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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

    Profiling the trapped and deactivating species on HZSM-5 zeolite during 1-butene oligomerization

    by Izaddoust, Hita, Kekalainen, Valecillos, Janis, Castaño, Epelde
    Fuel Process. Technol. Year: 2025 DOI: https://doi.org/10.1016/j.fuproc.2025.108297

    Abstract

    The transformation of 1-butene into valuable fuels using HZSM-5 zeolite catalysts is significantly hindered by deactivation caused by deposited species and coke formation. This work delves into the entrapment, formation, and growth of these species during 1-butene oligomerization at 275–325 °C, 1.5–40 bar, and space-times of 2–6 gcat h molC−1. We have employed an extensive characterization of the used catalysts, integrating conventional techniques with high-resolution mass spectrometry (Fourier Transform Ion Cyclotron Resonance Mass Spectrometry, FT-ICR MS). This advanced technique provides a detailed molecular-level analysis of these species. Our findings reveal that higher pressures promote oligomerization, resulting in an increased accumulation of trapped oligomer species. Conversely, higher temperatures facilitate the cracking of these oligomers into lighter fractions or their further conversion into coke molecules through condensation reactions. This dual behavior underscores the complex interplay between temperature and pressure in influencing the deactivation pathways. By understanding the overall reaction mechanism and the formation and growth patterns of trapped and deactivating species, we can develop strategies to mitigate catalyst deactivation, ultimately leading to more efficient industrial applications.

    Keywords

    OLG ANW