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

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.

Regulation of the Si/Al ratios and Al distributions of zeolites and their impact on properties

Zeolites are typically a class of crystalline microporous aluminosilicates that are constructed by SiO₄ and AlO₄ tetrahedra. Because of their unique porous structures, strong Brönsted acidity, molecular-level shape selectivity, exchangeable cations, and high thermal/hydrothermal stability, zeolites are widely used as catalysts, adsorbents, and ion-exchangers in industry. The activity, selectivity, and stability/durability of zeolites in applications are closely related to their Si/Al ratios and Al distributions in the framework. In this review, we discussed the basic principles and the state-of-the-art methodologies for regulating the Si/Al ratios and Al distributions of zeolites, including seed-assisted recipe modification, interzeolite transformation, fluoride media, and usage of organic structure-directing agents (OSDAs), etc. The conventional and newly developed characterization methods for determining the Si/Al ratios and Al distributions were summarized, which include X-ray fluorescence spectroscopy (XRF), solid state ²⁹Si/²⁷Al magic-angle-spinning nuclear magnetic resonance spectroscopy (²⁹Si/²⁷Al MAS NMR), Fourier-transform infrared spectroscopy (FT-IR), etc. The impact of Si/Al ratios and Al distributions on the catalysis, adsorption/separation, and ion-exchange performance of zeolites were subsequently demonstrated. Finally, we presented a perspective on the precise control of the Si/Al ratios and Al distributions of zeolites and the corresponding challenges.

Dual-Cycle Mechanism Based Kinetic Model for DME-to-Olefin Synthesis on HZSM-5-Type Catalysts

A kinetic model for the olefins synthesis from dimethyl ether on zeolite HZSM-5 based catalysts is developed. The model includes the reaction pathways for the synthesis of olefins from oxygenates in the olefinic and aromatic cycles according to modern concepts of the dual-cycle reaction mechanism. The kinetic parameters were determined for the time-stable hydrothermally treated catalysts of various activities Mg-HZSM-5/Al2O3, HZSM-5/Al2O3, and Zr-HZSM-5/Al2O3. The kinetic parameters determination and the solution of the ordinary differential equations system were carried out in the Python software environment. The preliminary estimation of the kinetic parameters was carried out using the Levenberg-Marquardt algorithm, and the parameters were refined using the genetic algorithm. It is shown that reactions activation energies for different catalysts are close, which indicates that the priority of the reaction paths on the studied catalysts is the same. Thus, the topology of the zeolite plays a leading role in the determination of the synthesis routes, rather than the nature of the modifying metal. The developed model fits the experimental data obtained in an isothermal reactor in the range of temperature 320–360 °C, specified contact time 0.1–3.6 h*gcat/gC with a relative error of less than 15%.

Facile and Rapid Synthesis of Durable SSZ-13 Catalyst Using Choline Chloride Template for Methanol-to-Olefins Reaction

In the current study, a facile and rapid synthesis approach for a SSZ-13 catalyst using choline chloride (CC) as a template was proposed, and the catalytic performance for the methanol-to-olefins (MTO) reaction was examined. With a proper amount of CC addition (i.e., m(CC)/m(SiO2) = 0.14), uniform and homogeneously distributed cubic SSZ-13 crystals were obtained within 4 h with lower aggregation. The synthesized catalyst demonstrated excellent porous features with a total specific surface area and mesopore volume of 641.71 m2·g−1 and 0.04 cm3·g−1, respectively. The optimized strong and weak acid sites on SSZ-13 were obtained by regulating the m(CC)/m(SiO2) ratio. The less strong acid sites and a larger amount of weak acid sites in the synthesized catalyst were conducive to the catalytic performance of the MTO reaction under a lower reaction temperature (450 °C). The appropriate acidity and well-developed pore structure of synthesized SSZ-13 could also slow down the carbon deposition rate and, thus, significantly improve the catalytic lifetime of the catalyst. The methanol conversion rate and initial selectivity of light olefin using the synthesized catalyst could maintain over 95% and 50%, respectively, and a lifetime of 172 min was achieved. Although the low olefin selectivity of the synthesized SSZ-13 catalyst was slightly lower than that of the purchased one, its desirable features were thought to have good potential for industrial application.

Effect of Ethanol on the Morphology and Textual Properties of ZSM-5 Zeolite

The morphology of ZSM-5 zeolite impacts the adsorption, separation and diffusion of molecules. The morphology and textural properties of ZSM-5 zeolites were adjusted by regulating the content of ethanol in the synthesis gel. When the ratio of ethanol/SiO2 was lower than 2, the obtained crystals were isolated particles. With higher ethanol concentration, the chainlike zeolite was generated due to the condensation of terminal Si-OH groups. The crystals stacked more and more compactly with the increase in ethanol concentration, resulting in decreased specific surface area, total volume and mesoporous volume. The crystal size increased gradually with the increase in the ethanol concentration. Moreover, some other small molecular alcohols could also induce the formation of chainlike morphology of ZSM-5.

Propene Adsorption-Chemisorption Behaviors on H-SAPO-34 Zeolite Catalysts at Different Temperatures

Propene is an important synthetic industrial product predominantly formed by a methanol-to-olefins (MTO) catalytic process. Propene is known to form oligomers on zeolite catalysts, and paramters to separate it from mixtures and its diffusion properties are difficult to measure. Herein, we explored the adsorption–chemisorption behavior of propene by choosing SAPO-34 zeolites with three different degrees of acidity at various adsorption temperatures in an ultra-high-vacuum adsorption system. H-SAPO-34 zeolites were prepared by a hydrothermal method, and their structural, morphological, and acidic properties were investigated by XRD, SEM, EDX, and temperature-programmed desorption of ammonia (NH3-TPD) analysis techniques. The XRD analysis revealed the highly crystalline structure which posses cubic morphology as confirmed by SEM images. The analysis of adsorption of propene on SAPO-34 revealed that a chemical reaction (chemisorption) was observed between zeolite and propene at room temperature (RT) when the concentration of acidic sites was high (0.158 mmol/g). The reaction was negligible when the concentration of the acidic sites was low (0.1 mmol/g) at RT. However, the propene showed no reactivity with the highly acidic SAPO-34 at low temperatures, i.e., −56 °C (using octane + dry ice), −20 °C (using NaCl + ice), and 0 °C (using ice + water). In general, low-temperature conditions were found to be helpful in inhibiting the chemisorption of propene on the highly acidic H-SAPO-34 catalysts, which can facilitate propene separation and allow for reliable monitoring of kinetic parameters.

Multiscale and Innovative Kinetic Approaches in Heterogeneous Catalysis

Kinetics and reactor modeling for heterogeneous catalytic reactions are prominent tools for investigating, and understanding, the catalyst functionalities at nanoscale, and related rates of complex reaction networks [...]