​​

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

    Dual Coke Deactivation Pathways during the Catalytic Cracking of Raw Bio-Oil and Vacuum Gasoil in FCC Conditions

    by Ibarra, Veloso, Bilbao, Arandes, Castaño
    Appl. Catal. B: Environ. Year: 2016

    Extra Information

    Open Access.

    Abstract

    Coke deposition pathways have been studied during the fluid catalytic cracking of bio-oil, vacuum gasoil (VGO) and a blend of the previous two (80 wt% VGO and 20 wt% bio-oil), under realistic riser conditions of the fluid catalytic cracking (FCC) unit, using a commercial catalyst at 500 °C and contact times of 1.5–10 s. Amount and composition of soluble and insoluble coke in dichloromethane have been analyzed using a set of techniques (TPO, FTIR, 13C NMR, XPS, Raman, GC–MS and MALDI-TOF MS, among others). The relationship of coke deposition with its composition and the reaction medium has allowed us to set two pathways of coke formation: (i) heavy hydrocarbon pathway tend to form ordered polycondensed aromatic nanostructures; whereas (ii) oxygenate pathway tend to form a lighter fraction of coke containing oxygen, less ordered and more aliphatic coke. A synergy between the two pathways have been verified due to the lower coke deposition of the blend compared to the individual components, and this has been explained in terms of (i) attenuation of the heavy hydrocarbon pathway caused by the steam contained or originated from the bio-oil, and (ii) the hydride transfer from hydrocarbons to the precursors of the oxygenate pathway.

    Keywords

    O2H FCC W2C MKM