Guoqing Zhao,
Huanhui Chen,
Junhui Li,
Qunlong Wang,
Yanan Wang,
Shuwen Ma and
Zhirong Zhu*
Department of Chemistry, Tongji University, Shanghai, China. E-mail: zhuzhirong@tongji.edu.cn
First published on 3rd September 2015
A variety of the modified X zeolites were used to catalyse the oxidative dehydrogenation of ethylbenzene to styrene with CO2 for the first time. The results showed that X zeolites modified by alkali metal cation exchange, such as KX and CsX, exhibited high catalytic activity and selectivity with a good stability. The reaction temperature 818 K over the modified X zeolites is much less than 923 K over the current metallic oxide catalyst. Moreover, the co-catalysis between acid sites and base sites over the modified X zeolite was indispensable in this reaction, and the basicity of the catalyst greatly determined the selectivity of styrene. The participation of CO2 in the co-catalysis process improves the conversion of ethylbenzene and the selectivity of styrene.
Driven by the increasing concern for global warming, it is urgent to reduce the emission of greenhouse gas, especially for CO2, to meet the worldwide requirements.6 One efficient way is to utilize CO2 as a reactant instead of emitting it into atmosphere. Some chemical reactions can use CO2 as a source of “oxygen” atoms, or as an oxidant. For example, CO2 has been found to be beneficial for oxidative dehydrogenation of ethylbenzene to form styrene, which was advocated for the first time by Sugino7 in 1995. They found that the conversion of dehydrogenation of ethylbenzene over an iron-loaded activated-carbon catalyst was highly promoted with CO2. Further research indicated that the new process using CO2 as an oxidant should be an energy-saving process. The energies required for the present commercial process using steam and for the new process using CO2 were estimated to be 1.5 × 109 cal per t-styrene and 6.3 × 108 cal per t-styrene, respectively.8 Therefore, as an important economical and energy-saving process, the oxidative dehydrogenation of ethylbenzene with CO2 to styrene has evoked a lot of interest.9–12
However, the dehydrogenation of ethylbenzene with CO2 cannot be performed at industrial scale because of lacking of active and stable catalysts. At present, many catalysts have been prepared for the dehydrogenation of ethylbenzene with CO2 in lab. With the development of mesoporous materials, the MCM-41 or SBA-15 molecular sieves were used as promising catalyst supports for the oxidative dehydrogenation of ethylbenzene in the presence of CO2.13–19 Qiao et al. loaded vanadia on mesoporous MCM-41 to promote the catalytic performance for the oxidative dehydrogenation of ethylbenzene with CO2, and they found that it was more active than vanadium supported on conventional amorphous SiO2.16 V, Cr, Fe or Ga/MCM-41 zeolites prepared by direct hydrothermal synthesis have been tested for dehydrogenation of ethylbenzene with CO2, and Cr–MCM-41 showed the highest catalytic activity.17 CeO2–ZrO2 supported on SBA-15 exhibited the superior activity than bulk single oxides for the dehydrogenation of ethylbenzene to styrene with CO2 shown by Burri et al.18 VOx supported on SBA-15 were also tested as a catalyst in the oxidative dehydrogenation of ethylbenzene to styrene in the presence of N2O, reported by Kuśtrowski et al.19 Although the high catalytic activity can be achieved over some MCM-41 or SBA-15 supported catalysts, high reaction temperature was needed above 873 K, and the poor stability was not solved as well. The catalytic activity of the modified MCM-41 catalyst decreased by 30% after 6 h, and the similar phenomenon also appeared over the SBA-type catalysts. Moreover, in the above reports, few attention has been devoted to its effect of the porous structure on the dehydrogenation of ethylbenzene with CO2.13,16–18 Up to now, the usual microporous zeolites have not been used to prepare the catalyst for dehydrogenation of ethylbenzene with CO2.
This work focuses on the effect of the different X zeolites on the dehydrogenation of ethylbenzene with CO2 for the first time. A variety of the modified X zeolites with different acid sites and base sites were prepared by metallic ion-exchange. After the catalytic performance of the modified X zeolites was investigated, the mechanism of acid-based co-catalysis for the dehydrogenation of ethylbenzene with CO2 was discerned.
HX containing Cs2O was prepared by impregnation of HX with CsOH solution, and calcined at 793 K for 2 h after drying. The modified catalyst was denoted as HX-D%Cs2O, where D referred to the weight percentage of Cs2O in the catalyst.
