The purpose of this research was to characterize the rhodium exchanged NaX and NaY zeolites as propylene hydroformylation catalysts. Catalytic activity was measured in a differential bed reactor. Flow in situ infrared spectroscopy was used to probe the coordination chemistry of the zeolite modified rhodium carbonyls.

The catalytic activity of rhodium zeolites at atmospheric pressure and between 100-150ºC was measured. The rate of n-butyraldehyde production was approximately 5x10⁻³ moles/g-Rh hr at 150°C. Regioselectivity was dependent upon pretreatment. Precarbonylation with carbon monoxide, drying with air, and heating with N₂ prior to hydroformylation conditions produced a straight to branched isomer ratio (n/i) of 1.9-2.3. Partial reduction with 10% H₂ in N₂ at 127°C lowered n/i to 1.3. Hydrogenation to propane was 3-10 times faster than the hydroformylation rate at 150°C.

Catalytic activity was sensitive to cation exchange conditions. Rhodium form, pH, temperature, and salt concentration altered catalyst behavior. Only RhCl₃•3H₂O preparations on NaY zeolite produced above 80ºC, a pH above 4, and a salt concentration of 0.1N NaCl were required in order to produce an active hydroformylation catalyst. Ammine complexes did not activate under any circumstances.

It was found that the degree of hydration controlled the formation of rhodium carbonyls. On NaY, the hydrated rhodium zeolite reacted with CO at 120ºC to form Rh₆(CO)₁₆. By drying the zeolite in air at 190ºC, two rhodium dicarbonyls, Rh(CO)₂(O_z)₂-NaY and Rh(CO)₂(O_z)(H₂O)-NaY, were formed. The rhodium carbonyls were reacted with n-hexyl diphenylphosphine to determine rhodium locations. Rh(CO)₂(O_z)₂-NaY was located at the surface while the other two species were located within the zeolite cages. One dicarbonyl species, Rh(CO)₂(O_z)₂-NaX, was observed on NaX. It was determined by reactions with phosphines that this species resides in the zeolite cages.

Reaction intermediates identified by FTIR under hydroformylation conditions suggested that the heterogeneous catalyst proceeds through a mechanism similar to that occurring in solution. Heterogeneous reaction orders also agreed with those reported for homogeneous hydroformylations.

Addition of dimethylphenylphosphine (DMP) to the rhodium zeolites significantly increased regioselectivity. Rates were slightly less than those from the unmodified rhodium carbonyls. However, the phosphine modified rhodium zeolites deactivated within 16 hours. Continuous exposure to DMP decreased the rate of deactivation.