A rapid and eco-friendly approach for the synthesis of low-silica SAPO-34 with excellent MTO catalytic performance

A rapid and eco-friendly route has been developed for the synthesis of SAPO-34 with short crystallization time (1-3 h), low silica content (as low as 6.2 wt%) and excellent methanol-to-olefin (MTO) catalytic performance by utilization of a recycled mother liquid at elevated crystallization temperature.

Design Synthesis of Low-Silica SAPO-34 Nanocrystals by Constructing Isomorphous Core-Shell Structure: An Effective Catalyst for Improving Catalytic Performances in Methanol-to-Olefins Reaction

It is well known that low-silica SAPO-34, with an extra porosity (meso- and/or macropores) system, affords excellent catalytic performance in the methanol-to-olefins (MTO) reaction, while the direct synthesis of low-silica SAPO-34 with a hierarchical structure is difficult to achieve, principally because the crystal impurities are usually formed under a low silica content in a gel precursor. Herein, low-silica SAPO-34 nanocrystals were successfully fabricated for the first time by constructing an isomorphous core-shell structure in an epitaxial growth manner. In which, low-silica, ultrasmall nanosquare-shaped SAPO-34 crystals with the same growth orientation along the (100) crystal plane compactly grow on the monocrystal SAPO-34 cores. Crucially, the external surface acid properties of the core SAPO-34 with the Si-rich outer layer are effectively modified by the low-silica SAPO-34 shell. Furthermore, the growth process and Si-substitution mechanism of the shell zeolite were comprehensively investigated. It was found that with the prolonged crystallization time, more and more coordinated Si(4Al) and Si(3Al) structures via two substitution mechanisms (SM2 and SM3) are generated in the nanocrystalline SAPO-34 shell, which endow moderate acidity of the core-shell SAPO-34. Compared to the uncoated SAPO-34, the core-shell SAPO-34 performs a longer lifespan and a higher average selectivity of light olefins (ethylene plus propylene) when applied to the MTO reaction, which is attributed to the positive effects of the luxuriant interstitial pores offering a fast diffusion channel and the moderate acid density depressing the hydrogen transfer reaction of light olefins. This work provides new insights into the fabrication of low-silica SAPO-34 nanocrystals, which are based on the rational design of the isomorphous core-shell zeolite.

The effects of templates and seeds on the properties of nanosheet SAPO-34 molecular sieves and their catalytic performance in the MTO reaction

Nanoscale SAPO-34 molecular sieves were synthesized by adding different types of seed into hydrothermal synthesis systems with tetraethylammonium hydroxide (TEAOH) and triethylamine (TEA) & tetraethylammonium bromide (TEABr) as templates. The effects of different types of template and seed on the crystal structure, morphology, grain size and acidity of the molecular sieves were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), N2 isothermal adsorption–desorption and ammonia temperature-programmed desorption (NH3-TPD). The methanol-to-olefins (MTO) reaction performance of the synthesized samples was investigated in a fixed-bed reactor. The results showed that crystalline supernatant and seed soaking solution could be used as liquid seeds to assist in the synthesis of SAPO-34 molecular sieves with a lamellar structure. The yield of SAPO-34 synthesized by seed increased from 38.64 to 59.68%, and the methanol conversion rate was significantly improved as compared with that of SAPO-34 synthesized without seed. The nano-thickness of SAPO-34 synthesized with TEA&TEABr instead of TEAOH as template decreased from 100–150 to 40–50 nm, and the lifetime increased from 360 to 400 min with the original yield kept constant.

