity of the catalyst. The longer induction period of the Fe/ZSM-5 catalyst indicates the slow growth of hydrocarbon pool intermediates inside the zeolite pores and thus explains its poor catalytic performance. Finally, both the formation of hydrocarbon pool species and the activity of Fe/ZSM-5 can be improved by increasing the Fe loading, reaction pressure, and space velocity.
Dehydroaromatization of methane (MDA) under non-oxidative conditions is a promising reaction for direct valorization of natural gas and biogas. Typically, Fe-modified ZSM-5 catalysts display low aromatic productivity and high coke selectivity in the MDA reaction. Herein, we show the benefit of starting from isomorphously substituted Fe-sites in [Fe,Al]ZSM-5 zeolites prepared by direct hydrothermal synthesis. Upon calcination, these samples contain predominantly isolated Fe 3+ species, either atomically dispersed within the zeolite framework or anchored at exchange sites inside zeolite channels. In terms of the integral hydrocarbon productivity, [Fe,Al]ZSM-5 catalysts outperform Fe/ZSM-5, prepared by impregnation, as well as Mo/ ZSM-5 catalysts with the same Si/Al ratio and molar metal loading. Operando X-ray absorption spectroscopy coupled with mass spectrometry (XANES-MS) demonstrates that the initial tetrahedral Fe 3+ within the zeolite framework or at exchange sites are transformed into octahedral extraframework Fe 2+ active sites during the MDA reaction and form small Fe 2 O 3 clusters during oxidative regeneration. Combining activity measurements and operando thermogravimetry shows that the duration of the induction period, related to the formation of active hydrocarbon pool intermediates, strongly depends on the Fe dispersion and loading and can be used as a suitable descriptor for the MDA activity of [Fe,Al]ZSM-5. The shorter induction period of [Fe,Al]ZSM-5 in comparison to impregnated Fe/ZSM-5 can be linked to the higher methane conversion rate over highly dispersed Fe-sites and faster formation of active hydrocarbon pool intermediates.
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