Engineering Lewis Acidity in Zeolite Catalysts by Electrochemical Release of Heteroatoms during Synthesis.

The creation of heteroatom nodes in zeolite frameworks is a challenging but rewarding pathway to superior materials for numerous catalytic applications. Here, we present a novel method for precise control over heteroatom incorporation by in situ anodic release of a desired metal during hydrothermal zeolite synthesis. The generic character of the technique and the applicability of the new synthesis reactor are shown across 3 zeolite structures crystallized and 4 electrode metals in two pH zones and by offering access to a new mixed-metal zeolite. The timed and voltage-controlled metal release offers a minimized interference between the metal precursor state and critical events in the zeolite's crystallization. A mechanistic study for Sn-MFI revealed the key importance of controlled release: while keeping its concentration lower than in batch, a lot more Sn can be incorporated into the framework. The method grants access to 10× increased framework Lewis acid site densities (vs batch controls) for the most relevant stannosilicates. As a proof, the electro-made materials demonstrate higher productivity than their classic counterparts in lactate catalysis. This innovative approach effectively expands the synthesis space of zeolites.

Synthesis strategies to control the Al distribution in zeolites: thermodynamic and kinetic aspects.

The activity and selectivity of acid-catalyzed chemistry is highly dependent on the Brønsted and Lewis acid sites generated by Al substitutions in a zeolite framework with the desired pore architecture. The siting of two Al atoms in close proximity in the framework of high-silica zeolites can also play a decisive role in improving the performance of redox catalysts by producing exchangeable positions for extra-framework multivalent cations. Thus, considerable attention has been devoted to controlling the Al incorporation through direct synthesis approaches and post-synthesis treatments to optimize the performance as (industrial) solid catalysts and to develop new acid- and redox-catalyzed reactions. This Feature Article highlights bottom-up synthetic strategies to fine-tune the Al incorporation in zeolites, interpreted with respect to thermodynamic and kinetic aspects. They include (i) variation in extra-framework components in zeolite synthesis, (ii) isomorphous substitution of other heteroatoms in the zeolite framework, and (iii) control over the (alumino)silicate network in the initial synthesis mixture via in situ and ex situ methods. Most synthetic approaches introduced here tentatively showed that the energy barriers associated with Al incorporation in zeolites can be variable during zeolite crystallization processes, occurring in complex media with multiple chemical interactions. Although the generic interpretation of each strategy and underlying crystallization mechanism remains largely unknown (and often limited to a specific framework), this review will provide guidance on more efficient methods to prepare fine-tuned zeolites with desired chemical properties.

Sustainable Polythioesters via Thio(no)lactones: Monomer Synthesis, Ring-Opening Polymerization, End-of-Life Considerations, and Industrial Perspectives.

As the environmental effects of plastics are of ever greater concern, the industry is driven towards more sustainable polymers. Besides sustainability, our fast-developing society imposes the need for highly versatile materials. Whereas aliphatic polyesters (PEs) are widely adopted and studied as next-generation biobased and (bio)degradable materials, their sulfur-containing analogs, polythioesters (PTEs), only recently gained attention. Nevertheless, the introduction of S atoms is known to often enhance thermal, mechanical, electrochemical, and optical properties, offering prospects for broad applicability. Furthermore, thanks to their thioester-based backbone, PTEs are inherently susceptible to degradation, giving them a high sustainability potential. The key route to PTEs is through ring-opening polymerization (ROP) of thio(no)lactones. This Review critically discusses the (potential) sustainability of the most relevant state-of-the-art in every step from sulfur source to end-of-life treatment options of PTEs, obtained through ROP of thio(no)lactones. The benefits and drawbacks of PTEs versus PEs are highlighted, including their industrial perspective.

Truly combining the advantages of polymeric and zeolite membranes for gas separations.

Mixed-matrix membranes (MMMs) have been investigated to render energy-intensive separations more efficiently by combining the selectivity and permeability performance, robustness, and nonaging properties of the filler with the easy processing, handling, and scaling up of the polymer. However, truly combining all in one single material has proven very challenging. In this work, we filled a commercial polyimide with ultrahigh loadings of a high-aspect ratio, CO2-philic Na-SSZ-39 zeolite with a three-dimensional channel system that precisely separates gas molecules. By carefully designing both zeolite and MMM synthesis, we created a gas-percolation highway across a flexible and aging-resistant (more than 1 year) membrane. The combination of a CO2-CH4 mixed-gas selectivity of ~423 and a CO2 permeability of ~8300 Barrer outperformed all existing polymer-based membranes and even most zeolite-only membranes.

