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Controlling selectivity and stability of zeolite catalysts for methanol to hydrocarbons and ethylene oligomerization


    Problem Statement

    Olefins are commodity chemicals with applications in the production of plastics (petrochemical industry), lubricants, plasticizers, and surfactants, among many others. However, there is an imbalance between their production and demand, which oligomerization-cracking reactions over zeolites could solve. At the same time, zeolites are excellent catalysts for methanol to hydrocarbons (MTH), olefins (MTO), or aromatics (MTA). The processes aim to produce light hydrocarbons like propylene or convert ethylene into higher-value a-olefins, aromatic hydrocarbons (BTX), and jet fuel.

    Our focus in this project is to modify, synthesize, and develop novel materials of different porosity (engineered at the multiscale): from hierarchical zeolites, nano zeolites, and hollow zeolites to catalytic particles, bodies, spray-dried, and extrudates with tuned properties. Additionally, we incorporate different metals (i.e., Ni, Cr, Zn) to adjust the selectivity of desired products.

    We use various reactors, such as operando or high-throughput packed-bed and batch reactors.

    OLG-O2H

    Goals

    • Control structure–selectivity: Tune zeolite porosity and acidity to maximize propylene and α-olefin yields.
    • 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.

    Related People

    Hend Omar Mohamed
    Kiruthika Jayaseelan

    Related Publications

    Dispersing zeolite in technical catalyst particles using a top spray fluidized bed reactor for methanol to hydrocarbons reaction

    by Alkadhem, Mohamed, Hoffmann, Fan, Musteata, Ogg, Ruiz-Martinez, Tsotsas, Castaño
    Chem. Eng. J. Year: 2025 DOI: https://doi.org/10.1016/j.cej.2025.161126

    Abstract

    This work investigates catalyst shaping in top spray fluidized beds and its impact on properties at different levels: particle growth stages, zeolite dispersion within the catalyst particles, and their combined effects on active site accessibility and activity in methanol to hydrocarbons (MTH) reaction. We examine the influence of process parameters such as viscosity, atomization, fluidization, temperature, slurry flow, and initial bed mass on particle size distribution and morphology. Dimensionless number analysis clarifies the dominant growth stage for a given set of process parameters. We elaborate more on optimizing the conditions that maximize zeolite, linked to smaller zeolite size, faster diffusion of probes such as 2, 2-dimethylbutane, and slightly higher activity (without violating the reaction mechanism). By optimizing the dispersion of zeolite through catalyst shaping conditions, we achieved 100 % zeolite utilization, compared to 70 % under non-optimized conditions. This improvement would have a significant impact on scaling this shaping technology.

    Keywords

    HCE O2H