Effect of the Operating Conditions in the Transformation of DME to olefins over a HZSM-5 Zeolite Catalyst

Combined Strategies Enable Highly Selective Light Olefins and -Xylene Production on Single Catalyst Bed

Achieving multiple high-value-added chemical production through novel reaction processes and shape-selective catalytic strategy is the key to realizing efficient low-carbon catalytic processes. In this work, a methanol-toluene coreaction system was developed, and combined control strategies of reaction pathway guidance and shape-selective catalysis were applied for the successful production of light olefins and para-xylene on single HZSM-5 catalyst bed. Cofeeding toluene additionally provides reactive and flowing aromatic hydrocarbon pool species that change the dominant reaction pathway in the complex network of the methanol reaction on HZSM-5 and promote the formation of ethylene. For the first time, the key reaction intermediates methylmethylenecyclodiene are directly captured and identified by experimental and theoretical techniques. This helps to propose the catalytic cycle for the dominant generation of ethylene and, more importantly, enriches the methanol-to-hydrocarbons (MTH) chemistry and hydrocarbon pool mechanism. Furthermore, 0.4HZSM-5@S-1-CLD, an optimized HZSM-5 catalyst modified by the silicalite-1 epitaxial growth followed by silanization approach, realizes highly selective production of light olefins (especially ethylene) and para-xylene, while excellent reactant activity is maintained. This highly efficient coreaction route gives an important leading significance in synthesizing the raw materials for the polyolefin and polyester industries. The establishment of the combined control strategies provides a model for the joint production of multiple target chemicals in complex catalytic processes.

Kinetic Model for the Direct Conversion of CO2/CO into Light Olefins over an In2O3-ZrO2/SAPO-34 Tandem Catalyst

An original kinetic model is proposed for the direct production of light olefins by hydrogenation of CO2/CO (COx) mixtures over an In2O3-ZrO2/SAPO-34 tandem catalyst, quantifying deactivation by coke. The reaction network comprises 12 individual reactions, and deactivation is quantified with expressions dependent on the concentration of methanol (as coke precursor) and H2O and H2 (as agents attenuating coke formation). The experimental results were obtained in a fixed-bed reactor under the following conditions: In2O3-ZrO2/SAPO-34 mass ratio, 0/1-1/0; 350-425 °C; 20-50 bar; H2/COx ratio, 1-3; CO2/COx ratio, 0-1; space time, 0-10 gIn2O3-ZrO2 h molC-1, 0-20 gSAPO-34 h molC-1; time, up to 500 h; H2O and CH3OH in the feed, up to 5% vol. The utility of the model for further scale-up studies is demonstrated by its application in optimizing the process variables (temperature, pressure, and CO2/COx ratio). The model predicts an olefin yield higher than 7% (selectivity above 60%), a COx conversion of 12% and a CO2 conversion of 16% at 415 °C and 50 bar, for a CO2/COx = 0.5 in the feed. Additionally, an analysis of the effect of In2O3-ZrO2 and SAPO-34 loading in the configuration of the tandem catalyst is conducted, yielding 17% olefins and complete conversion of CO2 under full water removal conditions.

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Methanol to Gasoline (MTG): Preparation, Characterization and Testing of HZSM-5 Zeolite-Based Catalysts to Be Used in a Fluidized Bed Reactor

The preparation of catalysts suitable for MTG processes in a fluidized bed reactor has been studied with emphasis on improving the textural, physico-chemical, morphological, structural and mechanical properties. A mixture of HZSM-5 zeolite (active material), boehmite or bentonite (binder) and alumina (inert filler) was used to prepare different catalysts. After preparation, characterization by physical adsorption of N2, XRF, XRD and SEM-EDX techniques was carried out. The screening of catalysts was performed in a fluidized bed reactor. The distribution of products was very similar in all cases, with the yield of light hydrocarbons always being higher than that of gasoline. Among the catalysts tested, the one containing boehmite as a binder (HZ_Boeh) was found as the most appropriate due to its high mechanical strength, high yield to aromatics and lower yield to durene.

