Hydrothermal synthesis is the state-of-the-art technique for the preparation of zeolites and related porous solids. However, when it comes to the preparation of nanosized zeolites, this technique is limited by low yields, separation problems and high amounts of waste. In this work, we utilized the strengths of a combination of spray drying and steam-assisted crystallization (SAC), also known as dry gel conversion, to reduce these problems. At spray drying temperatures between 300 and 400 °C, it was possible to convert all the amorphous material via SAC into zeolite particles without extra addition of template. Kinetic studies of SAC revealed that about 4 to 8 days are needed to achieve the formation of a 100% crystalline product. The newly formed crystalline phase was crystallized on the surface of the nanosized zeolites and led to a slight increase in the primary particle size while the macroscopic morphology of the spray-dried aggregates was preserved. This work demonstrates that the combination of spray drying and SAC are useful tools in supplementing the hydrothermal synthesis of nanosized zeolites.

The direct synthesis of dimethyl ether (DME) from synthesis gas (STD) via methanol as an intermediate is a promising option for implementation of the Power-to-X concept, involving the storage of renewable electrical energy via hydrogen or synthesis gas in synthetic fuels or chemicals. The STD reaction shifts the equilibrium conversion dictated by thermodynamics to higher values compared to methanol synthesis alone at given conditions. Notwithstanding, proper catalyst materials and a suitable configuration have to be found that would support high CO-conversion as well as high DME-selectivity. In this work, different catalyst configurations obtained by combining CuO/ZnO/Al2O3 (CZA) for methanol synthesis with zeolite H-ZSM-5 (Z) for its dehydration are investigated via simulation based on a crystallite-pore network model, able to describe e.g. the polycrystalline anisotropic zeolite. In this way, hybrid particles with proximity of the two catalysts in both, the micrometer-scale (medium proximity, CZA+Z) and in the sub-micrometer-scale (close proximity, CZA&Z) as well as structured core@shell particles (CZA@Z) were investigated for a tubular reactor. Moreover, their planar (coated) counterparts, namely the hybrid layered systems with medium (CZA#Z) and close proximity (CZA&/Z) and a structured double layer system (CZA//Z) were investigated for a wall-coated microchannel reactor. The performance of these systems in the STD reaction was studied focusing on the influence of the CZA/Z ratio and the operational parameters (temperature, GHSV, feed composition). According to this study, hybrid particles with close proximity of the two catalysts as well as the double layer structures showed the best performance in terms of CO-conversion and DME-selectivity.

The direct synthesis of dimethyl ether (DME) from synthesis gas via methanol as an intermediate is a promising process for realizing a decentralized, small-scale Power-to-X concept. The efficient realization of this coupled process depends to a large extent on the appropriate catalyst configuration, i.e. the combination of the catalyst for methanol formation with the one for the subsequent dehydration step. In this work, two catalyst configurations were compared in terms of CO-conversion and DME-selectivity using modelling and experiments. Catalysts for methanol formation (Cu/ZnO/Al2O3, CZA) and dehydration (Zeolite H-ZSM-5, Z) prepared via flame spray pyrolysis and hydrothermal synthesis, respectively, were combined in the form of hybrid pellets (CZA&Z) and CZA-core@zeolite-shell (CZA@Z) particles. During the synthesis of the CZA@Z system, alteration of the CZA core in terms of CuO-reducibility and activity in methanol synthesis were found after individual steps of calcination and hydrothermal shell synthesis. In contrast, the preparation of the CZA&Z system presents an easy and tunable method with promising catalytic properties in terms of CO-conversion and DME-selectivity, once the proper mass ratio of the two catalysts was set. From modelling, for the same CZA/Z ratio in general higher CO-conversion was found for the CZA&Z system as compared to the CZA@Z, while the latter system shows higher DME-selectivity.

We present a high-temperature and high-pressure gas adsorption measurement device based on a high-frequency oscillating microbalance (5 MHz langatate crystal microbalance, LCM) and its use for gas adsorption measurements in zeolite H-ZSM-5. Prior to the adsorption measurements, zeolite H-ZSM-5 crystals were synthesized on the gold electrode in the center of the LCM, without covering the connection points of the gold electrodes to the oscillator, by the steam-assisted crystallization (SAC) method, so that the zeolite crystals remain attached to the oscillating microbalance while keeping good electroconductivity of the LCM during the adsorption measurements. Compared to a conventional quartz crystal microbalance (QCM) which is limited to temperatures below 80 °C, the LCM can realize the adsorption measurements in principle at temperatures as high as 200-300 °C (i.e., at or close to the reaction temperature of the target application of one-stage DME synthesis from the synthesis gas), owing to the absence of crystalline-phase transitions up to its melting point (1,470 °C). The system was applied to investigate the adsorption of CO2, H2O, methanol and dimethyl ether (DME), each in the gas phase, on zeolite H-ZSM-5 in the temperature and pressure range of 50-150 °C and 0-18 bar, respectively. The results showed that the adsorption isotherms of these gases in H-ZSM-5 can be well fitted by Langmuir-type adsorption isotherms. Furthermore, the determined adsorption parameters, i.e., adsorption capacities, adsorption enthalpies, and adsorption entropies, compare well to literature data. In this work, the results for CO2 are shown as an example.