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MFI zeolites stabilize rhodium hydroformylation catalysts through two cooperating effects: their ten-membered-ring channels and pore intersections physically confine Rh atoms or subnanometre clusters, while framework oxygen, silanol nests, phosphate and Zn–O motifs coordinate the metal. Confinement limits migration and sintering, fixes how an olefin approaches Rh, and can favor linear aldehydes. The site is not a single permanent molecule: CO and H2 change Rh coordination and oxidation state during operation, so the working catalyst is a dynamic family of confined Rh–O environments.
What MFI contributes to a rhodium catalyst
MFI is a zeolite framework represented by silicalite-1, ZSM-5 and related structures. Its intersecting ten-membered-ring channels create pockets on the scale of individual metal atoms, clusters and reactant molecules. A Rh species placed inside those channels cannot move or grow as freely as a species on an open oxide or carbon surface.
Confinement controls metal geometry
The channel walls restrict the number of neighboring Rh atoms that can meet. That geometric constraint slows the migration and coalescence that produce larger, less selective particles. It also gives incoming olefins a narrower range of approach angles. In subnanometre Rh-MFI clusters, this effect produced linear-to-branched aldehyde ratios as high as 400 for C6–C12 alpha-olefins in a 2024 Nature Catalysis study. The result shows that pore shape can replace part of the geometric control normally supplied by a soluble ligand.
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The framework acts as a solid ligand
MFI is not merely a container. Framework oxygen atoms and defect sites can donate or withdraw electron density and hold Rh in defined positions. Silanol nests (clusters of Si–OH groups created by framework defects), phosphate groups and Zn–O motifs each provide different coordination environments. These contacts reduce Rh mobility while leaving enough flexibility for the metal to bind CO, H2 and an olefin in sequence.
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Local enrichment improves effective contact
Hydrophobic or defect-rich pore walls can concentrate an olefin near an internal Rh site. A higher local olefin concentration raises the probability of productive insertion without requiring a high bulk concentration. This explains why a catalyst can show strong activity even when the total Rh loading is small, provided the sites are inside accessible channels rather than buried in inaccessible crystal regions.
How a confined Rh site carries out hydroformylation
Hydroformylation adds CO and H2 across an olefin to form linear (normal, or n-) and branched (iso, or i-) aldehydes. In MFI, each elementary step must occur within a changing pore-bound coordination sphere.
- Olefin entry and orientation. The substrate diffuses through MFI channels and is enriched near Rh. The ring aperture and channel intersections orient the C=C bond before it binds.
- Olefin insertion. A Rh–alkyl intermediate forms when the coordinated olefin inserts into a Rh–H bond. Restricted space can favor the orientation that leads to the linear alkyl pathway.
- CO binding and insertion. CO coordinates to Rh and inserts into the Rh–alkyl bond to make an acyl intermediate. The framework must accommodate a temporary increase in Rh coordination without allowing neighboring Rh atoms to aggregate.
- Hydrogenolysis and aldehyde release. H2 supplies hydrogen for acyl conversion and product release. The resulting aldehyde exits through the same micropore network, leaving a Rh species ready for another cycle.
Because Rh changes coordination number during these steps, the best support is neither completely rigid nor completely mobile. MFI supplies a rigid boundary for position and shape, but Rh–O bonds, defect hydroxyls and adsorbates can rearrange as the cycle proceeds.
Why the active site is dynamic under syngas
There is no universal formula for the active site in every Rh-MFI sample. Rh0 and Rh2O3 precursors can evolve under CO/H2 into carbonyl species such as Rh(I)(CO)2 or into Rh3+-containing environments. The proportion of each state depends on preparation, support defects, gas composition, temperature, pressure and the current reaction intermediate.
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Phosphorus-containing environments are especially important because they preferentially stabilize productive oxidized Rh species. In one phosphate-containing MFI system, phosphate generated from a phosphonium template stabilized isolated Rh3+ sites; sites derived from Rh2O3 were more effective for low-temperature ethylene hydroformylation than reduced Rh0. This does not mean that Rh3+ is always the active state. It means that the oxidation-state distribution established under syngas is part of the catalyst design.
Stabilization motifs reported for MFI-supported Rh
Silanol-rich MFI
Silanol nests provide hydroxyl groups that can anchor Rh-containing particles and enrich olefins in the same local region. A 2023 Nature Communications study reported an approximately 50,000 h−1 turnover frequency for a silanol-rich MFI catalyst. The figure is the turnover frequency reported for that study’s catalyst and conditions; it is not a universal value for every silanol-rich sample.
Rh–O–P environments
Phosphate groups form stronger, more electronically distinctive contacts than ordinary siloxane walls. In the phosphate-derived system, isolated Rh3+ sites were retained in the MFI environment, and the support helped prevent the reduction and migration that would otherwise produce less useful Rh species. Phosphate therefore affects both physical anchoring and the electron density available for CO and olefin binding.
Atomically dispersed Rh inside silicalite-1
In Rh@S-1, atomically dispersed Rh resides inside silicalite-1 micropores. Internal sites can be distinguished from external Rh by selectively poisoning the external population with the bulky thiol DMBT. The separation is useful because it tests whether activity and regioselectivity come from true micropore confinement rather than from Rh deposited on the outside of the crystals.
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Subnanometre clusters in sinusoidal channels
Small Rh clusters use the sinusoidal MFI channels as a molecular-scale template. They retain more than one Rh atom for cooperative chemistry, yet remain too small for unrestricted particle growth. The very high linear selectivity observed for C6–C12 alpha-olefins is consistent with a channel that discriminates between the two possible insertion geometries.
