K. De Wispelaere

The catalytic conversion of methanol (MeOH) and dimethyl ether (DME) into fuels and chemicals over zeolites (MTH process) is industrially emerging as an alternative route to conventional oil-derived processes. After 40 years of research, a detailed mechanistic understanding of the intricate reaction network is still not fully accomplished. The overall reaction is described as two competitive catalytic cycles, dominated by alkenes and arenes, which are methylated and cracked or dealkylated to form effluent products. Herein, we present the reaction of isobutene with methanol and DME as an efficient tool for measuring the relative formation rates of alkenes and arenes, and we provide detailed mechanistic insight into the hydrogen-transfer reaction. We provide experimental and theoretical evidence that manifest a strong competition of methylation and hydrogen transfer of isobutene by methanol, while methylation is substantially favored by DME. Experiments performed at higher conversion facilitate projection of the results to the product distribution obtained when using MeOH or DME as feedstock during the MTH reaction.

Zeolites are the workhorses of today’s chemical industry. For decades they have been successfully applied, however many features of zeolite catalysis are only superficially understood and in particular the kinetics and mechanism of individual reaction steps at operating conditions. Herein we use state-of-the-art advanced ab initio molecular dynamics techniques to study the influence of catalyst topology and acidity, reaction temperature and the presence of additional guest molecules on elementary reactions. Such advanced modeling techniques provide complementary insight to experimental knowledge as the impact of individual factors on the reaction mechanism and kinetics of zeolite-catalyzed reactions may be unraveled. We study key reaction steps in the conversion of methanol to hydrocarbons, namely benzene and propene methylation. These reactions may occur either in a concerted or stepwise fashion, i.e. methanol directly transfers its methyl group to a hydrocarbon or the reaction goes through a framework-bound methoxide intermediate. The DFT-based dynamical approach enables mimicking reaction conditions as close as possible and studying the competition between two methylation mechanisms in an integrated fashion. The reactions are studied in the unidirectional AFI-structured H-SSZ-24, H-SAPO-5 and TON-structured H-ZSM-22 materials. We show that varying the temperature, topology, acidity and number of protic molecules surrounding the active site may tune the reaction mechanism at the molecular level. Obtaining molecular control is crucial in optimizing current zeolite processes and designing emerging new technologies bearing alternative feedstocks.

The role of water in the methanol-to-olefins (MTO) process over H-SAPO-34 has been elucidated by a combined theoretical and experimental approach, encompassing advanced molecular dynamics simulations and in-situ micro-spectroscopy. First principle calculations at the molecular level point out that water competes with methanol and propene for direct access to the Brønsted acid sites. This results in less efficient activation of these molecules, which are crucial for the formation of the hydrocarbon pool. Furthermore, lower intrinsic methanol reactivity towards methoxide formation has been observed. These observations are in line with a longer induction period observed from in-situ UV-Vis micro-spectroscopy experiments. These experiments revealed a slower and more homogeneous discoloration of H-SAPO-34, while in-situ confocal fluorescence microscopy confirmed the more homogeneous distribution and larger amount of MTO intermediates when co-feeding water. As such it is show that water induces a more efficient use of the H-SAPO-34 catalyst crystals at the microscopic level. The combined experimental theoretical approach gives a profound insight into the role of water on the catalytic process at the molecular and single particle level.

The methanol to olefins process is a show case example of complex zeolite-catalyzed chemistry. At real operating conditions, many factors such as framework flexibility, adsorption of various guest molecules and competitive reaction pathways, affect reactivity. In this paper we show the strength of first principle molecular dynamics techniques to capture this complexity by means of two case studies. Firstly, the adsorption behavior of methanol and water in H-SAPO-34 at 350 °C is investigated. Hereby we observed an important degree of framework flexibility and proton mobility. Secondly, we studied the methylation of benzene by methanol via a competitive direct and stepwise pathway in the AFI topology. Both case studies clearly show that a first principle molecular dynamics approach enables to obtain unprecedented insights into zeolite-catalyzed reactions at the nanometer scale.