Engineering Zeolites for Catalytic Cracking to Light Olefins

Deep Cracking of Bulky Hydrocarbons into Light Products via Tandem Catalysis over Uniform Interconnected ZSM-5@AlSBA-15 Composites

Deep cracking of bulky hydrocarbons on zeolite-containing catalysts into light products with high activity, desired selectivity, and long-term stability is demanded but challenging. Herein, the efficient deep cracking of 1,3,5-triisopropylbenzene (TIPB) on intimate ZSM-5@AlSBA-15 composites via tandem catalysis is demonstrated. The rapid aerosol-confined assembly enables the synthesis of the composites composed of a continuous AlSBA-15 matrix decorated with isolated ZSM-5 nanoparticles. The two components at various ZSM-5/AlSBA-15 mass ratios are uniformly mixed with chemically bonded pore walls, interconnected pores, and eliminated external surfaces of nanosized ZSM-5. The typical composite with a ZSM-5/AlSBA-15 mass ratio of 0.25 shows superior performance in TIPB cracking with outstanding activity (≈100% conversion) and deep cracking selectivity (mass of propylene + benzene > 60%) maintained for a long time (> 6 h) under a high TIPB flux (2 mL h-1), far better (several to tens of times higher) than the single-component and physically mixed catalysts and superior to literature results. The high performance is attributed to the cooperative tandem catalytic process, that is, selective and timely pre-cracking of TIPB to isopropylbenzene (IPB) in AlSBA-15 and subsequently timely diffusion and deep cracking of IPB in nanosized ZSM-5.

Comparative study on Al-SBA-15 prepared by spray drying and traditional methods for bulky hydrocarbon cracking: Properties, performance and influencing factors

Mesoporous aluminosilicates Al-SBA-15 with large pore sizes and suitable acid properties are promising substitutes to zeolites for catalytic cracking of bulky hydrocarbons without molecular diffusion limitation. The conventional processes to synthesize Al-SBA-15 are time-consuming and often suffer from low "framework" Al contents. Herein, Al-SBA-15 microspheres are synthesized using the rapid and scalable microfluidic jet spray drying technique. They possess uniform particle sizes (45-60 μm), variable surface morphologies, high surface areas (264-340 m2/g), uniform mesopores (3.8-4.9 nm) and rich acid sites (126-812 μmol/g) and high acid strength. Their physicochemical properties are compared with the counterparts synthesized using traditional hydrothermal and evaporation-induced self-assembly methods. The spray drying technique results in a higher incorporation of aluminum (Al) atoms into the silica "framework" compared to the other two methods. The catalytic cracking efficiencies of 1,3,5-triisopropylbenzene (TIPB) on the Al-SBA-15 materials synthesized using the three different methods and nanosized ZSM-5 are compared. The optimal spray-dried Al-SBA-15 exhibits the best performance with 100 % TIPB conversion, excellent selectivity (about 75 %) towards the formation of deeply cracked products (benzene and propylene) and high stability. The catalytic performances of the spray-dried Al-SBA-15 with varying Si/Al ratios are also compared. The reasons for the different performances of the different materials are discussed, where the mesopores, high acid density and strength are observed to play the most critical role. This work might provide a basis for the synthesis of mesoporous rich metal-substituted silica materials for different catalytic applications.

The effect of Si/Al ratio of ZSM-12 zeolite on its morphology, acidity and crystal size for the catalytic performance in the HTO process

