Isomorphously Substituted [Fe,Al]ZSM-5 Catalysts for Methane Dehydroaromatization

Dehydroaromatization of methane (MDA) under non-oxidative conditions is a promising reaction for direct valorization of natural gas and biogas. Typically, Fe-modified ZSM-5 catalysts display low aromatic productivity and high coke selectivity in the MDA reaction. Herein, we show the benefit of starting from isomorphously substituted Fe-sites in [Fe,Al]ZSM-5 zeolites prepared by direct hydrothermal synthesis. Upon calcination, these samples contain predominantly isolated Fe3+ species, either atomically dispersed within the zeolite framework or anchored at exchange sites inside zeolite channels. In terms of the integral hydrocarbon productivity, [Fe,Al]ZSM-5 catalysts outperform Fe/ZSM-5, prepared by impregnation, as well as Mo/ZSM-5 catalysts with the same Si/Al ratio and molar metal loading. Operando X-ray absorption spectroscopy coupled with mass spectrometry (XANES-MS) demonstrates that the initial tetrahedral Fe3+ within the zeolite framework or at exchange sites are transformed into octahedral extraframework Fe2+ active sites during the MDA reaction and form small Fe2O3 clusters during oxidative regeneration. Combining activity measurements and operando thermogravimetry shows that the duration of the induction period, related to the formation of active hydrocarbon pool intermediates, strongly depends on the Fe dispersion and loading and can be used as a suitable descriptor for the MDA activity of [Fe,Al]ZSM-5. The shorter induction period of [Fe,Al]ZSM-5 in comparison to impregnated Fe/ZSM-5 can be linked to the higher methane conversion rate over highly dispersed Fe-sites and faster formation of active hydrocarbon pool intermediates.