Unraveling templated-regulated distribution of isolated SiO4 tetrahedra in silicoaluminophosphate zeolites with high-throughput computations

Silicoaluminophosphate (SAPO) zeolites are well-known catalytic materials because of the mild acidity originating from the isolated SiO₄ tetrahedra in their frameworks. Regulating the distribution of isolated SiO₄ tetrahedra in SAPO zeolites is formidably challenging because SiO₄ tetrahedra tend to agglomerate to form Si islands and the isolated SiO₄ tetrahedra are difficult to determine using conventional characterization techniques. Here we synthesized Si-island-free SAPO-35 zeolites by using N-methylpiperidine as a new template, which exhibited excellent thermal stability compared to conventional SAPO-35 zeolites and a substantially improved methanol-to-olefins catalytic lifetime even comparable to that of commercial SAPO-34 zeolites. More strikingly, with the aid of high-throughput computations on 44 697 structure models combined with various state-of-the-art characterization techniques, for the first time, we reveal that the host–guest interactions between template molecules and SAPO frameworks determine the specific distributions of isolated SiO₄ tetrahedra, which are responsible for the improvement in the chemical properties of zeolites. Our work provides an insight into the template-based regulation of isolated SiO₄ tetrahedra in SAPO zeolites, which opens a new avenue in the discovery of promising zeolite catalysts with optimal SiO₄ distribution.

Morphology control of SAPO-34 and its catalytic performance for methanol to olefin reaction

SAPO-34 molecular sieves with various special morphologies were synthesized using mixed templates and by varying the silicon content in the gel.

Exclusive SAPO-seeded synthesis of ZK-5 zeolite for selective synthesis of methylamines

ZK-5 zeolite with superior selectivity for monomethylamine (MMA) plus dimethylamine (DMA) is fast synthesized using the exclusive silicoaluminophosphate SAPO-34 seed and K+ and Na+ cations.

Synthesis and Applications of SAPO-34 Molecular Sieves

Silicoaluminophosphate zeolite (SAPO-34) has been attracting increasing attention due to its excellent form selection and controllability in the chemical industry, as well as being one of the best industrial catalysts for methanol-to-olefin (MTO) reaction conversion. However, as a microporous molecular sieve, SAPO-34 easily generates carbon deposition and rapidly becomes inactivated. Therefore, it is necessary to reduce the crystal size of the zeolite or to introduce secondary macropores into the zeolite crystal to form a hierarchical structure in order to improve the catalytic effect. In this review, the synthesis methods of conventional SAPO-34 molecular sieves, hierarchical SAPO-34 molecular sieves and nanosized SAPO-34 molecular sieves are introduced, and the properties of the synthesized SAPO-34 molecular sieves are described, including the phase, morphology, pore structure, acid source, and catalytic performance, in particular with respect to the synthesis of hierarchical SAPO-34 molecular sieves. We hope that the review can provide guidance to the preparation of the SAPO-34 catalysts, and stimulate the future development of high-performance hierarchical SAPO-34 catalysts to meet the growing demands of the material and chemical industries.

Superior ZSM-5@γ-Al2O3 Composite Catalyst for Methanol and Ethanol Coconversion to Light Olefins

This paper proposes a ZSM-5@γ-Al₂O₃ composite with a core-shell structure for the high-efficiency cocatalytic conversion of a methanol-ethanol system to light olefins. Using ZSM-5 and γ-Al₂O₃ as sole catalysts for comparison, the effects of physical blending, impregnation, and liquid-phase precipitation coating strategies on the catalytic performance and physicochemical properties of the composite catalysts were systematically investigated. The results indicated that the ZSM-5@γ-Al₂O₃ composite catalyst prepared by a liquid-phase precipitation coating exhibited excellent catalytic performance. When the ethanol content was 25 wt % and the reaction occurred at 350 °C, the conversion rates of methanol and ethanol were 96.1 and 99.9%, respectively; the selectivity and yield of light olefins reached 92.3 and 89.9%, respectively. The introduction of ethanol into methanol enhanced the selectivity of light olefins as target products. The interfacial composite phase formed by in situ nucleation growth of pseudoboehmite produced distinct Brønsted-Lewis acid synergistic active centers. It also increased the mesopore/micropore ratio in the composite catalyst.

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.

The synthesis of SAPO-34 zeolite for an improved MTO performance: tuning the particle size and an insight into the formation mechanism

Effect of gel systems, additives and crystallization conditions on the size of SAPO-34 and the MTO performance has been studied.

Construction of SAPO-34/SiO2 composite: effective catalyst for methanol to olefins reaction

The SAPO-34/SiO2 composite is superior to the SAPO-34–SiO2 catalyst in methanol conversion and product selectivity.

