Zeolite alkylation performance

Notwithstanding some obviously contradictory results in the literature, the data summarized above can be summarized as follows the general trend is that high aluminum contents are beneficial for the alkylation performance. This inference is supported by results from cracking experiments with zeolites having various Si/Al ratios. The bimolecular hydride transfer step is favored in materials with low Si/Al ratios (54,145,146). Thus, zeolites with low Si/Al ratios should exhibit better time-on-stream behavior than those with high Si/Al ratios. 

In principle, the same rules hold true when zeolitic alkylation catalysts are used. A detailed study of the influence of PO and OSV on the performance of zeolite H-BEA in a backmix reactor was reported by de Jong et al. (80). The authors developed a simple model of the kinetics, which predicted catalyst lifetimes as a function of P/O and OSV. Catalyst lifetime (which is equivalent to the catalyst productivity, the reciprocal of acid consumption) increased with increasing P/O ratio and decreasing OSV. Furthermore, the authors persuasively demonstrated the superiority of a backmix reactor over a plug flow reactor. Qualitatively similar results were obtained by Taylor and Sherwood (222) employing a USY zeolite catalyst in a backmix reactor. The authors stressed the detrimental effect of unreacted alkene on the catalyst lifetime and product quality. Feller et al. (89) tested LaX zeolites in a backmix reactor and found the catalyst productivity to be nearly independent of the OSV within the examined OSV range. At higher values of OSV, the catalyst life was shorter, but in this shorter time the same total amount of product was produced. The P/O ratio had only a moderate influence on the catalyst performance. 

The method of zeolite synthesis, the Si/Al ratio in the synthesis gel, and the crystallite size of Beta zeolite are factors to be considered for optimum alkylation performance [123,128,129[. For both USY and Beta zeolites, the amount and type of extraframework Al species (EFAL) remaining in the zeolite after calcination and/or post-synthesis treatments also affected the catalyst performance [130,131], For both zeolites, elimination of highly dispersed cationic-type EFAL formed under mild (hydro)thermal treatments decreased the alkylation... 

Currently, benzene alkylation to produce ethylbenzene and cumene is routinely carried out using zeohtes. We performed a study comparing a zeohte Y embedded in TUD-1 to a commercial zeolite Y for ethylbenzene synthesis. Two different particle diameters (0.3 and 1.3 mm) were used for each catalyst. In Figure 41.7, the first-order rate constants were plotted versus particle diameter, which is analogous to a linear plot of effectiveness factor versus Thiele modulus. In this way, the rate constants were fitted for both catalysts. 

Performances of these acidic mordenite zeolites have been examined as a function of the level of fluoride treatment. For mordenites treated with HF to fluoride levels of 0.25, 0.5, and 1.0%, batch alkylation at ca. 80 °C of typical benzene/l-dodecene mixtures show (after 1 hr) very similar levels of activity and 2-... 

Alkylation of benzene with propylene was carried out with the acid zeolites, pelletized, crushed, and sieved at 0.25-0.42 mm diameter. The reaction was performed in an automated high pressure stainless steel reactor, at 3.5 MPa, temperatures ranging from 125 to 200°C, WF1SV from 12 to 18 h"1 referred to the olefin, and benzene to propylene (B/P) molar ratio of 3.5. More details can be found in [7]. 

For the non-oxidative activation of light alkanes, the direct alkylation of toluene with ethane was chosen as an industrially relevant model reaction. The catalytic performance of ZSM-5 zeolites, which are good catalysts for this model reaction, was compared to the one of zeolite MCM-22, which is used in industry for the alkylation of aromatics with alkenes in the liquid phase. The catalytic experiments were carried out in a fixed-bed reactor and in a batch reactor. The results show that the shape-selective properties of zeolite ZSM-5 are more appropriate to favor the dehydroalkylation reaction, whereas on zeolite MCM-22 with its large cavities in the pore system and half-cavities on the external surface the thermodynamically favored side reaction with its large transition state, the disproportionation of toluene, prevails. 

A variety of solid acids besides zeolites have been tested as alkylation catalysts. Sulfated zirconia and related materials have drawn considerable attention because of what was initially thought to be their superacidic nature and their well-demonstrated ability to isomerize short linear alkanes at temperatures below 423 K. Corma et al. (188) compared sulfated zirconia and zeolite BEA at reaction temperatures of 273 and 323 K in isobutane/2-butene alkylation. While BEA catalyzed mainly dimerization at 273 K, the sulfated zirconia exhibited a high selectivity to TMPs. At 323 K, on the other hand, zeolite BEA produced more TMPs than sulfated zirconia, which under these conditions produced mainly cracked products with 65 wt% selectivity. The TMP/DMH ratio was always higher for the sulfated zirconia sample. These distinctive differences in the product distribution were attributed to the much stronger acid sites in sulfated zirconia than in zeolite BEA, but today one would question this suggestion because of evidence that the sulfated zirconia catalyst is not strongly acidic, being active for alkane isomerization because of a combination of acidic character and redox properties that help initiate hydrocarbon conversions (189). The time-on-stream behavior was more favorable for BEA, which deactivated at a lower rate than sulfated zirconia. Whether differences in the adsorption of the feed and product molecules influenced the performance was not discussed. 

Patents assigned to Mobil (217) describe the use of boron trifluoride supported on several porous carriers. BF3 supported on silica was found to exhibit a slightly higher performance with added water in the alkylation of a mixed alkene feed at 273 K. It was also shown that self-alkylation activity was considerably lower than that with HF as catalyst. Another patent (218) describes the use of a pillared layered silicate, MCM-25, promoted with BF3 to give a high-quality alkylate at temperatures of about 273 K. BF3 was also supported on zeolite BEA, with adsorbed water still present (219). This composite catalyst exhibited low butene isomerization activity, which was evident from the inferior results obtained with 1-butene. At low reaction temperatures, the product quality was superior to that of HF alkylate. 

The choice of appropriate reaction conditions is crucial for optimized performance in alkylation. The most important parameters are the reaction temperature, the feed alkane/alkene ratio, the alkene space velocity, the alkene feed composition, and the reactor design. Changing these parameters will induce similar effects for any alkylation catalyst, but the sensitivity to changes varies from catalyst to catalyst. Table II is a summary of the most important parameters employed in industrial operations for different acids. The values given for zeolites represent best estimates of data available from laboratory and pilot-scale experiments. 

We have recently shown that metal-exchanged zeolites give rise to carbocationic reactions, through the interactions with alkylhalides (metal cation acts as Lewis acid sites, coordinating with the alkylhalide to form a metal-halide species and an alkyl-aluminumsilyl oxonium ion bonded to the zeolite structure, which acts as an adsorbed carbocation (scheme 2). We were able to show that they can catalyze Friedel-Crafts reactions (9) and isobutane/2-butene alkylation (70), with a superior performance than a protic zeolite catalyst. 

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