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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

    Related Publications

    Evaluating catalytic (gas–solid) spectroscopic cells as intrinsic kinetic reactors: Methanol-to-hydrocarbon reaction as a case study

    by Valecillos, Elordi, Cui, Aguayo, Castaño
    Chem. Eng. J. Year: 2022 DOI: https://doi.org/10.1016/j.cej.2022.137865

    Abstract

    Commercial spectroscopic gas–solid cell reactors are routinely used to analyze the dynamics of the catalyst (catalyst pelletized as a disc) structure and retained/adsorbed species using multiple operandotechniques. These instruments have revolutionized the understanding of many catalytic reactions, including the methanol-to-hydrocarbon reactions. We propose a reaction engineering framework to evaluate spectroscopic cells based on (a) analyzing the fluid dynamic performance, (b) comparing their performance with a reference packed-bed reactor, and (c) the assessment of the external and internal mass transfer limitations. We have used a Specac HTHP and a Linkam THMS600 cell reactors coupled with the corresponding gas conditioning, spectroscopic, and mass spectrometry apparatuses. Our results reveal that these cells approach a perfect mixing only with several equivalent tanks in series and they are reliable at low catalyst loadings (thin disc) and high flowrates (low spacetimes). Under these conditions, we can avoid external-internal mass transfer limitations and fluid dynamic artifacts (e.g., bypassing or dead/stagnant volume zones), obtaining intrinsic kinetics with the corresponding operando spectroscopic signatures. The proposed methodology allows to understand the influence of process parameters and potential design modifications on the observed kinetic performance.

    Keywords

    O2H MKM CRE