Methanol Conversion to Light Olefins over SAPO-34: Reaction Network and Deactivation Kinetics

Mathematical Model for the Industrial SMTO Reactor with a SAPO-34 Catalyst

The methanol-to-olefins (MTO) technology creates a new non-oil route to produce light olefins. This paper reports a 14-lump MTO kinetic model for SAPO-34 catalyst, combined with the hydrodynamic model for the fast fluidized bed reactor of the industrial SMTO process. Selective deactivation is considered to quantify the product selectivity and abrupt catalytic activity change. Moreover, referring to the parallel compartment (PC) model, the activity difference between the circulating spent catalyst and the regenerated catalyst is considered. The validation results with the optimized kinetic parameters showed good agreement between the calculated value and the actual value. Sensitivity analysis of the industrial SMTO process was performed. According to the results, the established mathematical model can provide guidance for industrial production operations.

Synthesis of Hierarchical Porous SAPO-34 and Its Catalytic Activity for 4,6-Dimethyldibenzothiophene

Zeolite SAPO-34 has been widely used in the industry because of its special pore structure and wide distribution of acid sites in the pore channel. However, traditional SAPO-34 with a small pore size suffers from carbon deposition and deactivation in catalytic reactions, and its inability to catalytically convert bulky organic molecules limits its industrial application. Meanwhile, impurities of SAPO-5, which have weak acidity leading to rapid catalyst deactivation, appear in SAPO-34 zeolite. Therefore, it is of great significance to synthesize SAPO-34 zeolite with a mesoporous pore structure, which can significantly improve the transfer of molecules in zeolites. In this paper, SAPO-34 zeolite with a hierarchical pore structure was synthesized, and its hydrodesulfurization performance for 4,6-dimethyldibenzothiophene (4,6-DMDBT) was studied in a fixed bed reactor. The characteristic results show that BET-specific surface area, micropore volume, and mesoporous volume of synthesized SAPO-34 are 754 m² g⁻¹, 0.25, and 0.23 cm³ g⁻¹ respectively, and the pore size is mainly concentrated at 4 nm. The catalytic conversion of 4,6-DMDMT with Co- and Mo-supported SAPO-34 is about 83%, which is much higher than the catalytic performance of Al₂O₃.

Zr-doped SAPO-34 with enhanced Lewis acidity

Zr-doped SAPO-34 has enhanced Lewis acidity, leading to high catalytic activity for LDPE cracking.

Presenting a Four-Lump Dynamic Kinetic Model for Methanol to Light Olefins Process Over the Hierarchical SAPO-34 Catalyst Using Power Law Models

OBJECTIVES

A four-lump dynamic kinetic model on the hierarchical SAPO-34 catalyst in the methanol to light olefins (MTO) process has been presented using the power law models. Since decreased catalyst activity in the MTO process is common, for the applicability of the proposed model, the function of catalyst activity was computed as a function of the coke percentage deposited on the catalyst.

MATERIALS AND METHODS

The reactant and products were divided into four lumps, including methanol and dimethyl ether (DME), light olefins (ethylene and propylene), light paraffin (methane, ethane, and propane) and heavier hydrocarbons from C4. The one-dimensional ideal plug reactor was used for the simulation of the MTO reactor. The kinetic parameters and the catalyst activity function were predicted using the particle swarm optimization (PSO) algorithm.

RESULTS

The comparison of product distribution in the experimental model and the results of the kinetic model indicated the high accuracy of the presented model. The effect of operational parameters such as temperature and weight hourly space velocity (WHSV) on the mole percent of light olefins was investigated using the proposed kinetic model. The optimized value of temperature and WHSV to reach the maximum yield of light olefins was respectively 460 ˚C and 4.2 h^-1.

CONCLUSION

The passive kinetic coefficients were estimated in the reaction rate constant and catalyst activity function with the help of the PSO optimization algorithm. The mole fraction of different products and the reactant arising from modeling at the reactor outlet was compared with experimental results, which indicated the high accuracy of the presented kinetic model. The results also revealed that the selection of high and low temperatures and WHSV decreases the yield of light olefins and the lifetime of the catalyst.

Life Time Improvement of Hierarchically Structured SAPO-34 Nanocatalyst in MTO Reaction via Applying Clinoptilolite: Investigating of Composite Design via RSM

AIM AND OBJECTIVE

The research focuses on recent progress in the production of light olefins. Hence, as the common catalyst of the reaction (SAPO-34) deactivates quickly because of coke formation, we reorganized the mechanism combining SAPO-34 with a natural zeolite in order to delay the deactivation time.