In this research, ZSM-12 zeolite with six Si/Al ratios (20 to 320) was synthesized by a hydrothermal method and systematically investigated. The physicochemical properties of the synthesized nano zeolites were evaluated and compared by XRD, FE-SEM,ICP-AES, NH3-TPD, BET, FT-IR, and TGA analyses. The results show that when the Si/Al ratio increases, the amount of microcrystals increases with the dominant competitive phase of cristobalite by decreasing the MTW phase. The catalytic assessment of synthesized zeolites in the (n-hexane to olefins) HTO process in a fixed bed reactor under atmospheric pressure and WHSV equal to 4 h-1 at 550 °C was evaluated and various parameters such as selectivity towards light olefins, P/E ratio, production of light alkanes, and aromatic compounds (BTX) were investigated. The result of the n-hexane to olefins process indicated that the presence of cristobalite as an impurity phase strongly affects the activity of the catalysts. The Z80 zeolite, with a Si/Al ratio of 80, corresponds to the pure form of ZSM-12 and exhibits the highest light olefin yield at 52.5%. This zeolite demonstrates superior propylene selectivity (P/E = 1.75) owing to its well-suited pore structure, wide channels, and optimal acidity derived from the MTW zeolite. On the other hand, zeolite Z320 has a lower light olefin yield (19.4%) and a lower P/E (1.1) ratio. In addition, according to the results of the TGA analysis, the content of coke on the Z80 catalyst after the catalytic reaction is much less than other catalysts after the catalytic reactor test.

Quasi-Discrete Pore Engineering via Ligand Racemization in Metal-Organic Frameworks for Thermodynamic-Kinetic Synergistic Separation of Propylene and Propane

The adsorptive separation of propylene and propane offers an energy-efficient alternative to the conventional cryogenic distillation technology. However, developing porous adsorbents with both high equilibrium and kinetic selectivity remains extremely challenging due to the similar size and physical properties of these gases. Herein, this work reports a ligand racemization strategy to construct quasi-discrete pores in MOFs for a synergistically enhanced thermodynamic and kinetic separation performance. The use of enantiopure l-malic acid versus racemic dl-malic acid as ligands afforded isoreticular Ni-based MOFs with contrasting one-dimensional channels (l-mal-MOF) and quasi-discrete cavities connected by small windows (dl-mal-MOF). The periodic pore constrictions in dl-mal-MOF significantly increased the differentiation in diffusion rates and binding energies between propylene and propane. dl-mal-MOF exhibited an exceptional propylene uptake of 1.82 mmol/g at 0.05 bar and 298 K along with an ultrahigh equilibrium-kinetic combined selectivity of 62.6. DFT calculations and MD simulations provided insights into the synergistic mechanism of preferential propylene adsorption and diffusion. Breakthrough column experiments demonstrated the excellent separation and high-purity recovery of propylene over propane on dl-mal-MOF. The robust stability and facile regeneration highlight its potential for propylene purification applications.

Feasibility of the Optimal Design of AI-Based Models Integrated with Ensemble Machine Learning Paradigms for Modeling the Yields of Light Olefins in Crude-to-Chemical Conversions

The prediction of the yields of light olefins in the direct conversion of crude oil to chemicals requires the development of a robust model that represents the crude-to-chemical conversion processes. This study utilizes artificial intelligence (AI) and machine learning algorithms to develop single and ensemble learning models that predict the yields of ethylene and propylene. Four single-model AI techniques and four ensemble paradigms were developed using experimental data derived from the catalytic cracking experiments of various crude oil fractions in the advanced catalyst evaluation reactor unit. The temperature, feed type, feed conversion, total gas, dry gas, and coke were used as independent variables. Correlation matrix analyses were conducted to filter the input combinations into three different classes (M1, M2, and M3) based on the relationship between dependent and independent variables, and three performance metrics comprising the coefficient of determination (R2), Pearson correlation coefficient (PCC), and mean square error (MSE) were used to evaluate the prediction performance of the developed models in both calibration and validations stages. All four single models have very low R2 and PCC values (as low as 0.07) and very high MSE values (up to 4.92 wt %) for M1 and M2 in both calibration and validation phases. However, the ensemble ML models show R2 and PCC values of 0.99-1 and an MSE value of 0.01 wt % for M1, M2, and M3 input combinations. Therefore, ensemble paradigms improve the performance accuracy of single models by up to 58 and 62% in the calibration and validation phases, respectively. The ensemble paradigms predict with high accuracy the yield of ethylene and propylene in the catalytic cracking of crude oil and its fractions.