The characterization of surface properties of materials as acid catalysts or base catalysts is necessary for predicting the catalytic performance. For X zeolites, several methods were reported,21 such as indicator/titration methods,22,23 use of probe molecules,24,25 calorimetry and temperature programmed desorption, spectroscopy of adsorbed molecules,26–30 and testing reactions,31–34 etc. Generally, the base catalysts lead to side-chain alkylation in aromatic alkylation, while the acid catalysts bring about ring alkylation. For example, the reaction of toluene with methanol over basic zeolites produces styrene and ethylbenzene, while xylene was formed over acid zeolites.31,35 Therefore, these two catalytic reactions could be used for identifying the surface acidity or basicity of the modified X zeolites in this work. The results are shown in Table 1.
Catalyst | Toluene conversion (%) | Product selectivity (%) | |||
---|---|---|---|---|---|
Styrene | Ethylbenzene | Xylene | Other aromatics | ||
a Reaction conditions: 703 K, toluene/methanol molar ratio of 5.0, WHSV of 1.0 h−1, atmosphere pressure (N2), N2 flow rate of 30 ml min−1. The detailed calculation equation of the conversion, selectivity and yield is shown in the ESI (with page 1, mass balance obtained, 2). | |||||
NaX | 1.21 | 6.50 | 13.52 | 55.83 | 24.15 |
HX | 9.25 | 0 | 0.72 | 87.92 | 12.08 |
HX-5%Cs2O | 6.16 | 0 | 0 | 82.36 | 16.92 |
KX | 3.91 | 20.62 | 79.38 | 0 | 0 |
CsX | 7.10 | 20.70 | 79.30 | 0 | 0 |
As listed in Table 1, different modified X-type zeolites exhibited different reactivity in the alkylation of toluene with methanol. KX and CsX presents 3.91% and 7.10% conversion of side-chain alkylation of toluene with methanol, only producing ethylbenzene and styrene. HX and HX-5%Cs2O zeolite catalysts led to aromatic-ring alkylation (9.25% and 3.91% conversion of toluene), with xylene as the main product. NaX zeolite catalysed the side-chain alkylation and aromatic-ring alkylation simultaneously, with the reaction products of styrene (6.50%), ethylbenzene (13.52%), xylenes (55.83%) and other aromatics (24.15%). Above these facts imply that alkali cation-exchanged zeolites such as KX and CsX mainly possess base sites, and NaX zeolite possesses both weaker base sites and acid sites. In contrast, there are mainly acid sites on HX and HX-5%Cs2O zeolites. Different types of alkali metal ion-exchanged X zeolites were applied to the side chain alkylation of toluene with methanol by Yashima.31 They found that total basicity of molecular sieve was proportional to the catalytic activity of side-chain alkylation of toluene with methanol, and the catalytic activity of CsX was higher than KX. Other investigations on the side-chain alkylation of toluene with methanol by adjusting the acid-based property of X zeolite drew the same conclusion.36–39 From Table 1, X zeolites modified by K+, Cs+ showed higher catalytic activity for the side-chain alkylation, whereas HX zeolite showed higher catalytic activity for the aromatic-ring alkylation. This phenomenon arises from the order of total alkalinity of X-type zeolites, ranking as HX < NaX < KX < CsX.
The amount of acid sites and base sites of the modified X zeolites were also characterized by IR with pyridine adsorption and phenol adsorption, as shown in Tables 2 & 3, respectively. More detailed dates are shown in Tables S2 and S3.† Obviously, the total acidity of X-type zeolites was in order of HX > HX-5%Cs2O > NaX > KX > CsX, whereas the total basicity behaved a completely opposite tendency. The loading of Cs2O or ion exchange with K+, Cs+ increased the total basicity of X zeolite, which significantly accompanied with the reduction of acidity. The characterization results are in accordance with the results obtained from the reaction of the alkylation of toluene with methanol.
