α-Fe(II)
active sites in iron zeolites catalyze N2O decomposition
and form highly reactive α-O that selectively
oxidizes unreactive hydrocarbons, such as methane. How these α-Fe(II)
sites are formed remains unclear. Here different methods of iron introduction
into zeolites are compared to derive the limiting factors of Fe speciation
to α-Fe(II). Postsynthetic iron introduction procedures on small
pore zeolites suffer from limited iron diffusion and dispersion leading
to iron oxides. In contrast, by introducing Fe(III) in the hydrothermal
synthesis mixture of the zeolite (one-pot synthesis) and the right
treatment, crystalline CHA can be prepared with >1.6 wt % Fe, of
which
>70% is α-Fe(II). The effect of iron on the crystallization
is investigated, and the intermediate Fe species are tracked using
UV–vis-NIR, FT-IR, and Mössbauer spectroscopy. These
data are supplemented with online mass spectrometry in each step,
with reactivity tests in α-O formation and with methanol yields
in stoichiometric methane activation at room temperature and pressure.
We recover up to 134 μmol methanol per gram in a single cycle
through H2O/CH3CN extraction and 183 μmol/g
through steam desorption, a record yield for iron zeolites. A general
scheme is proposed for iron speciation in zeolites through the steps
of drying, calcination, and activation. The formation of two cohorts
of α-Fe(II) is discovered, one before and one after high temperature
activation. We propose the latter cohort depends on the reshuffling
of aluminum in the zeolite lattice to accommodate thermodynamically
favored α-Fe(II).