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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.

    OLG-O2H

    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.

    Related People

    Faseeh Kulangara Kandiyil
    Hend Omar Mohamed
    Kiruthika Jayaseelan

    Related Publications

    Effect of Operating Conditions on the Coke Nature and HZSM-5 Catalysts Deactivation in the Transformation of Crude Bio-Oil into Hydrocarbons

    by Ibanez, Valle, Bilbao, Gayubo, Castaño
    Catal. Today Year: 2012

    Abstract

    A study has been carried out on the effect of operating conditions (bio-oil/methanol ratio in the feed, temperature) on the deactivation of HZSM-5 catalysts used in the production of hydrocarbons by catalytic conversion of crude bio-oil continuously fed into a fluidized bed reactor. The bio-oil to be fed into the reactor has previously been subjected to an on-line thermal transformation in which the pyrolytic lignin derivatives have been re-polymerized. The coke deposited on the catalyst has been studied using different analytical techniques (FTIR spectroscopy, MS/FTIR-TPO, 13C CP-MAS NMR spectroscopy). The results evidence a direct relationship between coke deposition and deactivation and the concentration of bio-oil oxygenates in the reaction medium. Consequently, bio-oil conversion should be promoted in order to mitigate coke deposition. This is achieved using a HZSM-5 zeolite catalyst with a reduced SiO2/Al2O3 ratio and increasing reaction temperature and methanol/bio-oil ratio in the feed. The acidity of the HZSM-5 zeolite also has an influence on the nature of the coke, given that it contributes to increasing coke condensation towards polycondensed aromatic structures, although this has a minor effect on bio-oil conversion decrease with time on stream. The results obtained evidence the interest of the initiatives for co-feeding bio-oil with methanol to obtain hydrocarbons.

    Keywords

    O2H FCC W2C ANW