MATERIALS AND METHODS

The synthesis of nanocomposite catalyst was conducted hydrothermally using experimental design. Firstly, Clinoptilolite was modified using nitric acid in order to achieve nano-scaled material. Then, the initial gel of the SAPO-34 was prepared using DEA, aluminum isopropoxide, phosphoric acid and TEOS as the organic template, sources of Aluminum, Phosphor, and Silicate, respectively. Finally, the modified zeolite was combined with SAPO-34's gel.

RESULTS

20 different catalysts due to D-Optimal design were synthesized and the nanocomposite with 50 weight percent of SAPO-34, 4 hours Crystallization and early Clinoptilolite precipitation showed the highest relative crystallinity, partly high BET surface area and hierarchical structure.

CONCLUSION

Different analyses illustrated the existence of both components. The most important property alteration of nanocomposite was the increment of pore mean diameters and reduction in pore volumes in comparison with free SAPO-34. Due to the low price of Clinoptilolite, the new catalyst renders the process as economical. Using this composite, according to the formation of multi-sized pores located hierarchically on the surface of the catalyst and increased surface area, significant amounts of Ethylene and Propylene, in comparison with free SAPO-34, were produced, as well as the deactivation time was improved.

Performance Enhanced SAPO-34 Catalyst for Methanol to Olefins: Template Synthesis Using a CO2-Based Polyurea

Introducing mesopores into the channels and cages of conventional micropores CHA (Chabazite) topological structure SAPO-34 molecular sieves can effectively improve mass transport, retard coke deposition rate and enhance the catalytic performance for methanol to olefins (MTO) reaction, especially lifetime and olefins selectivity. In order to overcome the intrinsic diffusion limitation, a novel CO2-based polyurea copolymer with affluent amine group, ether segment and carbonyl group has been firstly applied to the synthesis of SAPO-34 zeolite under hydrothermal conditions. The as-synthesized micro-mesoporosity SAPO-34 molecular sieve catalysts show heterogeneous size distribution mesopores and exhibit slightly decrease of BET surface area due to the formation of defects and voids. Meanwhile, the catalysts exhibit superior catalytic performance in the MTO reaction with more than twice prolonged catalytic lifespan and improvement of selectivity for light olefins compared with conventional microporous SAPO-34. The methodology provides a new way to synthesize and control the structure of SAPO-34 catalysts.

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.

One-Pot Conversion of Methane to Light Olefins or Higher Hydrocarbons through H-SAPO-34-Catalyzed in Situ Halogenation

Methane was converted to light olefins (ethene and propene) or higher hydrocarbons in a continuous flow reactor below 375 °C over H-SAPO-34 catalyst via an in situ halogenation (chlorination/bromination) protocol. The reaction conditions can be efficiently tuned toward selective monohalogenation of methane to methyl halides or their in situ oligomerization to higher hydrocarbons. The presence of C5+ hydrocarbons in the reaction products clearly indicates that by using a properly engineered catalyst under optimized reaction conditions, hydrocarbons in the gasoline range can be produced. This approach has significant potential for feasible application in natural gas refining to gasoline and materials under moderate operational conditions.

On the Role of Acidity in Bulk and Nanosheet [T]MFI (T=Al3+, Ga3+, Fe3+, B3+) Zeolites in the Methanol-to-Hydrocarbons Reaction

The influence of framework substituents (Al³⁺, Ga³⁺, Fe³⁺ and B³⁺) and morphology (bulk vs. nanometer‐sized sheets) of MFI zeolites on the acidity and catalytic performance in the methanol‐to‐hydrocarbons (MTH) reaction was investigated. The Brønsted acid density and strength decreased in the order Al(OH)Si>Ga(OH)Si>Fe(OH)Si≫B(OH)Si. Pyridine ¹⁵N NMR spectra confirmed the differences in the Brønsted and Lewis acid strengths but also provided evidence for site heterogeneity in the Brønsted acid sites. Owing to the lower efficiency with which tervalent ions can be inserted into the zeolite framework, sheet‐like zeolites exhibited lower acidity than bulk zeolites. The sheet‐like Al‐containing MFI zeolite exhibited the greatest longevity as a MTH catalyst, outperforming its bulk [Al]MFI counterpart. Although the lower acidity of bulk [Ga]MFI led to a better catalytic performance than bulk [Al]MFI, the sheet‐like [Ga]MFI sample was found to be nearly inactive owing to lower and heterogeneous Brønsted acidity. All Fe‐ and B‐substituted zeolite samples displayed very low catalytic performance owing to their weak acidity. Based on the product distribution, the MTH reaction was found to be dominated by the olefins‐based catalytic cycle. The small contribution of the aromatics‐based catalytic cycle was larger for bulk zeolite than for sheet‐like zeolite, indicating that shorter residence time of aromatics can explain the lower tendency toward coking and enhanced catalyst longevity.

