Preparation of Cs/CuAl-LDO@Al2O3@Fe3O4 magnetic catalysts and reaction mechanism of the side-chain alkylation of toluene to styrene

Abstract

A series of Cs/CuAl-LDO@Al2O3@Fe3O4 magnetic catalysts with varied CuAl-LDO contents were prepared by growing CuAl-LDH layers on the surface of Al2O3@Fe3O4 magnetic cores, impregnated with Cs and followed by calcination. The as-synthesized catalysts were characterized by XRD, N2 adsorption-desorption, SEM, TEM(EDS), XPS, NH3-TPD, CO2-TPD, and VSM techniques. The catalytic performance and reusability of the catalysts for the side-chain alkylation of toluene with formaldehyde were evaluated in a micro-high-pressure reactor, and the reaction mechanism was further studied. The results showed that the Al2O3@Fe3O4 magnetic core of the catalyst was about 110 nm, and the CuAl-LDO formed a staggered lamellar structure with a shell thickness of around 30–45 nm. The magnetic catalyst demonstrated excellent catalytic performance and reusability for the side-chain alkylation of toluene with formaldehyde in one-step to styrene. As-synthesized magnetic Cs/CuAl-LDO@Al2O3@Fe3O4 catalyst with CuAl-LDO content of 20 wt% delivered toluene conversion of 7.97% under optimized conditions, while the styrene selectivity and the selectivity of side-chain alkylation were 90.17% and 98.36%, respectively. The reaction mechanism showed that the benzene ring of toluene was stably adsorbed on the Al3+ acid sites of the CuAl-LDO layers. The C–H group of the side-chain of toluene formed carboanions and protons under the action of the Cuδ+–Oδ– base sites. Formaldehyde formed a transition state of adsorbed formaldehyde under the action of Cuδ+ acid sites. Finally, these adsorbed states and intermediate species accomplished the side-chain alkylation of toluene with formaldehyde to styrene in one-step under the synergic action of acid-base sites. The synergistic effects of suitable acid-base sites and lamellar spatial structures in the catalyst were the key to styrene formation with high selectivity.