Chinese Journal of Catalysis ›› 2025, Vol. 78: 215-228.DOI: 10.1016/S1872-2067(25)64806-6

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Channel-passing growth mechanism of coke in ZSM-5 catalyzed methanol-to-hydrocarbons conversion: From molecular structure, spatiotemporal dynamics to catalyst deactivation

Nan Wanga, Yimo Wua, Jingfeng Hana, Yanan Zhanga,f, Li Wangb, Yang Yub, Jiaxing Zhangc, Hao Xiongd, Xiao Chend, Yida Zhoua, Hanlixin Wange,f, Zhaochao Xue, Shutao Xua, Xinwen Guoc, Fei Weid, Yingxu Weia,*(), Zhongmin Liua,f,*()   

  1. aNational Engineering Research Center of Lower-Carbon Catalysis Technology, Dalian Institute of Chemical Physics, Chinese Academy of Sciences, Dalian 116023, Liaoning, China
    bDivision of Energy Research Resources, CAS Key Laboratory of Separation Science for Analytical Chemistry, Dalian Institute of Chemical Physics, Chinese Academy of Sciences, Dalian 116023, Liaoning, China
    cState Key Laboratory of Fine Chemicals, Frontiers Science Center for Smart Materials, School of Chemical Engineering, Dalian University of Technology, Dalian 116024, Liaoning, China
    dBeijing Key Laboratory of Green Chemical Reaction Engineering and Technology, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
    eCAS Key Laboratory of Separation Science for Analytical Chemistry, Dalian Institute of Chemical Physics, Chinese Academy of Sciences, Dalian 116023, Liaoning, China
    fUniversity of Chinese Academy of Sciences, Beijing 100049, China
  • Received:2025-07-02 Accepted:2025-08-05 Online:2025-11-18 Published:2025-10-14
  • Contact: *E-mail: weiyx@dicp.ac.cn (Y. Wei), liuzm@dicp.ac.cn (Z. Liu).
  • Supported by:
    National Natural Science Foundation of China(22288101);National Natural Science Foundation of China(21991090);Distinguished Research Assistant Funding Project of Chinese Academy of Sciences(CAS)

Abstract:

Coke formation is the primary cause of zeolite deactivation in industrial catalysis, yet the structural identity, spatial location and molecular routes of polycyclic aromatic hydrocarbons (PAHs) within confined zeolite pores remain elusive. Here, by coupling matrix-assisted laser desorption/ionization Fourier-transform ion cyclotron resonance mass spectrometry with multi-dimensional chemical imaging, we unveil a channel-passing growth mechanism for PAHs in ZSM-5 zeolites during methanol conversion through identifying the molecular fingerprints of larger PAHs, pinpointing and visualizing their 3D location and spatiotemporal evolution trajectory with atomic resolution and at both channel and single-crystal scales. Confined aromatic entities cross-link with each other, culminating in multicore PAH chains as the both thermodynamically favorable and kinetically trapped host-guest entanglement wrought and templated by the defined molecular-scale constrained microenvironments of zeolite. The mechanistic concept proves general across both channel- and cage-structured zeolite materials. Our multiscale deactivating model based on the full-picture coke structure-location correlations—spanning atom, molecule, channel/cage and single crystal scales—would shed new light on the intertwined chemical and physical processes in catalyst deactivation. This work not only resolves long-standing puzzles in coke formation but also provides design principles for coke-resistant zeolites. The methods and insights would rekindle interest in confinement effects and host-guest chemistry across broader chemistry fields beyond catalysis and carbon materials.

Key words: Zeolites, Methanol-to-hydrocarbons, Coke characterization, Deactivation, Reaction mechanisms