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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

    Improving the dehydrogenation function and stability of Zn-modified ZSM-5 catalyst in methanol-to-aromatics reaction by Ca addition

    by Vicente, Liu, Gayubo, Castaño, Pidko
    Appl. Catal. A: Gen. Year: 2024 DOI: https://doi.org/10.1016/j.apcata.2024.119854

    Abstract

    Adding Zn to the ZSM-5 zeolite effectively increases the aromatic selectivity in the methanol-to-aromatics (MTA) process. The formation of metal-derived Lewis acid sites promotes the dehydrogenation but at the cost of a rapid deactivation of the catalyst by coke, due to the increased aromatic formation. In this work, we impregnated a Zn-modified catalyst (2 wt%) with variable contents of Ca (0.02 and 0.5 wt%) and evaluated their kinetic behavior in the MTA and ethane dehydrogenation reactions. The results proved the superior performance of the Zn(2)Ca(0.02) catalyst due to a synergistic effect between the two metals. The Ca ions limit coke formation from excessive aromatization, increasing catalyst stability and removing Zn clusters, resulting in a recovery of Brønsted acid sites (BAS) active for the formation of light aromatics. Combining these effects results in a more efficient and viable catalyst for aromatic production from methanol.

    Keywords

    O2H HCE