Alkylation catalysts sulfated metal oxides

An interesting variation on sulfated metal oxide type catalysts was presented by Sun et al. (198), who impregnated a dealuminated zeolite BEA with titanium and iron salts and subsequently sulfated the material. The samples exhibited a better time-on-stream behavior in the isobutane/1-butene alkylation (the reaction temperature was not given) than H-BEA and a mixture of sulfated zirconia and H-BEA. The product distribution was also better for the sulfated metal oxide-impregnated BEA samples. These results were explained by the higher concentration of strong Brpnsted acid sites of the composite materials than in H-BEA. 

Several metal oxides could be used as acid catalysts, although zeolites and zeo-types are mainly preferred as an alternative to liquid acids (Figure 13.1). This is a consequence of the possibility of tuning the acidity of microporous materials as well as the shape selectivity observed with zeolites that have favored their use in new catalytic processes. However, a solid with similar or higher acid strength than 100% sulfuric acid (the so-called superacid materials) could be preferred in some processes. From these solid catalysts, nation, heteropolyoxometalates, or sulfated metal oxides have been extensively studied in the last ten years (Figure 13.2). Their so-called superacid character has favored their use in a large number of acid reactions alkane isomerization, alkylation of isobutene, or aromatic hydrocarbons with olefins, acylation, nitrations, and so forth. 

About 10 years have passed since this study began to be seriously undertaken, but the usage of solid superacids as catalysts is still limited. Table IX summarizes the acid-catalyzed reactions on sulfated metal oxides, i.e., cracking, isomerization, alkylation, acylation, esterification,... 

Initial experiments performed at the INL compared different catalysts, fluids, and operating conditions to determine the effect of SCF on solid acid catalyst alkylation (5). Three sets of studies were performed a catalyst comparison using six different catalysts (i.e., two zeolites, two sulfated metal oxides, and two Nafion catalysts) with methane as a cosolvent an exploration of the effect of varying methane addition on alkylation using a USY zeolite catalyst and a study of the effect of seven cosolvents (i.e., three hydrocarbons, two fluorocarbons, carbon dioxide, and sulfur hexafluoride) at L, ML, NC-L, and SCF conditions on the USY catalyst performance. 

Moreover, the efficiency of these catalysts could be modihed by tailoring the nature of the metal oxide support and/or reaction conditions (especially the reaction temperature). In this way, interesting conclusions can be obtained when comparing the isobutane/2-butene alkylation catalyzed on two of the most studied catalysts, that is, beta zeolite and sulfated zirconia, when operating at different reaction temperatures. (Table 13.2). ... 

Benzylation of toluene with benzyl chloride, which is a typical example of Friedel-Crafts alkylation, is known to be catalyzed by Lewis-type superacids such as A1C13 and BF3. This type of catalyst has been mostly used for the Friedel-Crafts reaction, which is one of the most studied of organic reactions. This reaction was performed over several metal oxides and sulfates, and iron sulfates showed an unexpected effectiveness for the reaction (102-104). The catalytic activities of FeS04 and Fe2(S04)3 for the reaction were examined in detail the activities were remarkably dependent on calcination temperature, the maximum activity being observed with calcination at 700°C (105-107). Catalytic actions analogous to the above case were also observed with other Friedel-Crafts reactions, the benzoyl-ation of toluene with benzoyl chloride (108), the isopropylation of toluene with isopropyl halides (109), and the polycondensation of benzyl chloride UIO). 

Mesoporous Metal Oxide Solid Acids Three-dimensional porous metal oxides have been recently synthesized and applied to acid-catalyzed reactions. The use of mesoporous metal oxides is an interesting approach to develop a solid acid catalyst with enhanced activity. The mesopores in the oxide allow the reactants to access additional active acid sites in the pores, resulting in improved rates of acid catalysis. Mesoporous niobium oxides and tantalum oxides treated with phosphoric acid or sulfuric acid have been examined as solid acid catalysts [57-59]. These mesoporous oxides exhibited remarkable activity in Friedel-Crafts alkylation and 1-hexene isomerization in the liquid phase. For sulfated mesoporous tantalum oxides /m-TsL O ), the effect of pore size has been investigated using... 

In an attempt to combine acidity, stability, and easy catalyst regeneration, other solid acid catalysts, among which zeolites have been of particular interest, have been looked to. The following part of this article reviews some of the alkylation works carried out using zeolites as well as other solids with stronger acidities such as sulfated transition metal oxides and heteropolyacids (HPAs) and related compounds. 

Studies with sulfated zirconia also show similar fast catalyst deactivation in the alkylation of isobutane with butenes. It was found, however, that original activities were easily restored by thermal treatment under air without the loss of selectivity to trimethylpentanes. Promoting metals such as Fe, Mn, and Pt did not have a marked effect on the reaction.362,363 Heteropoly acids supported on various oxides have the same characteristics as sulfated zirconia.364 Wells-Dawson heteropoly acids supported on silica show high selectivity for the formation of trimethylpentanes and can be regenerated with 03 at low temperature (125°C).365... 

Another important and well studied paramagnetic ion in the lattice of oxide semiconductors is Zr3+ in Zr02. Zirconia dioxide is widely used both as a catalyst of different chemical processes, and as a carrier for constructing supported metal-complex catalysts. In the last years, sulfated zirconia attracted significant interest as an active and selective catalyst in skeletal isomerization of normal alkanes at low temperatures, cracking of paraffins, alkylation and acylation of aromatics [42, 53 and Refs therein]. The appropriate experimental data are collected in the following Table 8.2. 

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