Shifts in catalyst deactivation mechanisms as a function of surface coverage during Friedel-Crafts acylation in zeolites

The production of commodity chemicals from renewable resources is often accompanied by rapid catalyst deactivation rates. An important example is direct Friedel Crafts acylation, which can yield a range of valuable products from surfactants to renewable transportation fuels. Furanic acyl acceptors are among the most intriguing and promising possible acceptors; however, they undergo self-coupling reactions in the presence of Bronsted acid surface sites leading to rapid catalyst deactivation. In this contribution, we study 2-methylfuran acylation with acetic acid over HZSM-5 catalysts at temperatures ranging from 160 to 240 degrees C, revealing the remarkable shift in deactivation behavior as a function of surface coverage of acetic acid. We reveal that a surface saturated with acetic acid lowers the deactivation rate by blocking the direct access of furanic species to surface sites. However, on surfaces fully saturated with carboxylic acids, deactivation is revealed to proceed via reactions between adsorbed products with gas phase methylfuran reactants.