Catalytic amination of lactic acid using Ru-zeolites.

In this work we investigate the synthesis of alanine from lactic acid, a biobased platform chemical, using ammonia as a nitrogen source and Ru/zeolite catalysts. We report a high alanine selectivity when using Ru/BEA of 80-93%. Reaction side products were identified as ethanol, propionic acid or propanamide and the reaction mechanism was investigated. We further optimised reaction conditions resulting in turn over numbers five times higher than previously reported and could reduce Ru leaching by 30-40%. However, leaching and catalyst stability remains a concern. Furthermore, we critically analyse the benefits of Ru/zeolites versus their stability under the basic, high temperature reaction conditions.

Selective Formation of α-Fe(II) Sites on Fe-Zeolites through One-Pot Synthesis.

α-Fe(II) active sites in iron zeolites catalyze N2O decomposition and form highly reactive α-O that selectively oxidizes unreactive hydrocarbons, such as methane. How these α-Fe(II) sites are formed remains unclear. Here different methods of iron introduction into zeolites are compared to derive the limiting factors of Fe speciation to α-Fe(II). Postsynthetic iron introduction procedures on small pore zeolites suffer from limited iron diffusion and dispersion leading to iron oxides. In contrast, by introducing Fe(III) in the hydrothermal synthesis mixture of the zeolite (one-pot synthesis) and the right treatment, crystalline CHA can be prepared with >1.6 wt % Fe, of which >70% is α-Fe(II). The effect of iron on the crystallization is investigated, and the intermediate Fe species are tracked using UV-vis-NIR, FT-IR, and Mössbauer spectroscopy. These data are supplemented with online mass spectrometry in each step, with reactivity tests in α-O formation and with methanol yields in stoichiometric methane activation at room temperature and pressure. We recover up to 134 µmol methanol per gram in a single cycle through H2O/CH3CN extraction and 183 µmol/g through steam desorption, a record yield for iron zeolites. A general scheme is proposed for iron speciation in zeolites through the steps of drying, calcination, and activation. The formation of two cohorts of α-Fe(II) is discovered, one before and one after high temperature activation. We propose the latter cohort depends on the reshuffling of aluminum in the zeolite lattice to accommodate thermodynamically favored α-Fe(II).

A Cooperative OSDA Blueprint for Highly Siliceous Faujasite Zeolite Catalysts with Enhanced Acidity Accessibility.

A cooperative OSDA strategy is demonstrated, leading to novel high-silica FAU zeolites with a large potential for disruptive acid catalysis. In bottom-up synthesis, the symbiosis of choline ion (Ch+ ) and 15-crown-5 (CE) was evidenced, in a form of full occupation of the sodalite (sod) cages with the trans Ch+ conformer, induced by the CE presence. CE itself occupied the supercages along with additional gauche Ch+ , but in synthesis without CE, no trans was found. The cooperation, and thus the fraction of trans Ch+ , was closely related to the Si/Al ratio, a key measure for FAU stability and acidity. As such, a bottom-up handle for lowering the Al-content of FAU and tuning its acid site distribution is shown. A mechanistic study demonstrated that forming sod cages with trans Ch+ is key to the nucleation of high-silica FAU zeolites. The materials showed superior performances to commercial FAU zeolites and those synthesized without cooperation, in the catalytic degradation of polyethylene.

Boosting PLA melt strength by controlling the chirality of co-monomer incorporation.

Bio-based and degradable polymers such as poly(lactic acid) (PLA) have become prominent. In spite of encouraging features, PLA has a low melt strength and melt elasticity, resulting in processing and application limitations that diminish its substitution potential vis-a-vis classic plastics. Here, we demonstrate a large increase in zero shear viscosity, melt elasticity, elongational viscosity and melt strength by random co-polymerization of lactide with small amounts, viz. 0.4-10 mol%, of diethylglycolide of opposite chiral nature. These enantiomerically pure monomers can be synthesized using one-step zeolite catalysis. Screening of the ester linkages in the final PLA chains by the ethyl side groups is suggested to create an expanding effect on the polymer coils in molten state by weakening of chain-chain interactions. This effect is suspected to increase the radius of gyration, enabling more chain entanglements and consequently increasing the melt strength. A stronger melt could enable access to more cost-competitive and sustainable PLA-based biomaterials with a broader application window. Amongst others, blow molding of bottles, film blowing, fiber spinning and foaming could be facilitated by PLA materials exhibiting a higher melt strength.