The hydrothermal synthesis of hierarchical SAPO-34 with improved MTO performance

A two-step hydrothermal approach for the synthesis of hierarchical SAPO-34 in the absence of any mesoporogen.

Investigation of synthesis time and type of seed along with reduction of template consumption in the preparation of SAPO-34 catalyst and its performance in the MTO reaction

SAPO-34 catalysts were synthesized through the seeding approach under different seed conditions. The different seed synthesis times (6 h, 12 h, and 24 h) and three types of seeds were evaluated: the dried seed, the calcined seed, and the mother liquor from an unseeded synthesis, called the solution seed. Pure SAPO-34 was obtained using 12 h and 24 h solution seeds, in which a 40% reduction of template consumption was achieved simultaneously. All seeding induced samples represented higher catalytic performance in the MTO process than conventional SAPO-34 due to the smaller crystallite/particle sizes and larger external surface areas and mesopore volume. Furthermore, the changes in the acidity of samples affect their performance. The maximum olefin selectivity under industrial feed conditions (72 wt% methanol in water) was 91.79% for the sample prepared from the 12 h solution seed, which was 14.43% higher than the unseeded sample. Although this sample did not have the longest lifetime, it showed a 330 min lifespan, which was at least twice more than that of the conventional one (150 min). The sample prepared from the 6 h solution seed showed the longest lifetime of more than 500 min among all catalysts, although it was contaminated with a little SAPO-5.

SAPO-34 catalysts were synthesized through the seeding approach under different seed conditions.

Positive Role of Synthesis Method and Hard Template on the Catalytic Performance of SAPO-34 in Methanol to Olefin Reaction

In the present study, SAPO-34 particles were synthesized using hydrothermal (HT) and dry gel (DG) conversion methods in the presence of diethyl amine (DEA) as an organic structure directing agent (SDA). Carbon nanotubes (CNT) were used as a hard template in the synthesis procedure to introduce transport pores into the structures of the synthesized samples. The synthesized samples were characterized with different methods to reveal the effects of synthesis method and using hard template on their structure and catalytic performance in methanol to olefin reaction (MTO). DG conversion method results in smaller particle size in comparison with hydrothermal method, resulting in enhancing catalytic performance. On the other side, using CNT in the synthesis procedure with DG method results in more reduction in particle size and formation of hierarchical structure, which drastically improves catalytic performance.

Facile synthesis of SAPO-34 with excellent methanol-to-olefin activity in a short time via a conventional hydrothermal method

Small sized SAPO-34 obtained by a hydrothermal method in a short time (4 h) exhibits excellent MTO performance.

Recent Progress in Methanol-to-Olefins (MTO) Catalysts

Methanol conversion to olefins, as an important reaction in C1 chemistry, provides an alternative platform for producing basic chemicals from nonpetroleum resources such as natural gas and coal. Methanol-to-olefin (MTO) catalysis is one of the critical constraints for the process development, determining the reactor design, and the profitability of the process. After the construction and commissioning of the world's first MTO plant by Dalian Institute of Chemical Physics, based on high-efficiency catalyst and fluidization technology in 2010, more attention has been attracted for a deep understanding of the reaction mechanism and catalysis principle, which has led to the continuous development of catalysts and processes. Herein, the recent progress in MTO catalyst development is summarized, focusing on the advances in the optimization of SAPO-34 catalysts, together with the development efforts on catalysts with preferential ethylene or propylene selectivity.

Synthesis of sub-micrometric SAPO-34 by a morpholine assisted two-step hydrothermal route and its excellent MTO catalytic performance

SAPO-34 with a sub-micrometer crystal size was synthesized by a double hydrothermal treatment employing cost-effective morpholine as a structure directing agent, which presented an enhanced catalytic lifetime (nearly 3 times the conventional one) in the reaction of methanol to olefins with a higher light olefin selectivity (total selectivity of 97.1%). Detailed studies of the sample after different time intervals in the second crystallization with and without additional morpholine were carried out, which offered insight into crystal degradation and re-crystallization phenomena. The samples with different morpholine concentrations during the second hydrothermal treatment were also prepared, in which the sample with 80% MOR aqueous solution exhibited the smallest crystal size and the longest MTO lifetime. Furthermore, the investigation on the additional amount of mother liquor (from the first crystallization) required for the second crystallization showed that the presence of half the amount of the mother liquor (nutrients) could give us the required results effectively.

