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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

    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