Impact of the Spatial Organization of Bifunctional Metal-Zeolite Catalysts on the Hydroisomerization of Light Alkanes.

Improving product selectivity by controlling the spatial organization of functional sites at the nanoscale is a critical challenge in bifunctional catalysis. We present a series of composite bifunctional catalysts consisting of one-dimensional zeolites (ZSM-22 and mordenite) and a γ-alumina binder, with platinum particles controllably deposited either on the alumina binder or inside the zeolite crystals. The hydroisomerization of n-heptane demonstrates that the catalysts with platinum particles on the binder, which separates platinum and acid sites at the nanoscale, leads to a higher yield of desired isomers than catalysts with platinum particles inside the zeolite crystals. Platinum particles within the zeolite crystals impose pronounced diffusion limitations on reaction intermediates, which leads to secondary cracking reactions, especially for catalysts with narrow micropores or large zeolite crystals. These findings extend the understanding of the "intimacy criterion" for the rational design of bifunctional catalysts for the conversion of low-molecular-weight reactants.

Maximizing noble metal utilization in solid catalysts by control of nanoparticle location.

Maximizing the utilization of noble metals is crucial for applications such as catalysis. We found that the minimum loading of platinum for optimal performance in the hydroconversion of n-alkanes for industrially relevant bifunctional catalysts could be reduced by a factor of 10 or more through the rational arranging of functional sites at the nanoscale. Intentionally depositing traces of platinum nanoparticles on the alumina binder or the outer surface of zeolite crystals, instead of inside the zeolite crystals, enhanced isomer selectivity without compromising activity. Separation between platinum and zeolite acid sites preserved the metal and acid functions by limiting micropore blockage by metal clusters and enhancing access to metal sites. Reduced platinum nanoparticles were more active than platinum single atoms strongly bonded to the alumina binder.

Control and Impact of Metal Loading Heterogeneities at the Nanoscale on the Performance of Pt/Zeolite Y Catalysts for Alkane Hydroconversion.

The preparation of zeolite-based bifunctional catalysts with low noble metal loadings while maintaining optimal performance has been studied. We have deposited 0.03 to 1.0 wt % Pt on zeolite H-USY (Si/Al ∼ 30 at./at.) using either platinum(II) tetraammine nitrate (PTA, Pt(NH3)4(NO3)2) or hexachloroplatinic(IV) acid (CPA, H2PtCl6·6H2O) and studied the nanoscale Pt loading heterogeneities and global hydroconversion performance of the resulting Pt/Y catalysts. Pt/Y samples prepared with PTA and a global Pt loading as low as 0.3 wt % Pt (n Pt/n A = 0.08 mol/mol, where nPt is the number of Pt surface sites and n A is the number of acid sites) maintained catalytic performance during n-heptane (T = 210-350 °C, P = 10 bar) as well as n-hexadecane (T = 170-280 °C, P = 5 bar) hydroisomerization similar to a 1.0 wt % Pt sample. For Pt/Y catalysts prepared with CPA, a loading of 0.3 wt % Pt (n Pt/n A = 0.08 mol/mol) sufficed for n-heptane hydroisomerization, whereas a detrimental effect on n-hexadecane hydroisomerization was observed, in particular undesired secondary cracking occurred to a significant extent. The differences between PTA and CPA are explained by differences in Pt loading per zeolite Y crystal (size ∼ 500 nm), shown from extensive transmission electron microscopy energy-dispersive X-ray spectroscopy experiments, whereby crystal-based n Pt/n A ratios could be determined. From earlier studies, it is known that the Al content per crystal of USY varied tremendously and that PTA preferentially is deposited on crystals with higher Al content due to ion-exchange with zeolite protons. Here, we show that this preferential deposition of PTA on Al-rich crystals led to a more constant value of n Pt/n A ratio from one zeolite crystal to another, which was beneficial for catalytic performance. Use of CPA led to a large variation of Pt loading independent of Al content, giving rise to larger variations of n Pt/n A ratio from crystal to crystal that negatively affected the catalytic performance. This study thus shows the impact of local metal loading variations at the zeolite crystal scale (nanoscale) caused by different interactions of metal precursors with the zeolite, which are essential to design and synthesize optimal catalysts, in particular at low noble metal loadings.

Assessment of the Location of Pt Nanoparticles in Pt/zeolite Y/γ-Al2O3 Composite Catalysts.

The location of Pt nanoparticles was studied in Pt/zeolite Y/γ-Al2O3 composite catalysts prepared by H2PtCl6 ⋅ 6H2O (CPA) or Pt(NH3)4(NO3)2 (PTA) as Pt precursors. The aim of this study is to validate findings from Transmission Electron Microscopy (TEM) by using characterization techniques that sample larger amounts of catalyst per measurement. Quantitative X-ray Photoelectron Spectroscopy (XPS) showed that the catalyst prepared with CPA led to a significantly higher Pt/Al atomic ratio than the catalyst prepared with PTA confirming that the 1-2 nm sized Pt nanoparticles in the former catalyst were located on the open and mesoporous γ-Al2O3 component, whereas they were located in the micropores of zeolite Y in the latter. By using infrared spectroscopy, a shift in the absorption band maximum of CO chemisorbed on Pt nanoparticles was observed, which can be attributed to a difference in electronic properties depending on the support of the Pt nanoparticles. Finally, model hydrogenation experiments were performed using ß-phenylcinnamaldehyde, a reactant molecule with low diffusivity in zeolite Y micropores, resulting in a 5 times higher activity for the catalyst prepared by CPA compared to PTA. The combined use of these characterization techniques allow us to draw more robust conclusions on the ability to control the location of Pt nanoparticles by using either CPA or PTA as precursors in zeolite/γ-Al2O3 composite catalyst materials.

Influence of Nanoscale Intimacy and Zeolite Micropore Size on the Performance of Bifunctional Catalysts for n-Heptane Hydroisomerization.

In this study, Pt nanoparticles on zeolite/γ-Al2O3 composites (50/50 wt) were located either in the zeolite or on the γ-Al2O3 binder, hereby varying the average distance (intimacy) between zeolite acid sites and metal sites from "closest" to "nanoscale". The catalytic performance of these catalysts was compared to physical mixtures of zeolite and Pt/γ-Al2O3 powders, which provide a "microscale" distance between sites. Several beneficial effects on catalytic activity and selectivity for n-heptane hydroisomerization were observed when Pt nanoparticles are located on the γ-Al2O3 binder in nanoscale proximity with zeolite acid sites, as opposed to Pt nanoparticles located inside zeolite crystals. On ZSM-5-based catalysts, mostly monobranched isomers were produced, and the isomer selectivity of these catalysts was almost unaffected with an intimacy ranging from closest to microscale, which can be attributed to the high diffusional barriers of branched isomers within ZSM-5 micropores. For composite catalysts based on large-pore zeolites (zeolite Beta and zeolite Y), the activity and selectivity benefitted from the nanoscale intimacy with Pt, compared to both the closest and microscale intimacies. Intracrystalline gradients of heptenes as reaction intermediates are likely contributors to differences in activity and selectivity. This paper aims to provide insights into the influence of the metal-acid intimacy in bifunctional catalysts based on zeolites with different framework topologies.