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The selective conversion of methane to methanol (MTM) under mild conditions remains one of the major challenges in heterogeneous catalysis due to the C-H bond strength in methane and hence, the tendency of methanol to undergo overoxidation. Among the catalyst systems investigated for this transformation, Cu-exchanged zeolites, particularly Cu-mordenite (Cu-MOR), have emerged as promising materials because of their ability to stabilize reactive copper-oxo species within confined microporous environments. Despite extensive investigation, substantial differences in methanol productivity are reported for nominally similar Cu-MOR catalysts, highlighting the absence of consistent and transferable synthesis-structure-activity relationships. In particular, the influence of zeolite synthesis history and framework formation on copper speciation and subsequent catalytic performance remains insufficiently understood.
This thesis addresses this challenge through a synthesis-driven investigation of mordenite zeolites, focusing on how hydrothermal synthesis parameters such as structure directing agents and aging time influence framework formation, aluminium siting, copper incorporation, and methane activation. Rather than relying on commercially sourced materials, all zeolites investigated in this work were synthesized in-house under systematically controlled conditions. The work specifically examines the influence of inorganic structure-directing agents (ISDA), gel aging, and isomorphous framework substitution on the resulting framework topology, pore architecture, acidity, and local coordination environments.
A combination of advanced characterization techniques, including diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS), electron paramagnetic resonance (EPR), X-ray absorption spectroscopy (XAS), X-ray diffraction (XRD), solid-state nuclear magnetic resonance (ssNMR), Raman spectroscopy, nitrogen adsorption, and MTM testing, was employed to establish direct synthesis-structure-activity relationships. The obtained results demonstrate that variations in synthesis conditions lead to significant differences in aluminium distribution and framework ordering, which subsequently govern copper speciation as well as the nature of the active Cu species.
The findings reveal that synthesis-induced framework variations strongly influence the stabilization of mono-, and di-meric, copper species within the MOR framework and thereby determine extent of methane activation and thus methanol productivity. Differences in aging conditions and inorganic structure-directing agents were found to alter aluminium siting and Brønsted acidity, leading to measurable differences in copper incorporation and catalytic behaviour during methane-to-methanol conversion. Furthermore, isomorphous site substitution using heteroatoms such as Ga and Fe demonstrated how subtle modifications to framework composition influence crystallinity, copper speciation, and catalytic performance.
Collectively, the results demonstrate that methane-to-methanol performance in CuMOR cannot be optimized solely through adjustment of copper loading or reaction conditions but is intrinsically governed by the synthesis history and directly linked to the framework formation. The zeolite framework must therefore be regarded not as passive support, but rather as an integral component of the catalytic system that dictates active-site formation, copper reactivity, and methane activation behaviour. Ultimately, this work establishes a unified synthesis-framework-activity relationship for Cu-MOR based materials and provides design principles for the rational development of improved methane activation materials and other framework-controlled catalytic systems.