Shape selective hydrocarbon conversion

Molecular Shape-Selective Hydrocarbon Conversion over Erionite... 

N.Y. Chen and W.E. Garwood, Molecular Shape-Selective Hydrocarbon Conversion over Erionite. In Molecular Sieves , ed. W.M. Meier and J.B. Uytlerhoeven, ACS Symp. Ser 121, 1973, 575-582. 

Mobil MTG and MTO Process. Methanol from any source can be converted to gasoline range hydrocarbons using the Mobil MTG process. This process takes advantage of the shape selective activity of ZSM-5 zeoHte catalyst to limit the size of hydrocarbons in the product. The pore size and cavity dimensions favor the production of C-5—C-10 hydrocarbons. The first step in the conversion is the acid-catalyzed dehydration of methanol to form dimethyl ether. The ether subsequendy is converted to light olefins, then heavier olefins, paraffins, and aromatics. In practice the ether formation and hydrocarbon formation reactions may be performed in separate stages to faciHtate heat removal. 

In shape-selective catalysis, the pore size of the zeoHte is important. For example, the ZSM-5 framework contains 10-membered rings with 0.6-nm pore size. This material is used in xylene isomerization, ethylbenzene synthesis, dewaxing of lubricatius oils and light fuel oil, ie, diesel and jet fuel, and the conversion of methanol to Hquid hydrocarbon fuels (21). 

Because the pore dimensions in narrow pore zeolites such as ZSM-22 are of molecular order, hydrocarbon conversion on such zeolites is affected by the geometry of the pores and the hydrocarbons. Acid sites can be situated at different locations in the zeolite framework, each with their specific shape-selective effects. On ZSM-22 bridge, pore mouth and micropore acid sites occur (see Fig. 2). The shape-selective effects observed on ZSM-22 are mainly caused by conversion at the pore mouth sites. These effects are accounted for in the hydrocracking kinetics in the physisorption, protonation and transition state formation [12]. 

The catalyst used for the conversion of methanol to gasoline is based on a new class of shape-selective zeolites (105-108), known as ZSM-5 zeolites, with structures distinctly different from other well-known zeolites. Apparently, the pore dimensions of the ZSM-5 zeolites are intermediate between those of wide-pore faujasites (ca. 10 A) and very narrow-pore zeolites such as Zeolite A and erionite (ca. 5 A) (109). The available structural data indicate a lattice of interconnecting pores all having approximately the same diameter (101). Hydrocarbon formation... 

As an illustration, the isomerization of 1-butene adsorbed on NaGeX or mixed tin-antimony oxides has been carried out. In the methanol to hydrocarbon conversion on the shape selective H-ZSM-5 zeolite, the surface methylation could be observed, the role of... 

Further research has shown that bifunctional acid-base catalysts such as WO3 on AI2O3 or tungstophosphoric acid, lacking shape-selective nature can also bring about the methyl alcohol-hydrocarbon conversions.79 Shape selectivity of the catalyst thus is important in controlling product distributions and also to limit coking over the catalysts. 

Continuous Catalytic Conversion of Acetylene to Higher Hydrocarbons over a Metal Modified Shape Selective Zeolite Catalyst... 

Elements such as B, Ga, P and Ge can substitute for Si and A1 in zeolitic frameworks. In naturally-occurring borosilicates B is usually present in trigonal coordination, but four-coordinated (tetrahedral) B is found in some minerals and in synthetic boro- and boroaluminosilicates. Boron can be incorporated into zeolitic frameworks during synthesis, provided that the concentration of aluminium species, favoured by the solid, is very low. (B,Si)-zeolites cannot be prepared from synthesis mixtures which are rich in aluminium. Protonic forms of borosilicate zeolites are less acidic than their aluminosilicate counterparts (1-4). but are active in catalyzing a variety of organic reactions, such as cracking, isomerization of xylene, dealkylation of arylbenzenes, alkylation and disproportionation of toluene and the conversion of methanol to hydrocarbons (5-11). It is now clear that the catalytic activity of borosilicates is actually due to traces of aluminium in the framework (6). However, controlled substitution of boron allows fine tuning of channel apertures and is useful for shape-selective sorption and catalysis. 

The applications of the ZSM-5 family of zeolites for shape-selective cracking of paraffins in the gasoline (2, 10), distillate (11) and lube oil range (12) have all been reported. In this paper, we have established evidence of the converse reaction, shape-selective polymerization, to produce hydrocarbons in the same product range. 

Afterwards, the synthesis of various new zeolites, especially ZSM5 (MFI, 1967), the discovery of new shape selective transformations such as the (accidental) discovery of the remarkably stable and selective conversion of methanol into gasoline range hydrocarbons over HZSM5 (7), the development of post-synthesis treatments of zeolites,. .. combined to make them the single most important family of catalysts used all other the world. 

One of the most significant stages in the development of zeolite catalysts was the synthesis by Mobil scientists (U.S. Patent 3,702, 866) of the zeolite now universally known as ZSM-5 (i.e. Zeolite Socony Mobil-5). This was the first - and most important - member of a new class of shape selective catalysts, which have made viable the production of synthetic gasoline . In this process, high-octane gasoline is produced by the catalytic conversion of methanol to a mixture of aromatic and aliphatic hydrocarbons (Derouane, 1980). Because of its unique combination of chemical nature and pore structure, ZSM-5 is a highly effective dehydration, isomerization and polymerization catalyst. 

Synthetic zeolites have gained importance as industrial catalysts for cracking and isomerization processes, because of their unique pore structures, which allow the shape-selective conversion of hydrocarbons, combined with their surface acidity, which makes them active for acid-catalyzed reactions. Many attempts have been made to introduce redox-active TMI into zeolite structures to create catalytic activity for the selective oxidation and ammoxidation of hydrocarbons as well as for SCR of nitrogen oxides in effluent gases (69-71). In particular, ZSM-5 doped with Fe ions has attracted attention since the surprising discovery of Panov et al. (72) that these materials catalyze the one-step selective oxidation of benzene to phenol... 

Protonic zeolites find industrial applications as acid catalysts in several hydrocarbon conversion reactions. The excellent activity of these materials is due to two main properties a strong Bronsted acidity of bridging Si—(OH)-Al sites (Scheme 3.4, right) generated by the presence of aluminum inside the silicate framework and shape selectivity effects due to the molecular sieving properties associated with the well defined crystal pore sizes, where at least some of the catalytically active sites are located. 

Jang, B. Conversion of Polychlorinated Hydrocarbons and Acetylene over a Nickel Modified Shape Selective Zeolite Catalyst, Ph.D. Thesis, University Of Texas, Arlington, 1992. 

It has been shown by the independent experiments that for the model hydrocarbon mixture (isooctane n-octane cyclohexane =1 1 1 wt), the degree of conversion of isoparaffmes owing to shape selectivity is much smaller than that of n-paraffines and... 

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