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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

    Selectivity and Microkinetic Insights on Ethylene Oligomerization over Ni Encapsulated in a Brønsted-less Hollow ZSM-5 Zeolite

    by Abed, Mohamed, khairova, Hita, Velisoju, Morlanes, Meijerink, Emwas, Vernuccio, Castaño
    ChemCatChem Year: 2025 DOI: https://doi.org/10.1002/cctc.202500957

    Abstract

    We encapsulated Ni nanoparticles in a hollow ZSM-5 zeolite catalyst using the dissolution-recrystallization method to catalyze ethylene oligomerization. Our aim is to engineer an idealized catalyst free of Brønsted acid contributions to kinetics or deactivation, having isolated and encapsulated Ni2⁺–zeolite species, to study the intrinsic oligomerization kinetics on Ni2⁺–zeolite through an experimental and microkinetic standpoint. We proved how the hollow architecture encapsulates both Ni2⁺ and NiO species, being the former significantly more active and selective toward dimerization. A comprehensive microkinetic model, grounded in the Cossee-Arlman mechanism and parameterized using experimental data, provides a detailed understanding of the reaction network on isolated Ni2⁺ sites. The model reveals that while linear butene formation dominates, its selectivity decreases with increasing ethylene conversion, temperature, and pressure, highlighting the contribution of isomerization pathways at elevated temperatures. This study focuses on the method to develop isolated oligomerization sites and then studies the intrinsic microkinetic pathways and rates.

    Keywords

    OLG MKM HCE