Synergetic Regulation of the Microstructure and Acidity of HZSM-5/MCM-41 for Efficient Catalytic Cracking of n-Decane

Alkane catalytic cracking is regarded as one of the most significant processes for light olefin production; however, it suffers from serve catalyst deactivation due to coke formation. Herein, HZSM-5/MCM-41 composites with different Si/Al₂ ratios were first prepared by the hydrothermal method. The physicochemical properties of the prepared catalysts were analyzed by a series of bulk and surface characterization methods, and the catalytic performance was tested in n-decane catalytic cracking. It was found that HZSM-5/MCM-41 showed a higher selectivity to light olefins and a lower deactivation rate compared with the parent HZSM-5 due to an enhanced diffusion rate and decreased acid density. Moreover, the structure-reactivity relationship revealed that conversion, light olefin selectivity, and the deactivation rate strongly depended on the total acid density. Furthermore, HZSM-5/MCM-41 was further extruded with γ-Al₂O₃ to obtain the catalyst pellet, which showed an even higher selectivity to light olefins (∼48%) resulting from the synergy effect of the fast diffusion rate and passivation of external acid density.

Sustainable product-based approach in the production of olefins using a dual functional ZSM-5 catalyst

Investigation of the current industrial processes, such as methanol to olefin (MTO) and hexane to olefin (HTO), in terms of green and sustainable chemistry approaches in order to design the process, catalyst and reactor from the beginning in such a way as to minimize environmental pollution is compulsory. Therefore, the synthesis of a group of multifunctional catalysts, which can be used simultaneously in both industrial processes to produce a variety of products, was studied. The effect of incorporation of different metals (Fe, Mn, Zn, Ga and Al) on the strengthening of each of the products was also studied. The investigation of reactor productivity (WHSV_HTO = 25) in HTO showed that the production efficiency of propylene in microchannels is higher than the ideal value for all samples, which is a significant improvement for sustainable approaches in future technologies. Considering the overall performances, Ga-ZM showed the best performance in both processes due to the high P/E ratio. The significant effect of Ga on the increasing of propylene was confirmed in MTO at 400 °C (P/E ≃ ∞), which indicated the dramatic effect of this metal in directing the reaction mechanism to an olefin-based cycle by converting almost all ethylene to propylene by methylation.

Zeolites in Adsorption Processes: State of the Art and Future Prospects

Zeolites have been widely used as catalysts, ion exchangers, and adsorbents since their industrial breakthrough in the 1950s and continue to be state-of the-art adsorbents in many separation processes. Furthermore, their properties make them materials of choice for developing and emerging separation applications. The aim of this review is to put into context the relevance of zeolites and their use and prospects in adsorption technology. It has been divided into three different sections, i.e., zeolites, adsorption on nanoporous materials, and chemical separations by zeolites. In the first section, zeolites are explained in terms of their structure, composition, preparation, and properties, and a brief review of their applications is given. In the second section, the fundamentals of adsorption science are presented, with special attention to its industrial application and our case of interest, which is adsorption on zeolites. Finally, the state-of-the-art relevant separations related to chemical and energy production, in which zeolites have a practical or potential applicability, are presented. The replacement of some of the current separation methods by optimized adsorption processes using zeolites could mean an improvement in terms of sustainability and energy savings. Different separation mechanisms and the underlying adsorption properties that make zeolites interesting for these applications are discussed.

Investigating the Interaction between Methanol and the Heulandite-type Zeolite using First Principle Molecular Dynamic

The interaction between methanol and the Heulandite-type zeolite has been unveiled to give an atomic scale detail regarding the catalytic activity of this zeolite for methanol conversion. The study was carried out by first principle molecular dynamics to get an insight into the structure and electronic behaviour of methanol inside the zeolite structure at different temperatures. The behaviour of methanol was studied when the location of the proton of Bronsted acid sites was varied to give both possible direct and less interaction with methanol. The results show that methanol interacts with the proton from zeolite to give a cationic species of [CH3OH2]+ both in 300K and 573K conditions. However, when the proton is located at different location far from possible interaction with methanol, the formation of a cationic species is hindered. This study provides an insight into the design of Heulandite type zeolite to give a catalytic activity toward methanol transformation.

