Fluid catalytic cracking (FCC) produces
(the feedstock for) a major
part of the world’s fuels, as well as chemical building blocks
for, for example, polymers, pharmaceuticals, and specialty materials.
ZSM-5 is the active ingredient in propylene-selective FCC catalyst
systems and is stabilized or activated with phosphorus compounds.
Despite this process being one of the largest-scale industrially applied
catalytic processes, there is still considerable debate on the mechanism
of activation, as well as on the interaction between phosphate and
zeolite aluminum species. In this work, we use synchrotron-based powder
XRD, neutron diffraction, and subsequent pair distribution function
analysis to unequivocally corroborate the activation mechanism of
phosphorus-based promotion in FCC catalysis and localize the phosphate
groups inside the pore system of P-activated ZSM-5. We find local
disorder in the zeolite T–O coordination, which could not be
observed with traditional XRD analyses. Furthermore, we support these
experimental findings with full periodic quantum-mechanical modeling
(QMM) of the highly relevant, but often overlooked, combination of
dealumination by hydrolysis (steaming) and phosphatation of the zeolite
framework. We thereby show that phosphate can react with partially
dislodged aluminum species that remain stable and are still tethered
to their original framework position. Finally, by assessing all available
literature postulations by the same periodic QMM and comparing them
energetically with our obtained results, we can conclude that by accounting
for the highly relevant inclusion of steaming prior to phosphatation,
the two models resulting from this work rank among the three most
relevant remaining models. This combined experimental and theoretical
work fundamentally explains the activation and promotion mechanism
of one of the world’s most applied chemical processespropylene-selective
FCC.