Zeolites | Bronsted acid (mmol g−1) | Lewis acid (mmol g−1) | ||
---|---|---|---|---|
473 K | 673 K | 473 K | 673 K | |
HX | 1.82 | 0.35 | 0.64 | 0.10 |
HX-5%Cs2O | 0.31 | 0.10 | 0.40 | 0.07 |
NaX | 0.08 | 0.01 | 0.13 | 0.02 |
KX | 0.06 | 0.01 | 0.11 | 0.02 |
CsX | 0.04 | 0.00 | 0.07 | 0.01 |
Zeolites | Base sites/(mmol g−1) | |
---|---|---|
473 K | 673 K | |
HX | 0.06 | 0.03 |
HX-5%Cs2O | 0.19 | 0.05 |
NaX | 0.43 | 0.09 |
KX | 0.76 | 0.24 |
CsX | 1.12 | 0.33 |
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Fig. 2 The selectivity of oxidative dehydrogenation of ethylbenzene with CO2 over the modified X zeolites. Reaction conditions: 818 K, WHSV of 0.5 h−1, atmosphere pressure, CO2/ethylbenzene of 8.0, CO2 flow rates of 30 ml min−1, obtained from Fig. S1.† |
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Fig. 3 The oxidative dehydrogenation of ethylbenzene with CO2 over HX zeolite. Reaction conditions: 818 K, WHSV of 0.5 h−1, atmosphere pressure, CO2/ethylbenzene of 8.0, CO2 flow rates of 30 ml min−1, obtained from Fig. S1.† |
Catalyst | Ethylbenzene conversion (%) | Styrene yield (%) | Product selectivity (%) | ||
---|---|---|---|---|---|
Styrene | Benzene | Toluene | |||
a Reaction conditions: 818 K, WHSV of 0.5 h−1, atmosphere pressure, CO2/ethylbenzene of 8.0, CO2 flow rates of 30 ml min−1, obtained from Fig. S1. The detailed calculation equation of the conversion, selectivity and yield is shown in the ESI (with page 1, mass balance obtained, 1). | |||||
NaX | 9.47 | 8.49 | 89.61 | 3.02 | 7.37 |
KX | 10.53 | 9.69 | 92.08 | 2.27 | 5.56 |
CsX | 6.94 | 6.65 | 95.41 | 0 | 4.59 |
HX-5%Cs2O | 2.57 | 1.87 | 72.59 | 8.87 | 18.96 |
As shown in Fig. 3, with increasing the reaction time, the conversion of ethylbenzene, the selectivity of styrene and other by-products show different trends over HX. Combining with Table 4, it can be seen that HX, NaX, KX and CsX behaved different catalytic properties for ethylbenzene dehydrogenation, forming the different products including styrene, benzene and toluene. Besides, CO and H2 were detected in the effluent gases, but the content of H2 was very low. It is suggested that CO2 behaves as an oxidant for the oxidative dehydrogenation of ethylbenzene to styrene.
At the initial reaction stage, HX catalyst has higher activity, and the conversion of ethylbenzene can be up to 18.70%. However, ethylbenzene was mainly converted to benzene (50.37%) and toluene (22.14%) by dealkylation. The selectivity of objective styrene was only 18.98%, accompanied by a small amount of xylenes. As the reaction proceeds, the conversion of ethylbenzene was gradually reduced. However, the selectivity of styrene was increasing. As can be seen from Table 4, the reaction of ethylbenzene dehydrogenation has much higher selectivity over NaX (89.61%), KX (92.08%) and CsX (95.41%) than HX (16.14%) or HX-5%Cs2O (72.59%). Among them, KX catalyst shows the highest activity, and there is no benzene formed over CsX zeolite. In conclusion, it shows the distinct catalytic properties over different modified X zeolites for the oxidative dehydrogenation of ethylbenzene with CO2.
There are a lot of acid sites on the fresh HX zeolite, which are the active sites for the dealkylation and disproportionation of ethylbenzene. Therefore, the conversion of ethylbenzene is high and the selectivity of styrene is low at the initial stage. Generally, the strong acid sites on the surface of zeolites can cause the by-reaction to generate coke deposition, and the coke deposition in turn covers these strong acid sites. Therefore, the reactivity of dealkylation and disproportionation reaction significantly decreased after 4 h with the decreasing of the selectivity of benzene (from 56.02% to 14.90%) and toluene (from 20.87% to 12.96%). As a result, the selectivity of styrene significantly increased from 16.14% to 72.14% without forming multi-methylbenzene. In addition, the introduction of Cs2O species to HX zeolite, which neutralized a part of strong acid sites, weakens the activity of ethylbenzene dealkylation significantly (Table 4). This result indicates that the strong acid sites tend to cause side reactions, such as ethylbenzene dealkylation and disproportionation, etc.