Light olefin synthesis from a diversity of renewable and fossil feedstocks: state-of the-art and outlook

Light olefins are important feedstocks and platform molecules for the chemical industry. Their synthesis has been a research priority in both academia and industry. There are many different approaches to the synthesis of these compounds, which differ by the choice of raw materials, catalysts and reaction conditions. The goals of this review are to highlight the most recent trends in light olefin synthesis and to perform a comparative analysis of different synthetic routes using several quantitative characteristics: selectivity, productivity, severity of operating conditions, stability, technological maturity and sustainability. Traditionally, on an industrial scale, the cracking of oil fractions has been used to produce light olefins. Methanol-to-olefins, alkane direct or oxidative dehydrogenation technologies have great potential in the short term and have already reached scientific and technological maturities. Major progress should be made in the field of methanol-mediated CO and CO₂ direct hydrogenation to light olefins. The electrocatalytic reduction of CO₂ to light olefins is a very attractive process in the long run due to the low reaction temperature and possible use of sustainable electricity. The application of modern concepts such as electricity-driven process intensification, looping, CO₂ management and nanoscale catalyst design should lead in the near future to more environmentally friendly, energy efficient and selective large-scale technologies for light olefin synthesis.

Molecular Sieving of Propylene from Propane in Metal-Organic Framework-Derived Ultramicroporous Carbon Adsorbents

The development of adsorption-based separation processes alternative to the energy-intensive cryogenic distillation for a mixture of propylene and propane remains essential but challenging in gas industries. Molecular sieving separation of C₃H₆/C₃H₈ on stable carbon adsorbents appeals to be promising, while it is quite challenging to realize due to the random distributions and arrangements of the internal pores in common carbons. Herein, a series of polysaccharide-based CD-MOF-derived ultramicroporous carbon adsorbents with their pore size tuned at a subangstrom level were prepared. Molecular sieving separation of C₃H₆/C₃H₈ was realized on the optimal C-CDMOF-2-700 owing to the delicate structure with an appropriate pore size (5.0 Å). Besides, C-CDMOF-2-700 exhibited a high C₃H₆ uptake of 1.97 mmol g^-1 under ambient conditions. An ultrahigh uptake ratio of C₃H₆/C₃H₈ at 1.0 kPa (403) was also achieved, outperforming all reported adsorbents. Kinetic adsorption tests and breakthrough experiments further demonstrate this well-designed carbon adsorbent to be promising in industrial C₃H₆/C₃H₈ separation.

Computational Study of Alkane Adsorption in Brønsted Acid Zeolites for More Efficient Alkane Cracking

Alkane cracking using Brønsted acid zeolites, catalytically converting long-chain molecules into smaller ones, is critical to fuel and chemical production. To enable more energy-efficient cracking processes, developing zeolite catalysts with enhanced performance (i.e., a faster reaction rate with reduced methane formation) plays a substantial role. Given the adsorption thermodynamics of alkanes onto the protons of Brønsted acid zeolites is a key step in the overall cracking reactions; therefore, catalysts possessing a more negative Gibbs free energy of adsorption for alkanes with a larger central-to-terminal bond adsorption selectivity to promote central cracking are of particular interest. This Feature Article discusses recent computational developments and discoveries by Lin and co-workers in studying the adsorption of alkanes in Brønsted acid zeolites. Their developed approach, employing configurational bias Monte Carlo with domain decomposition, with a newly parametrized molecular potential to compute the adsorption properties is first introduced. With these developments, the roles of the Si/Al ratio and Al sitting are explored and discussed. Subsequently, the Feature Article discusses the key findings obtained from a large-scale computational screening of studying more than 100 000 possible zeolite structures. The performance of identified top candidates and associated key structural features leading to desirable adsorption properties are highlighted.

Direct Visualization of Supramolecular Binding and Separation of Light Hydrocarbons in MFM-300(In)

The purification of light olefins is one of the most important chemical separations globally and consumes large amounts of energy. Porous materials have the capability to improve the efficiency of this process by acting as solid, regenerable adsorbents. However, to develop translational systems, the underlying mechanisms of adsorption in porous materials must be fully understood. Herein, we report the adsorption and dynamic separation of C₂ and C₃ hydrocarbons in the metal-organic framework MFM-300(In), which exhibits excellent performance in the separation of mixtures of ethane/ethylene and propyne/propylene. Unusually selective adsorption of ethane over ethylene at low pressure is observed, resulting in selective retention of ethane from a mixture of ethylene/ethane, thus demonstrating its potential for a one-step purification of ethylene (purity > 99.9%). In situ neutron powder diffraction and inelastic neutron scattering reveal the preferred adsorption domains and host-guest binding dynamics of adsorption of C₂ and C₃ hydrocarbons in MFM-300(In).