On the key role of aluminium and other heteroatoms during interzeolite conversion synthesis.

Interzeolite conversion, a synthesis technique for several zeolite frameworks, has recently yielded a large amount of high-performing catalytic zeolites. Yet, the mechanisms behind the success of interzeolite conversion remain unknown. Conventionally, small oligomers with structural similarity between the parent and daughter zeolites have been proposed, despite the fact these have never been observed experimentally. Moreover, recent synthesis examples contradict the theory that structural similarity between the parent and daughter zeolites enhances interzeolite conversion. In this perspective it is proposed that heteroatoms, such as aluminium, are key players in the processes that determine the successful conversion of the parent zeolite. The role of Al during parent dissolution, and all consecutive stages of crystallization, are discussed by revising a vast body of literature. By better understanding the role of Al during interzeolite conversions, it is possible to elucidate some generic features and to propose some synthetic guidelines for making advantageous catalytic zeolites. The latter analysis was also expanded to the interconversion of zeotype materials where heteroatoms such as tin are present.

Spectroscopic Identification of the α-Fe/α-O Active Site in Fe-CHA Zeolite for the Low-Temperature Activation of the Methane C-H Bond.

The formation of single-site α-Fe in the CHA zeolite topology is demonstrated. The site is shown to be active in oxygen atom abstraction from N2O to form a highly reactive α-O, capable of methane activation at room temperature to form methanol. The methanol product can subsequently be desorbed by online steaming at 200 °C. For the intermediate steps of the reaction cycle, the evolution of the Fe active site is monitored by UV-vis-NIR and Mössbauer spectroscopy. A B3LYP-DFT model of the α-Fe site in CHA is constructed, and the ligand field transitions are calculated by CASPT2. The model is experimentally substantiated by the preferential formation of α-Fe over other Fe species, the requirement of paired framework aluminum and a MeOH/Fe ratio indicating a mononuclear active site. The simple CHA topology is shown to mitigate the heterogeneity of iron speciation found on other Fe-zeolites, with Fe2O3 being the only identifiable phase other than α-Fe formed in Fe-CHA. The α-Fe site is formed in the d6r composite building unit, which occurs frequently across synthetic and natural zeolites. Finally, through a comparison between α-Fe in Fe-CHA and Fe-*BEA, the topology's 6MR geometry is found to influence the structure, the ligand field, and consequently the spectroscopy of the α-Fe site in a predictable manner. Variations in zeolite topology can thus be used to rationally tune the active site properties.

Small-Pore Zeolites: Synthesis and Catalysis.

In the past decade or so, small-pore zeolites have received greater attention than large- and medium-pore molecular sieves that have historically dominated the literature. This is primarily due to the commercialization of two major catalytic processes, NOx exhaust removal and methanol conversion to light olefins, that take advantage of the properties of these materials with smaller apertures. Small-pore zeolites possess pores that are constructed of eight tetrahedral atoms (Si4+ and Al3+), each time linked by a shared oxygen These eight-member ring pores (8MR) provide small molecules access to the intracrystalline void space, e.g., to NOx during car exhaust cleaning (NOx removal) or to methanol en route to its conversion into light olefins, while restricting larger molecule entrance and departure that is critical to overall catalyst performance. In total, there are forty-four structurally different small-pore zeolites. Forty-one of these zeolites can be synthesized, and the first synthetic zeolite (KFI, 1948) was in fact a small-pore material. Although the field of 8MR zeolite chemistry has expanded in many directions, the progress in synthesis is framework-specific, leaving insights and generalizations difficult to realize. This review first focuses on the relevant synthesis details of all 8MR zeolites and provides some generalized findings and related insights. Next, catalytic applications where 8MR zeolites either have been commercialized or have dominated investigations are presented, with the aim of providing structure-activity relationships. The review ends with a summary that discusses (i) both synthetic and catalytic progress, (ii) a list of opportunities in the 8MR zeolite field, and (iii) a brief future outlook.

Catalytic Gas-Phase Production of Lactide from Renewable Alkyl Lactates.

A new route to lactide, which is a key building block of the bioplastic polylactic acid, is proposed involving a continuous catalytic gas-phase transesterification of renewable alkyl lactates in a scalable fixed-bed setup. Supported TiO2 /SiO2 catalysts are highly selective to lactide, with only minimal lactide racemization. The solvent-free process allows for easy product separation and recycling of unconverted alkyl lactates and recyclable lactyl intermediates. The catalytic activity of TiO2 /SiO2 catalysts was strongly correlated to their optical properties by DR UV/Vis spectroscopy. Catalysts with high band-gap energy of the supported TiO2 phase, indicative of a high surface spreading of isolated Ti centers, show the highest turnover frequency per Ti site.

