Direct methane utilization through benzene dehydroalkylation catalyzed by Co²⁺ sites in ZSM-5 intersections

Abstract

Cobalt cations exchanged in ZSM-5 are active for the direct dehydromethylation of benzene with CH4. While toluene is the primary product, an alternate reaction pathway leads also to the formation of biphenyl and phenyltoluene. This not only diminishes the selectivity but also contributes to the deactivation of the catalyst. Temperature-programmed surface reactions show that benzene adsorbs strongly on the exchanged Co2+ cations, essentially blocking the sites for alkylation below 400 °C. At temperatures exceeding 400 °C, the partial desorption of benzene enables its reaction with CH4, leading to the formation of toluene. The formation of biphenyl is kinetically hindered, and its onset is only observed at temperatures above 450 °C. When CH4 is allowed to chemisorb on Co2+ sites prior to exposure to benzene, the formation of toluene is detected at temperatures below 400 °C. By infrared spectroscopy of benzene adsorption and UV–Vis spectroscopic characterization, we identified the existence of intersections in ZSM-5 where three H+ are in proximity. The ion exchange of a zeolite lattice Al3+ pair in such positions leads to the formation of a Co2+ site near a free Brønsted acid site. We observed a correlation between the concentration of this type of Co2+ sites and the catalytic activity of Co-ZSM-5 in benzene alkylation with CH4. This is further supported by the catalytic tests of Co-ZSM-5 materials with specifically a larger proportion of Co sites in sinusoidal channels, as a result of acidic conditions during ion exchange. Based on this, we propose that toluene formation takes place via heterolytic dissociation of CH4 on a Co2+ site at intersections followed by reaction with benzene strongly interacting with an adjacent BAS.