Sm-CeO2/Zeolite Bifunctional Catalyst for Direct and Highly Selective Conversion of Bioethanol to Propylene

A series of Sm-CeO2/Beta composites with various Beta contents were prepared by an incipient impregnation method, followed by calcination at 650 °C. They were characterized by XRD, N2 adsorption, SEM, NH3-TPD, CO2-TPD and 27Al MAS NMR. The Sm-CeO2/Beta bifunctional catalysts exhibit eminent catalytic performances in the selective conversion of ethanol to propylene. In particular, the Sm-CeO2/10%Beta catalyst with 10% Beta zeolite gives the highest C3H6 yield of 59.3%. A good match between Sm-CeO2 and Beta accounts for its optimal result.

Facile Synthesis of Nanosheet-Stacked Hierarchical ZSM-5 Zeolite for Efficient Catalytic Cracking of n-Octane to Produce Light Olefins

The development of an effective strategy for synthesizing two-dimensional MFI zeolites has attracted more and more attention. Herein, nanosheet-stacked hierarchical ZSM-5 zeolite was obtained by a seed-assisted hydrothermal synthesis route using a small amount of [C18H37-N+(CH3)2-C6H12-N+(CH3)2-C6H12]Br2 (C18-6-6Br2) as a zeolite structure-directing agent and triethylamine (TEA) as a zeolite growth modifier. By varying the molar ratio of C18-6-6Br2/TEA from 2.5/0 to 2.5/40, the morphologies and textural properties of the resultant HZ5-2.5/x catalysts were finely modulated. By increasing x from 5 to 40, the morphology of the HZ5-2.5/x changed from unilamellar assembly with narrow a–c plane to intertwined nanosheets with wide a–c plane and multilamellar nanosheets with house-of-cards morphology. The thickness of these nanosheets was almost 8–10 nm. In addition, selectivity to light olefins reached 70.7% for the HZ5-2.5/10 catalyst, which was 6.6% higher than that for CZSM-5 (64.1%). Furthermore, the MFI zeolite nanosheets exhibited better anticoking stability within the 60 h reaction time compared to conventional ZSM-5 zeolite, which could be attributed to the short diffusion path and hierarchical porosity. This work will provide valuable insights into the rational design of novel zeolite catalysts for the efficient cracking of hydrocarbons.

Dissolution Behavior and Varied Mesoporosity of Zeolites by NH4 F Etching

The mesopores formation in zeolite crystals has long been considered to occur through the stochastic hydrolysis and removal of framework atoms. Here, we investigate the NH₄ F etching of representative small, medium, and large pore zeolites and show that the zeolite dissolution behavior, therefore the mesopore formation probability, is dominated by zeolite architecture at both nano- and sub-nano scales. At the nano-scale, the hidden mosaics of zeolite structure predetermine the spatio-temporal dissolution of the framework, hence the size, shape, location, and orientation of the mesopores. At the sub-nano scale, the intrinsic micropore size and connectivity jointly determine the diffusivity of reactant and dissolved products. As a result, the dissolution propensity varies from removing small framework fragments to consuming nanodomains and up to full digestion of the outmost part of zeolite crystals. The new knowledge will lead to new understanding of zeolite dissolution behavior and new adapted strategies for tailoring hierarchical zeolites.