CIT-9: A Fault-Free Gmelinite Zeolite.

A synthetic, fault-free gmelinite (GME) zeolite is prepared using a specific organic structure-directing agent (OSDA), cis-3,5-dimethylpiperidinium. The cis-isomers align in the main 12-membered ring (MR) channel of GME. Trans-isomer OSDA leads to the small-pore zeolite SSZ-39 with the OSDA in its cages. Data from N2 -physisorption and rotation electron diffraction provide evidence for the openness of the 12 MR channel in the GME 12×8×8 pore architecture and the absence of stacking faults, respectively. CIT-9 is hydrothermally stable when K+ -exchanged, while in the absence of exchange, the material transforms into an aluminous AFI-zeolite. The process of this phase-change was followed by in situ variable temperature powder X-ray diffraction. CIT-9 has the highest Si/Al ratio reported for GME, and along with its good porosity, opens the possibility of using GME in a variety of applications including catalysis.

Lactide Synthesis and Chirality Control for Polylactic acid Production.

Polylactic acid (PLA) is a very promising biodegradable, renewable, and biocompatible polymer. Aside from its production, its application field is also increasing, with use not only in commodity applications but also as durables and in biomedicine. In the current PLA production scheme, the most expensive part is not the polymerization itself but obtaining the building blocks lactic acid (LA) and lactide, the actual cyclic monomer for polymerization. Although the synthesis of LA and the polymerization have been studied systematically, reports of lactide synthesis are scarce. Most lactide synthesis methods are described in patent literature, and current energy-intensive, aselective industrial processes are based on archaic scientific literature. This Review, therefore, highlights new methods with a technical comparison and description of the different approaches. Water-removal methodologies are compared, as this is a crucial factor in PLA production. Apart from the synthesis of lactide, this Review also emphasizes the use of chemically produced racemic lactic acid (esters) as a starting point in the PLA production scheme. Stereochemically tailored PLA can be produced according to such a strategy, giving access to various polymer properties.

Potential and challenges of zeolite chemistry in the catalytic conversion of biomass.

Increasing demand for sustainable chemicals and fuels has pushed academia and industry to search for alternative feedstocks replacing crude oil in traditional refineries. As a result, an immense academic attention has focused on the valorisation of biomass (components) and derived intermediates to generate valuable platform chemicals and fuels. Zeolite catalysis plays a distinct role in many of these biomass conversion routes. This contribution emphasizes the progress and potential in zeolite catalysed biomass conversions and relates these to concepts established in existing petrochemical processes. The application of zeolites, equipped with a variety of active sites, in Brønsted acid, Lewis acid, or multifunctional catalysed reactions is discussed and generalised to provide a comprehensive overview. In addition, the feedstock shift from crude oil to biomass involves new challenges in developing fields, like mesoporosity and pore interconnectivity of zeolites and stability of zeolites in liquid phase. Finally, the future challenges and perspectives of zeolites in the processing of biomass conversion are discussed.

GREEN CHEMISTRY. Shape-selective zeolite catalysis for bioplastics production.

Biodegradable and renewable polymers, such as polylactic acid, are benign alternatives for petrochemical-based plastics. Current production of polylactic acid via its key building block lactide, the cyclic dimer of lactic acid, is inefficient in terms of energy, time, and feedstock use. We present a direct zeolite-based catalytic process, which converts lactic acid into lactide. The shape-selective properties of zeolites are essential to attain record lactide yields, outperforming those of the current multistep process by avoiding both racemization and side-product formation. The highly productive process is strengthened by facile recovery and practical reactivation of the catalyst, which remains structurally fit during at least six consecutive reactions, and by the ease of solvent and side-product recycling.

Review of old chemistry and new catalytic advances in the on-purpose synthesis of butadiene.

