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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

    Ethylene Oligomerization: Unraveling the Roles of Ni Sites, Acid Sites, and Zeolite Pore Topology through Continuous and Pulsed Reactions

    by Abed, Mohamed, Hita, Velisoju, Morlanes, El Tall, Castaño
    ChemCatChem Year: 2024 DOI: https://doi.org/10.1002/cctc.202301220

    Abstract

    Herein, four catalysts, consisting of either MFI or BEA as the zeolite framework in the presence or absence of Ni, are compared to explore the individual and collective adsorptive and catalytic contributions of pore topology, Ni sites, and acid sites. Both continuous and pulsed chemisorption/reaction experiments are used to obtain a complete picture of the time-dependent adsorption-desorption behavior, reaction mechanisms, and deactivation steps. The methodology highlights the effect of acid sites, especially during the initial stages of reaction and in the BEA-based catalysts, which have higher acidity at a given Si/Al ratio. In addition, Ni accelerates the reaction and improves the selectivity towards intermediate oligomers. However, the tendency for the most active Ni and acid sites to saturate and deactivate more rapidly than the less active ones may lead to misinterpretation when using the continuous reactor alone. Hence, the dominant mechanisms over the different catalyst sites and reaction times are discussed based on the combined steady and dynamic experiments.

    Keywords

    CRE OLG