Production of Light Olefins via Fischer-Tropsch Process Using Iron-Based Catalysts: A Review

The production of light olefins, as the critical components in chemical industries, is possible via different technologies. The Fischer–Tropsch to olefin (FTO) process aims to convert syngas to light olefins with high selectivity over a proper catalyst, reduce methane formation, and avoid the production of excess CO2. This review describes the production of light olefins through the FTO process using both unsupported and supported iron-based catalysts. The catalytic properties and performances of both the promoted and bimetallic unsupported catalysts are reviewed. The effect of support and its physico-chemical properties on the catalyst activity are also described. The proper catalyst should have high stability to provide long-term performance without reducing the activity and selectivity towards the desired product. The good dispersion of active metals on the surface, proper porosity, optimized metal-support interaction, a high degree of reducibility, and providing a sufficient active phase for the reaction are important parameters affecting the reaction. The selection of the suitable catalyst with enhanced activity and the optimum process conditions can increase the possibility of the FTO reaction for light-olefins production. The production of light olefins via the FTO process over iron-based catalysts is a promising method, as iron is cheap, shows higher resistance to sulfur, and has a higher WGS activity which can be helpful for the feed gas with a low H2/CO ratio, and also has higher selectivity towards light olefins.

Supported metals on porous solids as heterogeneous catalysts for the synthesis of propargylamines

This perspective summarizes recent developments in the synthesis of propargylamines using porous solids (zeolites, MOFs and carbon) as supports/catalysts.

Understanding catalyst deactivation during the direct cracking of crude oil

In the formulation of zeolite-based catalysts for the direct cracking of crude, the use of kaolin matrixes prevents, to a large extent, zeolite dealumination. Metals and other impurities in crude oil provoke a slight decrease in activity and selectivity patterns.

Understanding the Catalytic Activity of Microporous and Mesoporous Zeolites in Cracking by Experiments and Simulations

Porous zeolite catalysts have been widely used in the industry for the conversion of fuel-range molecules for decades. They have the advantages of higher surface area, better hydrothermal stability, and superior shape selectivity, which make them ideal catalysts for hydrocarbon cracking in the petrochemical industry. However, the catalytic activity and selectivity of zeolites for hydrocarbon cracking are significantly affected by the zeolite topology and composition. The aim of this review is to survey recent investigations on hydrocarbon cracking and secondary reactions in micro- and mesoporous zeolites, with the emphasis on the studies of the effects of different porous environments and active site structures on alkane adsorption and activation at the molecular level. The pros and cons of different computational methods used for zeolite simulations are also discussed in this review.

Accurate heteronuclear distance measurements at all magic-angle spinning frequencies in solid-state NMR spectroscopy

Heteronuclear dipolar coupling is indispensable in revealing vital information related to the molecular structure and dynamics, as well as intermolecular interactions in various solid materials. Although numerous approaches have been developed to selectively reintroduce heteronuclear dipolar coupling under MAS, most of them lack universality and can only be applied to limited spin systems. Herein, we introduce a new and robust technique dubbed phase modulated rotary resonance (PMRR) for reintroducing heteronuclear dipolar couplings while suppressing all other interactions under a broad range of MAS conditions. The standard PMRR requires the radiofrequency (RF) field strength of only twice the MAS frequency, can efficiently recouple the dipolar couplings with a large scaling factor of 0.50, and is robust to experimental imperfections. Moreover, the adjustable window modification of PMRR, dubbed wPMRR, can improve its performance remarkably, making it well suited for the accurate determination of dipolar couplings in various spin systems. The robust performance of such pulse sequences has been verified theoretically and experimentally via model compounds, at different MAS frequencies. The application of the PMRR technique was demonstrated on the H-ZSM-5 zeolite, where the interaction between the Brønsted acidic hydroxyl groups of H-ZSM-5 and the absorbed trimethylphosphine oxide (TMPO) were probed, revealing the detailed configuration of super acid sites.

