Isothermal activation of Mo2O52+-ZSM-5 precursors during methane reactions: effects of reaction products on structural evolution and catalytic properties

The dynamics of carburization of Mo-oxo precursors exchanged onto H-ZSM-5 strongly influence initial induction periods and steady-state rates during catalytic pyrolysis of CH4 to alkenes and arenes at 900 - 1000 K. The effects of co-reactants and of activating conditions were examined by on-line time-resolved mass spectrometric analysis of effluent streams using rigorous analyses to account for equilibrium effects on measured rates. Ethene co-reactants and the larger hydrocarbons to which it converts on acid sites in H-ZSM-5 led to much faster carburization of exchanged (Mo2O5)(5+) dimers and to shorter induction periods than with pure CH4 reactants, but steady-state pyrolysis rates were unchanged, indicating that CH4 and C2H4 form similar MoCx clusters during carburization of exchanged Mo-oxo precursors. H-2 treatment at 973 K before CH4 reactions led to reduction of Mo6+ species to Mo4+, which carburize faster than (Mo2O5)(5+) precursors during initial contact with CH4. This H-2 pretreatment or the use of CH4 - H-2 reactant mixtures did not influence steady-state pyrolysis rates, once contributions from reverse reactions were taken into account. With pure CH4 streams, (Mo2O5)(5+)- ZSM- 5 converts to active MoCx clusters within zeolite channels via autocatalytic processes, in which higher hydrocarbons, initially formed during initial conversion of MoOx to MoCx structures, lead to faster carburization of downstream catalyst sections. Concurrently, H2O and CO2 formed during this incipient carburization of exchanged (Mo2O5)(5+) and unexchanged MoO3 present in trace amounts inhibit and even prevent carburization and lengthen activation periods. Activation protocols with C2H4 were also successful in the activation of more refractory high-valent metal-oxo species, such as WOx and VOx, exchanged onto H-ZSM-5. The formation of active carbide structures occurred in less than 300 s, instead of 4 ks and 16 ks for VOx and WOx samples, respectively, in pure CH4 reactants. These activation protocols led to VCx - ZSM5 catalysts about three times more active than those activated in pure CH4 reactants.