Self-pillared Rh1@SPP-MFI
Self-pillared pentasil (SPP-MFI) introduces interlayer mesopores alongside the normal MFI micropores. In Rh1@SPP-MFI, Rh1.5+–O4 units are confined in zeolite cages. Flexible Rh–O bonds allow the site to change coordination during turnover, while interlayer mesopores shorten the path for reactants and products. For 1-octene at 353 K and 2.5 MPa, the 2026 Angewandte Chemie International Edition study reported a turnover frequency of 7,074 h−1.
Rh–Zn anchoring
Co-encapsulated Zn can generate Rhδ+–(O–Zn)x motifs during the induction period. The Zn–O bridge gives Rh an additional anchor and is intended to limit leaching and aggregation. Because the motif develops under reaction conditions, its final structure should be assessed operando rather than inferred only from the calcined precursor.
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Linear selectivity comes from a combination of molecular shape and site chemistry. A narrow channel can make the less hindered end of a terminal olefin approach Rh in a reproducible orientation. Once the olefin is inserted, the same walls can disfavor the conformation leading to the branched alkyl intermediate. Framework oxygen and defects also polarize the adsorbed olefin, changing the relative energies of the two insertion pathways.
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Internal and external Rh do not necessarily behave alike. In the reported Rh@S-1 experiment, total 1-hexene conversion reached 98.3%. Under the study’s low-1-hexene-concentration condition, selectively poisoning external Rh with DMBT raised the measured n/i regioselectivity to 59.9. The comparison attributes a distinct selectivity contribution to the internal population; it should not be read as a general n/i value for all Rh@S-1 catalysts or all feed concentrations.
Accessibility: stabilization is useful only when molecules can reach the site
Micropore confinement can protect Rh so effectively that diffusion becomes the new limitation. Nanosized MFI crystallites shorten the distance from the external fluid to an internal site and expose a larger fraction of the pore network. A 2025 Journal of the American Chemical Society study found about a threefold improvement in specific activity for a nanosized Rh-MFI catalyst relative to the corresponding larger-crystallite design reported there.
Self-pillared architectures address the same trade-off by adding mesoporous interlayer voids while retaining MFI micropores for selectivity. The useful design target is therefore not maximum confinement alone, but confinement combined with short diffusion paths, open channel intersections and a low fraction of blocked entrances.
What the quantitative studies actually show
| Design or observation | Reported result | What it demonstrates |
|---|---|---|
| Silanol-rich MFI, Nature Communications (2023) | Approximately 50,000 h−1 TOF | Defect hydroxyls can combine olefin enrichment with strong Rh stabilization. |
| Rh@S-1, Inorganic Chemistry Frontiers (2026) | 98.3% 1-hexene conversion; n/i = 59.9 after DMBT poisoning under the reported low-1-hexene-concentration condition | Internal and external Rh populations make different contributions to conversion and regioselectivity. |
| Nanosized Rh-MFI, Journal of the American Chemical Society (2025) | About threefold higher specific activity than the larger-crystallite comparison in that study | Shorter diffusion paths and greater site exposure can outweigh the loss of bulk crystal size. |
| Subnanometre Rh-MFI clusters, Nature Catalysis (2024) | Linear-to-branched aldehyde ratio up to 400 for C6–C12 alpha-olefins | Sinusoidal-channel geometry can impose strong regioselectivity. |
| Rh1@SPP-MFI, Angewandte Chemie International Edition (2026) | 7,074 h−1 TOF for 1-octene at 353 K and 2.5 MPa | Isolated Rh–O units plus mesopore-assisted access can deliver high activity. |
These figures are not a league table. The studies use different olefins, phases, solvents or gas feeds, Rh loadings, temperatures, pressures and normalization conventions. A turnover frequency, a specific activity and a conversion percentage answer different questions and cannot be converted into one ranking without matched experiments.
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How to compare two Rh-MFI catalyst designs
Use the following checklist before treating one result as evidence that a design is intrinsically better:
- Rh nuclearity: single atom, subnanometre cluster or nanoparticle.
- Anchoring chemistry: silanol, ordinary framework oxygen, phosphate or Zn–O contact.
- Morphology: crystal size, channel length, interlayer mesopores and the fraction of external Rh.
- Substrate and phase: carbon-chain length, olefin concentration, liquid or gas phase and solvent.
- Operating conditions: temperature, total pressure, CO/H2 ratio, time on stream and Rh loading.
- Activity metric: conversion, aldehyde productivity, mass-specific rate or TOF, including its normalization basis.
- Selectivity: n/i ratio, side products and whether external sites were selectively blocked.
- Durability: Rh leaching, migration, aggregation, pore blockage and coke formation during extended operation.
This framework prevents a common error: attributing a high rate to “MFI confinement” when the real change was nanosizing, a different Rh oxidation state, a higher substrate concentration or a different rate normalization.
What remains uncertain
Operando characterization is essential because the coordination sphere observed after preparation may not be the one present under CO/H2. Rh can change nuclearity, oxidation state and ligand count as the reaction proceeds. A claim that a sample contains a particular Rh–O or carbonyl motif therefore needs evidence under reaction conditions, not only ex situ spectroscopy.
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Long-duration deactivation is also less established than initial activity. Industrial feeds contain mixtures of olefins and impurities unlike the model substrates used in many demonstrations. Whether a pore architecture that gives excellent selectivity for 1-hexene, 1-octene or C6–C12 alpha-olefins retains that advantage with commercial feeds, high throughput and repeated regeneration requires separate durability and scale-up studies.
The most defensible interpretation is that MFI stabilizes a condition-dependent family of Rh sites. Confinement supplies geometric control and suppresses aggregation; framework and defect chemistry anchor and electronically tune Rh; and nanoscale access determines how much of that stabilized population can actually turn over.
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