Supercritical ion exchange: A new method to synthesize copper exchanged zeolites

A new technique termed Supercritical Ion Exchange (SCIE) was developed and used to synthesize Cu-mordenite (Cu-MORS). The ion exchange takes place between the Cu complex (Copper(II)trifluoroacetylacetonate) dissolved in supercritical CO2 (scCO2) and the extraframework protons in mordenite zeolite without requiring an aqueous phase. The occurrence of the ion exchange reaction was demonstrated by using 1H NMR analysis of the high-pressure fluid phase samples and by visual inspection of the fluid phase color change during the synthesis. SCIE resulted in selective ion-exchange inferred by the equilibrium isotherm. The prepared catalysts were used for the stepwise direct methane to methanol (sDMTM) process and results showed that methanol productivity increased linearly with increasing Cu loading up to a certain Cu wt%. Cu-MORS displayed 16% higher methanol productivity as compared to Cu-MORA (prepared by aqueous ion exchange) with the same Cu loading. The results demonstrated the importance of site selective ion-exchange for zeolite catalysis.