Increasing demand for renewable feedstock-based chemicals is driving the interest of both academic and industrial research to substitute petrochemicals with renewable chemicals from biomass-derived resources. The search towards novel platform chemicals is challenging and rewarding, but the main research activities are concentrated on finding efficient pathways to produce familiar drop-in chemicals and polymer building blocks. A diversity of industrially important monomers like alkenes, conjugated dienes, unsaturated carboxylic acids and aromatic compounds are thus targeted from renewable feedstock. In this context, on-purpose production of 1,3-butadiene from biomass-derived feedstock is an interesting example as its production is under pressure by uncertainty of the conventional fossil feedstock. Ethanol, obtained via fermentation or (biomass-generated) syngas, can be converted to butadiene, although there is no large commercial activity today. Though practised on a large scale in the beginning of the 20th century, there is a growing worldwide renewed interest in the butadiene-from-ethanol route. An alternative route to produce butadiene from biomass is through direct carbohydrate and gas fermentation or indirectly via the dehydration of butanediols. This review starts with a brief discussion on the different feedstock possibilities to produce butadiene, followed by a comprehensive summary of the current state of knowledge regarding advances and achievements in the field of the chemocatalytic conversion of ethanol and butanediols to butadiene, including thermodynamics and kinetic aspects of the reactions with discussions on the reaction pathways and the type of catalysts developed.

Selective catalysis for cellulose conversion to lactic acid and other α-hydroxy acids.

This review discusses topical chemical routes and their catalysis for the conversion of cellulose, hexoses, and smaller carbohydrates to lactic acid and other useful α-hydroxy acids. Lactic acid is a top chemical opportunity from carbohydrate biomass as it not only features tremendous potential as a chemical platform molecule; it is also a common building block for commercially employed green solvents and near-commodity bio-plastics. Its current scale fermentative synthesis is sufficient, but it could be considered a bottleneck for a million ton scale breakthrough. Alternative chemical routes are therefore investigated using multifunctional, often heterogeneous, catalysis. Rather than summarizing yields and conditions, this review attempts to guide the reader through the complex reaction networks encountered when synthetic lactates from carbohydrate biomass are targeted. Detailed inspection of the cascade of reactions emphasizes the need for a selective retro-aldol activity in the catalyst. Recently unveiled catalytic routes towards other promising α-hydroxy acids such as glycolic acid, and vinyl and furyl glycolic acids are highlighted as well.

Top chemical opportunities from carbohydrate biomass: a chemist's view of the Biorefinery.

Cheap fossil oil resources are becoming depleted and crude oil prices are rising. In this context, alternatives to fossil fuel-derived carbon are examined in an effort to improve the security of carbon resources through the development of novel technologies for the production of chemicals, fuels, and materials from renewable feedstocks such as biomass. The general concept unifying the conversion processes for raw biomass is that of the biorefinery, which integrates biofuels with a selection of pivot points towards value-added chemical end products via so-called "platform chemicals". While the concept of biorefining is not new, now more than ever there is the motivation to investigate its true potential for the production of carbon-based products. A variety of renewable chemicals have been proposed by many research groups, many of them being categorized as drop-ins, while others are novel chemicals with the potential to displace petrochemicals across several markets. To be competitive with petrochemicals, carbohydrate-derived products should have advantageous chemical properties that can be profitably exploited, and/or their production should offer cost-effective benefits. The production of drop-ins will likely proceed in short term since the markets are familiar, while the commercial introduction of novel chemicals takes longer and demands more technological and marketing effort.Rather than describing elaborate catalytic routes and giving exhaustive lists of reactions, a large part of this review is devoted to creating a guideline for the selection of the most promising (platform) chemicals derived via chemical-catalytic reaction routes from lignocellulosic biomass. The major rationale behind our recommendations is a maximum conservation of functionality, alongside a high atom economy. Nature provides us with complex molecules like cellulose and hemicellulose, and it should be possible to transform them into chemical products while maintaining aspects of their original structure, rather than taking them completely apart only to put them back together again in a different order, or turning them into metabolites and CO2. Thus, rather than merely pursuing energy content as in the case of biofuels, the chemist sees atom efficiency, functional versatility, and reactivity as the key criteria for the successful valorization of biomass into chemicals.To guide the choice of renewable chemicals and their production, this review adopts the original van Krevelen plots and develops alternative diagrams by introducing a functionality parameter F and a functionality index F:C (rather than O:C). This index is more powerful than the O index to describe the importance of functional groups. Such plots are ideal to assess the effect of several reaction types on the overall functionality in biomass conversion. The atom economy is an additional arbitrator in the evaluation of the reaction types. The assessment is illustrated in detail for the case of carbohydrate resources, and about 25 chemicals, including drop-ins as well as novel chemicals, are selected.Most of these chemicals would be difficult to synthesize from petrochemicals feeds, and this highlights the unique potential of carbohydrates as feedstocks, but, importantly, the products should have a strong applied dimension in existing or rising markets. Ultimately, the production scales of those markets must be harmonized to the biomass availability and its collection and storage logistics.