Activation and conversion of alkanes in the confined space of zeolite-type materials

Microporous zeolite-type materials, with crystalline porous structures formed by well-defined channels and cages of molecular dimensions, have been widely employed as heterogeneous catalysts since the early 1960s, due to their wide variety of framework topologies, compositional flexibility and hydrothermal stability. The possible selection of the microporous structure and of the elements located in framework and extraframework positions enables the design of highly selective catalysts with well-defined active sites of acidic, basic or redox character, opening the path to their application in a wide range of catalytic processes. This versatility and high catalytic efficiency is the key factor enabling their use in the activation and conversion of different alkanes, ranging from methane to long chain n-paraffins. Alkanes are highly stable molecules, but their abundance and low cost have been two main driving forces for the development of processes directed to their upgrading over the last 50 years. However, the availability of advanced characterization tools combined with molecular modelling has enabled a more fundamental approach to the activation and conversion of alkanes, with most of the recent research being focused on the functionalization of methane and light alkanes, where their selective transformation at reasonable conversions remains, even nowadays, an important challenge. In this review, we will cover the use of microporous zeolite-type materials as components of mono- and bifunctional catalysts in the catalytic activation and conversion of C₁⁺ alkanes under non-oxidative or oxidative conditions. In each case, the alkane activation will be approached from a fundamental perspective, with the aim of understanding, at the molecular level, the role of the active sites involved in the activation and transformation of the different molecules and the contribution of shape-selective or confinement effects imposed by the microporous structure.

Solvent-Free Synthesis of SAPO-34 Zeolite with Tunable SiO2/Al2O3 Ratios for Efficient Catalytic Cracking of 1-Butene

Solvent-free synthesis methodology is a promising technique for the green and sustainable preparation of zeolites materials. In this work, a solvent-free route was developed to synthesize SAPO-34 zeolite. The characterization results indicated that the crystal size, texture properties, acidity and Si coordination environment of the resulting SAPO-34 were tuned by adjusting the SiO2/Al2O3 molar ratio in the starting mixture. Moreover, the acidity of SAPO-34 zeolite was found to depend on the Si coordination environment, which was consistent with that of SAPO-34 zeolite synthesized by the hydrothermal method. At an SiO2/Al2O3 ratio of 0.6, the SP-0.6 sample exhibited the highest conversion of 1-butene (82.8%) and a satisfactory yield of light olefins (51.6%) in the catalytic cracking of 1-butene, which was attributed to the synergistic effect of the large SBET (425 m2/g) and the abundant acid sites (1.82 mmol/g). This work provides a new opportunity for the design of efficient zeolite catalysts for industrially important reactions.

Incorporation of Active Metal Species in Crystalline Porous Materials for Highly Efficient Synergetic Catalysis

The design and development of efficient catalytic materials with synergistic catalytic sites always has long been known to be a thrilling and very dynamic research field. Crystalline porous materials (CPMs) mainly including metal-organic frameworks and zeolites with high scientific and industrial impact have recently been the subject of extensive research due to their essential role in modern chemical industrial processes. The rational incorporation of guest species in CPMs can synergize the respective strengths of these components and allow them to collaborate with each other for synergistic catalysis, leading to enhanced catalytic activity, selectivity, and stability in a broad range of catalytic processes. In this review, the recent advances in the development of CPMs-confined active metal species, including metal nanoparticles, metal/metal oxides heteroparticles, metal oxide, subnanometric metal clusters, and polyoxometalates, for heterogeneous catalysis, with a particular focus on synergistic effects between active components that result in an enhanced performance are highlighted. Insights into catalysts design strategies, host-guest interactions, and structure-property relationships have been illustrated in detail. Finally, the existing challenges and possible development directions in CPMs-based encapsulation-structured synergistic catalysts are discussed.

Recent progress in the improvement of hydrothermal stability of zeolites

Zeolites have been successfully employed in many catalytic reactions of industrial relevance. The severe conditions required in some processes, where high temperatures are frequently combined with the presence of steam, highlight the need of considering the evolution of the catalyst structure during the reaction. This review attempts to summarize the recently developed strategies to improve the hydrothermal framework stability of zeolites.

