Benzene Selective Oxidation with N2O on Fe/MFI Catalysts: Role of Zeolite and Iron Sites on the Deactivation Mechanism

The catalytic performances of Fe-zeolites having MFI structures and in which the Fe introduced either by ion exchange or during the hydrothermal synthesis has undergone partial framework to extra-framework migration induced by controlled heat treatment are reported. In particular, the catalytic behavior as function of time-on-stream and the formation of carbonaceous species were studied. The results suggest that only a small fraction of the iron is active in the selective oxidation of benzene to phenol in the presence of N2O. It is suggested that the active fraction is formed by isolated iron ions in a pseudo-octahedral configuration with the sites positioned in hydroxyl nests (defects) of the zeolite and is selective in phenol formation as a result of in situ reduction during the catalytic tests. Two possible pathways of carbonaceous species were identified, the first through the intermediate further hydroxylation of phenol and the second through the coupling of phenol with benzene or another phenol molecule. This second pathway is the dominant mechanism of formation of carbonaceous species, although the relative rate of the two pathways depends on the zeolite characteristics and iron loading. It is also suggested that the second pathway depends on the strong chemisorption of phenol, probably on Lewis acid sites, which hinders the fast back-desorption of phenol out from the zeolite channels and thus favors the formation of carbonaceous species. Catalysts prepared by hydrothermal treatment show a lower rate of deactivation than those prepared by ion exchange, although the latter show a comparable productivity to phenol for amounts of iron in extra-framework positions around 20 to 30 times lower. The results also indicate that the presence of Al in the zeolite framework is beneficial for reducing the rate of deactivation as compared to that of Fe-silicalite samples.