Highly Loaded Fe-MCM-41 Materials: Synthesis and Reducibility Studies

Fe-MCM-41 materials were prepared by different methods. The Fe was both incorporated into the structure and formed crystallites attached to the silica. High Fe content MCM-41 (~16 wt%) with retention of mesoporosity and long-range order was achieved by a range of new synthetic methodologies: (i) by delaying the addition of Fe(3+)(aq) to the stirred synthesis gel by 2 h, (ii) by addition of Fe(3+) precursor as a freshly-precipitated aqueous slurry, (iii) by exploiting a secondary synthesis with Si-MCM-41 as SiO(2) source. For comparative purposes the MCM-41 was also prepared by incipient wetness impregnation (IWI). Although all these synthesis methods preserved mesoporosity and long-range order of the SiO(2) matrix, the hydrothermally-fabricated Fe materials prepared via the secondary synthesis route has the most useful properties for exploitation as a catalyst, in terms of hydrothermal stability of the resulting support. Temperature-programmed reduction (TPR) studies revealed a three-peak reduction pattern for this material instead of the commonly observed two-peak reduction pattern. The three peaks showed variable intensity that related to the presence of two components: crystalline Fe(2)O(3) and Fe embedded in the SiO(2) matrix (on the basis of ESR studies). The role of secondary synthesis of Si-MCM-41 on the iron reducibility was also demonstrated in IWI of sec-Si-MCM-41.