Synergistic construction of bifunctional and stable Pt/HZSM-5-based catalysts for efficient catalytic cracking of n-butane

Efficient conversion of light alkanes is of essential significance for enhancing the utilization efficiency of resources and exploring the activation and evolution regulation of C-C and C-H bonds in stable molecules. The processes are often executed with catalysts under harsh conditions. The olefin yield and metal stability have been the long-standing concerns. Herein, we report a facile strategy of constructing a bifunctional Pt/HZSM-5-based catalyst by two-step atomic layer deposition (ALD) to achieve a high light olefin formation rate of 0.48 mmol gcat-1·min-1 in the catalytic cracking of n-butane at 600 °C, which is ∼2.2 times higher than that of the conventional Pt/HZSM-5 catalyst (0.22 mmol gcat-1·min-1). Moreover, the bifunctional Pt/HZSM-5-based catalyst exhibited outstanding recyclability and excellent metal stability against sintering in comparison with conventional Pt/HZSM-5. Detailed microscopic and spectroscopic characterization studies demonstrate that the metal oxide (TiO2 or Al2O3) coating not only prevents the metal from high-temperature sintering, but also regulates the proportion of coordinately unsaturated platinum surface atoms. Theoretical calculations further confirm the preference of nucleation of TiO2 or Al2O3 on coordinately unsaturated platinum sites, which in turn modulates the bifunctional dehydrogenation-cracking pathway to improve the olefin formation rate.

Waste Refinery: The Valorization of Waste Plastics and End-of-Life Tires in Refinery Units. A Review

This review collects a wide range of initiatives and results that expose the potential of the refineries to be converted into waste refineries. Thus, they will use their current units for the valorization of consumer society wastes (waste plastics and end-of-life tires in particular) that are manufactured with petroleum derivatives. The capacity, technological development, and versatility of fluid catalytic cracking (FCC) and hydroprocessing units make them appropriate for achieving this goal. Polyolefinic plastics (polyethylene and polypropylene), the waxes obtained in their fast pyrolysis, and the tire pyrolysis oils can be cofed together with the current streams of the industrial units. Conventional refineries have the opportunity of operating as waste refineries cofeeding these alternative feeds and tailoring the properties of the fuels and raw materials produced to be adapted to commercial requirements within the oil economy frame. This strategy will contribute in a centralized and rational way to the recycling of the consumer society wastes on a large scale. Furthermore, the use of already existing and, especially, depreciated units for the production of fuels and raw materials (such as light olefins and aromatics) promotes the economy of the recycling process.

A Review on Production of Light Olefins via Fluid Catalytic Cracking

The fluid catalytic cracking (FCC) process is an alternative olefin production technology, with lower CO2 emission and higher energy-saving. This process is used for olefin production by almost 60% of the global feedstocks. Different parameters including the operating conditions, feedstock properties, and type of catalyst can strongly affect the catalytic activity and product distribution. FCC catalysts contain zeolite as an active component, and a matrix, a binder, and a filler to provide the physical strength of the catalyst. Along with the catalyst properties, the FCC unit’s performance also depends on the operating conditions, including the feed composition, hydrocarbon partial pressure, temperature, residence time, and the catalyst-to-oil ratio (CTO). This paper provides a summary of the light olefins production via the FCC process and reviews the influences of the catalyst composition and operating conditions on the yield of light olefins.

Sustainable development and enhancement of cracking processes using metallic composites

Metallic composites represent a vital class of materials that has gained increased attention in crude oil processing as well as the production of biofuel from other sources in recent times. Several catalytic materials have been reported in the literature for catalytic cracking, particularly, of crude oil. This review seeks to provide a comprehensive overview of existing and emerging methods/technologies such as metal–organic frameworks (MOFs), metal–matrix composites (MMCs), and catalytic support materials, to bridge information gaps toward sustainable advancement in catalysis for petrochemical processes. There is an increase in industrial and environmental concern emanating from the sulphur levels of oils, hence the need to develop more efficient catalysts in the hydrotreatment (HDS and HDN) processes, and combating the challenge of catalyst poisoning and deactivation; in a bid to improving the overall quality of oils and sustainable use of catalyst. Structural improvement, high thermal stability, enhanced cracking potential, and environmental sustainability represent the various benefits accrued to the use of metallic composites as opposed to conventional catalysts employed in catalytic cracking processes.

Synergistic effect of Fe and Ga incorporation into ZSM-5 to increase propylene production in the cracking of n-hexane utilizing a microchannel reactor

Comprehensive investigation of the synergistic effect of incorporating Fe and Ga into ZSM-5 in cracking of hexane.