Controlling the selectivity–stability tradeoff in zeolite catalysis: oligomerization–alkylation, cracking, and methanol-to-hydrocarbons

Problem Statement

Olefins and aromatics are commodity chemicals used in producing plastics (in the petrochemical industry), lubricants, plasticizers, and surfactants, among other products. However, there is an imbalance between their production and demand, which reactions like oligomerization, alkylation, and cracking over zeolites could help address. At the same time, zeolites serve as excellent catalysts for converting methanol to hydrocarbons (MTH), olefins (MTO), or aromatics (MTA). These processes aim to produce light hydrocarbons such as propylene or to convert ethylene into higher-value alpha-olefins, aromatic hydrocarbons (BTX), and jet fuel.

Our focus in this project is to synthesize, modify, and develop new catalysts with engineered porosity at multiple scales: from hierarchical and hollow zeolites to catalytic particles, bodies, or technical catalysts intended for implementation. Additionally, we incorporate various metals (e.g., Ni, Cr, Zn) to influence the selectivity toward the desired products.

We utilize various reactors, including forced dynamic, operando, high-throughput packed-bed, and batch reactors.

Goals

Control the catalyst structure to balance selectivity and stability.
Metal modulation: Use Ni, Cr, Zn to bias reaction pathways and improve selectivity to target hydrocarbons.
Deactivation control: Reduce coke formation and extend catalyst lifetime with regeneration strategies.
Reactor optimization: Shape catalysts into bodies/extrudates and validate 100 h continuous stable operation.