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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

    Simultaneous Modeling of the Kinetics for n-Pentane Cracking and the Deactivation of a HZSM-5 Based Catalyst

    by Cordero-Lanzac, Aguayo, Gayubo, Castaño, Bilbao
    Chem. Eng. J. Year: 2018

    Abstract

    A kinetic model for the catalytic cracking of n-pentane over a HZSM-5 zeolite (Si/Al = 15) based catalyst has been proposed. In this model, the kinetic scheme of reactions is based on the paraffin cracking mechanisms and uses lumps (light olefins, light paraffins, C5+ paraffins, aromatics and methane). The reaction steps of the scheme are related with the catalytic cracking routes: protolytic cracking, β-scission, oligomerization-cracking, hydride transfer, olefin condensation and methane formation. In addition, a kinetic deactivation equation has been used for modeling the catalyst deactivation, depending on the coke precursors (light olefins and aromatics) concentration. The catalyst has been prepared by agglomerating the HZSM-5 zeolite with a mesoporous matrix of weak acidity, using pseudoboehmite as a binder. The kinetic runs have been carried out in a fixed bed reactor using the following conditions: 350–550 °C, 1.4 bar, space time up to 1.1 gcat h−1 molC−1 and time on stream up to 15 h. The formation of olefins and aromatics, as well as the catalyst deactivation, are favored at high temperatures. A mathematical methodology based on the Levenberg-Marquardt algorithm has been used for the kinetic parameters estimation. The method has allowed for the simultaneous computing of the kinetic parameters of each step of the reaction scheme and the deactivation kinetics, from the experimental results of evolution with the time on stream of each lump concentration.

    Keywords

    O2H CHA MKM