Monitoring complex catalytic pathways under industrially-relevant conditions is one of the key challenges in catalysis chemistry and technology. Herewith we describe a direct technique called ‘fast scanning-pulse analysis’ (FASPA) that allows the direct characterization and detailed kinetic analysis of intimately interweaved catalytic pathways. The power and potential of the FASPA approach are demonstrated with an industrially relevant methanol-to-hydrocarbons (MTH) process over H-ZSM-5 zeolite. This reaction proceeds via a hydrocarbon pool (HCP) mechanism producing olefins and aromatics. The HCP is built-up upon exposure to methanol during the induction period, followed by a transition regime to a quasi steady-state MTH operation. This FASPA technique allows (sub-)second resolution of the full temporal products response upon a methanol pulse providing direct and quantitative insights into the MTH reactions. Globally, two consecutive pathways can be discerned: a very fast primary product formation in the presence of methanol in a narrow active MTH reaction zone, followed by a slower formation of light aromatics, which is closely related to the decomposition and release of HCP species and secondary reactions in absence of methanol in the downstream part of the catalyst bed. The time delay between the appearance of inert tracer and primary products represents the time needed to build-up the HCP in the induction period, where methane is observed prior to other products. The primary products (alkanes, olefins, and light aromatics) are nearly instantaneously formed from the pulsed methanol. These results demonstrate the highly dynamic character of the HCP in the MTH process over H-ZSM-5.

The nature of hydrocarbon pool (HCP) intermediates in the methanol-to-hydrocarbons (MTH) process has been thoroughly investigated, especially for BEA- and CHA-type zeolite catalysts like H-β and H-SAPO-34. Herein, we further reveal the dynamic mechanistic details of the MTH process over the H-ZSM-5 catalyst at 400 °C, based on the dual-cycle mechanism and HCP in this medium-pore zeolite. Application of switching sequences of ¹³C-labeled and unlabeled methanol pulses over a model H-ZSM-5 catalyst combined with on-line MS analysis and a recently reported technique called “fast scanning-pulse GC analysis” provides a direct and quantitative insight into the MTH reactions under quasi-steady-state conditions. The transient product responses showed the almost instant formation of hydrocarbons upon a small pulse of methanol, followed by secondary formation of light aromatics via HCP decomposition and olefin alkylation-dealkylation, especially in a long catalyst bed when methanol is quickly consumed in the initial reaction zone in the catalyst bed. The isotopic analysis of typical aliphatic C₃₊ product responses after switching ¹³C-methanol pulses to the unlabeled methanol pulses showed a fast isotope scrambling in the formation of C₃₊ species. MS analysis of the light aromatics indicates a complete consecutive but slower isotope incorporation process of ¹²C into ¹³C-aromatics. Results provide direct experimental confirmation of the kinetically preferred olefin-based cycle over the aromatic-based cycle. The sequential isotopic incorporation strongly suggests that the paring reaction pathway through aromatic ring contraction and re-expansion steps is operative. In the appearance of aromatics upon pulsing methanol over larger catalyst beds, four processes are directly discerned, involving the displacement of adsorbed species by formed water, isotope incorporation yielding directly labeled and unlabeled products through the paring mechanism and direct aromatization, and HCP conversion through secondary reactions.

Identification of the catalyst characteristics correlating with the key performance parameters including selectivity and stability is key to the rational catalyst design. Herein we focused on the identification of property-performance relationships in the methanol-to-olefin (MTO) process by studying in detail the catalytic behaviour of MFI, MEL and their respective intergrowth zeolites. The detailed material characterization reveals that both the high production of propylene and butylenes and the large MeOH conversion capacity correlate with the enrichment of lattice Al sites in the channels of the pentasil structure as identified by ²⁷Al MAS NMR and 3-methylpentane cracking results. The lack of correlation between MTO performance and other catalyst characteristics, such as crystal size, presence of external Brønsted acid sites and Al pairing suggests their less pronounced role in defining the propylene selectivity. Our analysis reveals that catalyst deactivation is rather complex and is strongly affected by the enrichment of lattice Al in the intersections, the overall Al-content, and crystal size. The intergrowth of MFI and MEL phases accelerates the catalyst deactivation rate.

The production of valuable aromatics and the rapid catalyst deactivation due to coking are intimately related in the zeolite-catalyzed aromatization reactions. Here, we demonstrate that these two processes can be decoupled by promoting the Ga/HZSM-5 aromatization catalyst with Ca. The resulting bimetallic catalysts combine high selectivity to light aromatics with extended catalyst lifetime in the methanol-to-aromatics process. Evaluation of the catalytic performance combined with detailed catalyst characterization suggests that the added Ca interacts with the Ga-LAS, with a strong effect on the aromatization processes. A genetic algorithm approach complemented by ab initio thermodynamic analysis is used to elucidate the possible structures of bimetallic extraframework species formed under reaction conditions. The promotion effect of minute amounts of Ca is attributed to the stabilization of the intra-zeolite extraframework gallium oxide clusters with moderated dehydrogenation activity.

