Aquivion® PFSA-based spray-freeze dried composite materials with SiO2 and TiO2 as hybrid catalysts for the gas phase dehydration of ethanol to ethylene in mild conditions

Aquivion PFSA resin, a perfluorinated ion-exchange polymer, has been used as a heterogeneous strong acid catalyst for a range of reactions; however, the activity of this material is limited due to the extremely low surface area of the polymer. In this paper we described the one-step synthesis of Aquivion® PFSA-based hybrid materials using heterocoagulation and spray-freeze-drying of sols containing the precursor of the active phases. The intimated encapsulation of different nano-oxides, such as TiO2 and SiO2 in the superacid resin matrix was easily obtained using this technique and compared with similar catalysts prepared by the impregnation conventional route. The approach led to the preparation of porous micro-granules characterised by a high homogeneity in the phase distribution and high surface area. The prepared materials were active and selective for the gas phase dehydration of ethanol to ethylene in mild conditions. The increase of the porosity improved the activity of the composites, compared to the pure Aquivion® PFSA, and allowed to reduce the amount of the superacid resin. Moreover, the type of encapsulated oxide, TiO2 or SiO2, modified the improved performance of the catalysts, having TiO2 the higher efficiency for ethanol conversion and selectivity in ethylene at very low temperature.