As can be seen in Table 4, the catalytic activity of KX, NaX and CsX zeolite for the oxidative dehydrogenation of ethylbenzene with CO2 follows the order of KX > NaX > CsX. This phenomenon indicates that the basic strength of catalysts is too high to be unfavourable for this catalytic process.
Cesium oxide has been loaded onto HX zeolite to adjust the surface acidity and basicity by covering some acid sites and introducing the proper base sites. This modification greatly improved the selectivity of styrene (from 16.14% to 72.59%). However, the reactivity remarkably decreased (from 56.02% to 2.57%) with the reduction of acid sites.
Based on the above results, it is considered that the co-catalysis between acid sites with base sites is indispensable for the oxidative dehydrogenation of ethylbenzene to styrene with CO2, and the basic strength of the catalyst greatly influences the selectivity of styrene.
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Fig. 4 Ethylbenzene conversion over CsX under different carrier gases. Reaction conditions: 818 K, WHSV of 0.5 h−1, atmosphere pressure, CO2/ethylbenzene of 8.0, N2/ethylbenzene of 8.0, N2/CO2 flow rates of 30 ml min−1, obtained from Fig. S1.† |
In addition, in comparison to the selectivity of styrene and the by-products over all X-type zeolites (HX, HX-5%Cs2O, NaX, KX, CsX), it's found that the coordination between proper base sites and acid sites is more beneficial for the dehydrogenation of ethylbenzene to styrene. This result is similar to the conclusion on the combination of ethylbenzene dehydrogenation and CO2 shift-reaction over a sodium oxide/alumina catalyst by Sato et al.41 Based on the above facts, the mechanism of oxidative dehydrogenation of ethylbenzene with CO2 over the modified X zeolites was suggested, as shown in the Fig. 5.
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Fig. 5 Schematic of oxidation dehydrogenation of ethylbenzene with CO2 over the modified X zeolites. |
Firstly, ethylbenzene is strongly adsorbed on the large cations of zeolite extra framework due to the interactions of the ethylbenzene π-electrons (electron pair donor) and the cation (electron pair acceptor). These interactions withdraw electron from the aromatic ring and facilitate the polarization of the α-H of ethyl. Additionally, the ethyl group of ethylbenzene interacts with the oxygen atoms of the basic framework, further polarizing the α-H of ethyl.42 Secondly, a negatively charged O− is formed from CO2 adsorbed on the other oxygen atoms of the basic framework with a C-atom polarized positively. The negatively charged O− is bonded with the positively charged α-H, simultaneously polarized and captured a β-H. Finally, styrene molecules desorb from the X zeolites, and CO2 molecules activated by base sites react with the protons to produce H2O and CO. In this way, the process of the oxidative dehydrogenation of ethylbenzene is completed. Therefore, the cooperation of acid sites and base sites over the modified X zeolites promotes the oxidative dehydrogenation of ethylbenzene with CO2 efficiently.
As shown in Fig. 6, CsX zeolite catalyst presents a 29.94% conversion of ethylbenzene with high styrene selectivity (89.59%) and good stability (46 h) for oxidative dehydrogenation of ethylbenzene with CO2. At the initial stage of the reaction, the catalytic activity of CsX gradually increased from 16.10% to 29.94%. It indicates that the catalyst need to be activated, then it exhibits a higher catalytic activity. During the initial 39 h, the selectivity to styrene was stable (around 90%). Then the styrene selectivity gradually decreased from 89.59% to 69.75% with increasing activity of ethylbenzene dealkylation to toluene and benzene. The catalysts became deep black after time on stream of 46 h. The TG curve of the used CsX has two obvious weight loss peaks located at 333–553 K and 673–1043 K, respectively. The first weightlessness peak should be attributed to the peak of desorption of volatile organic compounds or decomposition components, and the second weight loss peak is assigned to the decomposition of coke. The amount of coke over CsX is 9.91% after 46 h. As shown in Table S4,† after the used zeolite was calcined at 873 K for 6 h in air atmosphere, the catalytic activity and the selectivity of styrene could be recovered to the level of fresh catalyst. And after the second time regeneration, the activity of catalysts can return to about 86% of the fresh catalyst with a little reduction. Therefore, it can be confirmed that coke deposition on CsX zeolite is the main reason for the catalyst deactivation in the oxidative dehydrogenation of ethylbenzene with CO2.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c5ra13107c |
This journal is © The Royal Society of Chemistry 2015 |