Conversion and coking of olefins on SAPO-34

Olefins' reactions lead to the formation of soluble and insoluble coke at the near-surface region of a SAPO-34 crystal.

Catalytic conversion of lignin pyrolysis model compound- guaiacol and its kinetic model including coke formation

Lignin is the most difficult to be converted and most easy coking component in biomass catalytic pyrolysis to high-value liquid fuels and chemicals. Catalytic conversion of guaiacol as a lignin model compound was conducted in a fixed-bed reactor over ZSM-5 to investigate its conversion and coking behaviors. The effects of temperature, weight hourly space velocity (WHSV) and partial pressure on product distribution were studied. The results show the maximum aromatic carbon yield of 28.55% was obtained at temperature of 650 °C, WHSV of 8 h⁻¹ and partial pressure of 2.38 kPa, while the coke carbon yield was 19.55%. The reaction pathway was speculated to be removing methoxy group to form phenols with further aromatization to form aromatics. The amount of coke increased with increasing reaction time. The surface area and acidity of catalysts declined as coke formed on the acid sites and blocked the pore channels, which led to the decrease of aromatic yields. Finally, a kinetic model of guaiacol catalytic conversion considering coke deposition was built based on the above reaction pathway to properly predict product distribution. The experimental and model predicting data agreed well. The correlation coefficient of all equations were all higher than 0.90.

A low-temperature approach to synthesize low-silica SAPO-34 nanocrystals and their application in the methanol-to-olefins (MTO) reaction

A facile low-temperature approach has been developed to synthesize low-silica SAPO-34 nanocrystals with excellent catalytic performance in the MTO reaction.

Investigating the mixing sequence and the Si content in SAPO-34 synthesis for selective conversion of methanol to light olefins using morpholine &/ TEAOH templates

SAPO-34 as the commercialized catalyst of methanol to olefin (MTO) process was synthesized by single and mixed-template methods using TEAOH and morpholine. The mixing sequence in gel preparation and the optimum Si content were investigated.

Evolution of confined species and their effects on catalyst deactivation and olefin selectivity in SAPO-34 catalyzed MTO process

A “three sections, three periods” mechanism is proposed to discuss the formation and transformation of confined species and its effects on catalyst deactivation and product selectivity.

Influence of template content on selective synthesis of SAPO-18, SAPO-18/34 intergrowth and SAPO-34 molecular sieves used for methanol-to-olefins process

The synthesized products were switched from SAPO-5/18, to SAPO-18, SAPO-18/34, and finally to SAPO-34 with the increasing of TEAOH amount.

Recent advances of pore system construction in zeolite-catalyzed chemical industry processes

The kaleidoscopic applications of zeolite catalysts (zeo-catalysts) in petrochemical processes has been considered as one of the major accomplishments in recent decades. About twenty types of zeolite have been industrially applied so far, and their versatile porous architectures have contributed their most essential features to affect the catalytic efficiency. This review depicts the evolution of pore models in zeolite catalysts accompanied by the increase in industrial and environmental demands. The indispensable roles of modulating pore models are outlined for zeo-catalysts for the enhancement of their catalytic performances in various industrial processes. The zeolites and related industrial processes discussed range from the uni-modal micropore system of zeolite Y (12-ring micropore, 12-R) in fluid catalytic cracking (FCC), zeolite ZSM-5 (10-R) in xylene isomerization and SAPO-34 (8-R) in olefin production to the multi-modal micropore system of MCM-22 (10-R and 12-R pocket) in aromatic alkylation and the hierarchical pores in FCC and catalytic cracking of C4 olefins. The rational construction of pore models, especially hierarchical features, is highlighted with a careful classification from an industrial perspective accompanied by a detailed analysis of the theoretical mechanisms.