The catalytic conversion of glycerol to aromatics (GTA, e.g., benzene, toluene, and xylenes, BTX) over a shaped H-ZSM-5/Al₂O₃ (60/40 wt%) catalyst was investigated in a continuous fixed-bed reactor to study the addition of the Al₂O₃ binder in the catalyst formulation on catalyst performance. The experiments were performed under N₂ at 550 °C, a WHSV of glycerol (pure) of 1 h⁻¹, and atmospheric pressure. The spent H-ZSM-5/Al₂O₃ catalysts were reused after an oxidative regeneration at 680 °C and in total 5 reaction-regeneration cycles were performed. Catalyst characterization studies show that the addition of the Al₂O₃ binder does not affect the surface area and crystallinity of the formulation, but increases the total pore volume (mesopores in particular) and total acidity (Lewis acidity in particular). The H-ZSM-5/Al₂O₃ (60/40 wt%) catalyst shows a considerably prolonged catalyst life-time (8.5 vs. 6.5 h for H-ZSM-5), resulting in a significant increase in the total BTX productivity (710 vs. 556 mg g⁻¹ H-ZSM-5). Besides, the addition of the Al₂O₃ binder retards irreversible deactivation. For instance, after 3 regenerations, catalyst performance is comparable to the fresh one. However, after 4 regenerations, some irreversible catalyst deactivation occurs, associated with a reduction in total pore volume, crystallinity, and acidity (Brønsted acidity in particular), and meso-porosity of the Al₂O₃ binder. This study shows that both the stability and reusability of H-ZSM-5-based catalysts for GTA are remarkably enhanced when using a suitable binder.

The catalytic conversion of pure glycerol to bio-aromatics (bio-BTX) over an un-modified H-ZSM-5 (SiO₂/Al₂O₃ molar ratio of 23) via an ex-situ catalytic pyrolysis approach in a continuous tandem-micro reactor at a scale of 1 g glycerol h⁻¹ was investigated. A BTX peak carbon yield of 28.1 ± 0.2 % was obtained at a pyrolysis temperature of 400 °C, catalytic upgrading temperature of 500 °C, atmospheric pressure and a WHSV of 1 h⁻¹. About 70 % of the bound oxygen in glycerol was converted to water. The latter was mainly formed in the catalytic upgrading unit (70 %), though conversion of glycerol to other oxygenates with water formation was also observed in the pyrolysis unit. Catalyst deactivation occurs at a time scale of hours and is mainly due to coke deposition (12.0 wt.%) on the catalyst surface. An oxidative regeneration procedure to remove coke was applied and 5 cycles of reaction-regeneration were performed successfully, though a drop in activity was observed after each cycle due to irreversible catalyst deactivation. Characterization of the fresh, deactivated and regenerated catalysts by various techniques revealed dealumination of the H-ZSM-5 framework and resulted in a dramatic decrease in Brønsted acidity of the catalyst. Dealumination mainly occurred in the catalytic upgrading reactor and to a by far lesser extent during catalyst regeneration. This information is relevant for a better understanding of the process on a molecular level but also for scale-up studies, e.g. for the design of pilot plants.

The use of H-ZSM-5 with various binders (Al₂O₃, SiO₂, and kaolinite, 10 wt% on catalyst formulation) for the catalytic conversion of glycerol to bio-based aromatics (GTA) was investigated in a continuous bench-scale unit at a pyrolysis temperature of 450 °C, catalytic upgrading temperature of 500 °C, WHSV of pure glycerol of 1 h⁻¹, and atmospheric pressure, and their performance was compared to H-ZSM-5 (SiO₂/Al₂O₃ molar ratio of 28). The latter gave a peak BTX carbon yield of ca. 31.1C.%, a life-time of ca. 220 min, and a total BTX productivity of ca. 312 mg BTX g⁻¹H-ZSM-5. The introduction of binders affects catalyst performance, which is the most profound and promising for the H-ZSM-5/Al₂O₃ catalyst. It shows a prolonged catalyst life-time of ca. 320 min and a higher total BTX productivity of ca. 518 mg BTX g⁻¹H-ZSM-5, compared to the H-ZSM-5 without a binder. Catalyst characterization studies show that the addition of the binder does not have a major effect on the specific surface area, total pore volume, and total acidity. Other relevant properties were affected, though, such as micropore volume (SiO₂), a reduced Brønsted acidity (Al₂O₃, and SiO₂), and reduced crystallinity (SiO₂). Coke formation causes severe catalyst deactivation, ultimately leading to an inactive catalyst for BTX formation. Catalyst characterization studies after an oxidative regeneration showed that the textural properties of the regenerated catalysts were close to those of the original catalysts. However, some dealumination of H-ZSM-5 occurs, resulting in decreased crystallinity and acidity, causing irreversible deactivation, which needs attention in future catalyst development studies.