Size control of SSZ-13 crystals with APAM and its influence on the coking behaviour during MTO reaction

Crystal size reduction of SSZ-13 with APAM activates more naphthalene in the CHA cages.

Design and in situ synthesis of hierarchical SAPO-34@kaolin composites as catalysts for methanol to olefins

An in situ synthesis strategy to fabricate SAPO-34@kaolin composites from kaolin microspheres as catalysts for methanol to olefins is developed.

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.

Heterogeneous catalysts for gas-phase conversion of ethylene to higher olefins

The reduced availability of propylene and C4 products from steam crackers continues to provoke on-purpose technologies for light olefins such that almost 30% of propylene in 2025 is predicted to be supplied from unconventional sources. Furthermore, the recent discoveries of natural gas reservoirs have urged interest in the conversion of surplus alkanes and alkenes, especially ethane and ethylene. The direct conversion of ethylene to propylene or a combination of value-added chemicals, including butylenes and oligomers in the range of gasoline and diesel fuel, provides the capability of responding to the fluctuations in the balance between supply and demand of the main petrochemicals. A comprehensive review of heterogeneous catalysts for the gas-phase conversion pathways is presented here in terms of catalytic performances (ethylene conversion and product selectivities), productivities, lifetimes, active sites, physicochemical properties, mechanisms, influence of operating conditions, deactivation and some unresolved/less-advanced aspects of the field. The addressed catalysts cover both zeolitic materials and transition metals, such as tungsten, molybdenum, rhenium and nickel. Efforts in both experimental and theoretical studies are taken into account. Aside from the potential fields of progress, the review reveals very promising performances for the emerging technologies to produce propylene, a mixture of propylene and butenes, or a liquid fuel from ethylene.

Understanding of the dissolution–crystallization fabrication strategy towards macro/microporous ZSM-5 single crystals

Amounts of NaOH, Si/Al ratios and crystallization temperature together determine the dissolution–crystallization balance and thus the generation of macropores in ZSM-5 crystals.

Synthesis of high-Si hierarchical beta zeolites without mesoporogen and their catalytic application in the methanol to propene reaction

High-Si single-crystalline beta zeolites with intracrystal mesopores were synthesized for the first time and investigated as catalysts for the methanol to propene (MTP) reaction.

Insight into the dissolution–crystallization strategy towards macro/meso/microporous Silicalite-1 zeolites and their performance in the Beckmann rearrangement of cyclohexanone oxime

A dissolution–crystallization strategy was investigated to synthesize macro/meso/microporous Silicalite-1.

CTAB-assisted size controlled synthesis of SAPO-34 and its contribution toward MTO performance

SAPO-34 shows higher light olefin selectivity in the reaction of methanol to olefin (MTO), but its small pore system implies diffusion limitations to bigger molecular products and results in coking too.

SAPO-34 with a low acidity outer layer by epitaxial growth and its improved MTO performance

SAPO-34 catalyst with a low acidity outer layer was synthesized by epitaxial growth, and its MTO performance was improved.

Elucidating the reaction pathway for ethene and propene formation in the methanol-to-hydrocarbons reaction over high silica H-Beta

High silica H-Beta exhibits high propene selectivity in methanol conversion due to the participation of an olefins-based cycle and domination of higher methylbenzenes in an aromatics-based cycle.

Synthesis of SAPO-34 nanoaggregates with the assistance of an inexpensive three-in-one non-surfactant organosilane

SAPO-34 nanoaggregates with improved MTO reaction catalytic activity were synthesized by the assistance of tri-functional organosilane PZPMS.

Synthesis of core–shell SAPO-34@SAPO-18 composites by the epitaxial growth method and their catalytic properties for the MTO reaction

A core/shell-structured SAPO-34@SAPO-18 composite catalyst was hydrothermally synthesized through the epitaxial growth method.