High-resolution electron zeolitic catalysts

FIGURE 9.2 This high-resolution electron micrograph shows the unique pore structure of the ZSM-5 zeolite catalyst. Molecules such as methanol and hydrocarbons can he catalytically converted within the pores to valuable fuels and lubricant products. Courtesy, Mobil Research and Development Corporation. 

We discuss the combined use of high-resolution electron microscopy, electron diffraction, optical diffractometry and computer graphics for investigating zeolitic structure. Particular attention is given to twinned faujasitic materials and to intergrowth structures in ZSM-5 and ZSM-11 catalysts. 

Structure Elucidation from Crystal Powders. For many practical materials, such as polymers and zeolite catalysts, it is impossible to synthesize large crystals. Therefore the structure has to be found from powders. Powder XRD (preferably using synchrotron radiation) and neutron diffraction are the most important techniques, but experiments using other analysis methods like High Resolution Electron Microscopy (HREM) and Electron Diffraction (ED), MAS-NMR and EXAFS can add valuable information (8). 

By the 1980s most of the aluminosilicate zeolites currently used industrially were known, and the emphasis shifted to the study of these materials using a range of powerful new techniques that came of age at this time. These included, in particular, solid state NMR, X-ray and neutron powder diffraction analysis, high resolution electron microscopy and computational methods. All were ideal for the study of structural details of solids that were rarely available, and never used in industrial applications, other than as microcrystalline powders. All these techniques are applicable to the bulk of the solid - this in turn makes up the (internal) surface, which is accessible to adsorbed molecules. Since the techniques are able to operate under any conditions of gas pressure, they may be used to extract structural details in situ under the operating conditions of ion exchange, adsorption and catalysis. In particular, zeolitic systems have proved ideal for the study, understanding and subsequent improvement of solid acid catalysts. 

For the detailed study of reaction-transport interactions in the porous catalytic layer, the spatially 3D model computer-reconstructed washcoat section can be employed (Koci et al., 2006, 2007a). The structure of porous catalyst support is controlled in the course of washcoat preparation on two levels (i) the level of macropores, influenced by mixing of wet supporting material particles with different sizes followed by specific thermal treatment and (ii) the level of meso-/ micropores, determined by the internal nanostructure of the used materials (e.g. alumina, zeolites) and sizes of noble metal crystallites. Information about the porous structure (pore size distribution, typical sizes of particles, etc.) on the micro- and nanoscale levels can be obtained from scanning electron microscopy (SEM), transmission electron microscopy ( ), or other high-resolution imaging techniques in combination with mercury porosimetry and BET adsorption isotherm data. This information can be used in computer reconstruction of porous catalytic medium. In the reconstructed catalyst, transport (diffusion, permeation, heat conduction) and combined reaction-transport processes can be simulated on detailed level (Kosek et al., 2005). 

The resurgence of interest in the field of zeolite chemistry, which has been stimulated by the appreciation of their enormous potential as catalysts, has led to the application of several sophisticated physical methods in the study of their structural properties. Important advances have already been made using high resolution, solid state NMR (1,2) and electron microscopy (3), and in this paper we discuss the scope and limitations of neutron diffraction studies with powder samples, with some specific applications to zeolite-A and synthetic faujasite. 

Analytical electron microscopy of individual catalyst particles provides much more information than just particle size and shape. The scanning transmission electron microscope (STEM) with analytical facilities allows chemical analysis and electron diffraction patterns to be obtained from areas on the order of lOnm in diameter. In this paper, examples of high spatial resolution chemical analysis by x-ray emission spectroscopy are drawn from supported Pd, bismuth and ferric molybdates, and ZSM-5 zeolite. 

---