n-Butene Synthesis in the Dimethyl Ether-to-Olefin Reaction over Zeolites

Zeolite catalysts that could allow the efficient synthesis of n-butene, such as 1-butene, trans-2-butene, and cis-2-butene, in the dimethyl ether (DME)-to-olefin (DTO) reaction were investigated using a fixed-bed flow reactor. The zeolites were characterized by N2 adsorption and desorption, X-ray diffraction (XRD), thermogravimetry (TG), and NH3 temperature-programmed desorption (NH3-TPD). A screening of ten available zeolites indicated that the ferrierite zeolite with NH4+ as the cation showed the highest n-butene yield. The effect of the temperature of calcination as a pretreatment method on the catalytic performance was studied using three zeolites with suitable topologies. The calcination temperature significantly affected DME conversion and n-butene yield. The ferrierite zeolite showed the highest n-butene yield at a calcination temperature of 773 K. Multiple regression analysis was performed to determine the correlation between the six values obtained using N2 adsorption/desorption and NH3-TPD analyses, and the n-butene yield. The contribution rate of the strong acid site alone as an explanatory variable was 69.9%; however, the addition of micropore volume was statistically appropriate, leading to an increase in the contribution rate to 76.1%. Insights into the mechanism of n-butene synthesis in the DTO reaction were obtained using these parameters.

Lower olefins from methane: recent advances

Modern methods for methane conversion to lower olefins having from 2 to 4 carbon atoms per molecule are generalized. Multistage processing of methane into ethylene and propylene via syngas or methyl chloride and methods for direct conversion of CH4 to ethylene are described. Direct conversion of syngas to olefins as well as indirect routes of the process via methanol or dimethyl ether are considered. Particular attention is paid to innovative methods of olefin synthesis. Recent achievements in the design of catalysts and development of new techniques for efficient implementation of oxidative coupling of methane and methanol conversion to olefins are analyzed and systematized. Advances in commercializing these processes are pointed out. Novel catalysts for Fischer – Tropsch synthesis of lower olefins from syngas and for innovative technique using oxide – zeolite hybrid catalytic systems are described. The promise of a new route to lower olefins by methane conversion via dimethyl ether is shown. Prospects for the synthesis of lower olefins via methyl chloride and using non-oxidative coupling of methane are discussed. The most efficient processes used for processing of methane to lower olefins are compared on the basis of degree of conversion of carbonaceous feed, possibility to integrate with available full-scale production, number of reaction stages and thermal load distribution.

The bibliography includes 346 references.

Kinetic Modeling of Catalytic Olefin Cracking and Methanol-to-Olefins (MTO) over Zeolites: A Review

The increasing demand for lower olefins requires new production routes besides steam cracking and fluid catalytic cracking (FCC). Furthermore, less energy consumption, more flexibility in feed and a higher influence on the product distribution are necessary. In this context, catalytic olefin cracking and methanol-to-olefins (MTO) gain in importance. Here, the undesired higher olefins can be catalytically converted and, for methanol, the possibility of a green synthesis route exists. Kinetic modeling of these processes is a helpful tool in understanding the reactivity and finding optimum operating points; however, it is also challenging because reaction networks for hydrocarbon interconversion are rather complex. This review analyzes different deterministic kinetic models published in the literature since 2000. After a presentation of the underlying chemistry and thermodynamics, the models are compared in terms of catalysts, reaction setups and operating conditions. Furthermore, the modeling methodology is shown; both lumped and microkinetic approaches can be found. Despite ZSM-5 being the most widely used catalyst for these processes, other catalysts such as SAPO-34, SAPO-18 and ZSM-23 are also discussed here. Finally, some general as well as reaction-specific recommendations for future work on modeling of complex reaction networks are given.

Nature and Location of Carbonaceous Species in a Composite HZSM-5 Zeolite Catalyst during the Conversion of Dimethyl Ether into Light Olefins

The deactivation of a composite catalyst based on HZSM-5 zeolite (agglomerated in a matrix using boehmite as a binder) has been studied during the transformation of dimethyl ether into light olefins. The location of the trapped/retained species (on the zeolite or on the matrix) has been analyzed by comparing the properties of the fresh and deactivated catalyst after runs at different temperatures, while the nature of those species has been studied using different spectroscopic and thermogravimetric techniques. The reaction occurs on the strongest acid sites of the zeolite micropores through olefins and alkyl-benzenes as intermediates. These species also condensate into bulkier structures (polyaromatics named as coke), particularly at higher temperatures and within the meso- and macropores of the matrix. The critical roles of the matrix and water in the reaction medium have been proved: both attenuating the effect of coke deposition.

New insights into catalyst deactivation and product distribution of zeolites in the methanol-to-hydrocarbons (MTH) reaction with methanol and dimethyl ether feeds

The ability of a zeolitic catalyst to dehydrate methanol to dimethyl ether affects catalyst deactivation and product distribution during the methanol-to-hydrocarbons (MTH) reaction.