Busting the efficiency of SAPO-34 catalysts for the methanol-to-olefin conversion by post-synthesis methods

As an effective non-petroleum based process for producing light olefins, the methanol-to-olefin(MTO) route has become an indispensable alternative to the industrial production of light olefins. The silicoaluminophosphate SAPO-34 zeolite(CHA-type structure) has proven to be an efficient industrial catalyst for the production of ethylene and propylene by the MTO reaction. However, the inherent structure and related diffusion limitations of SAPO-34 limit the mass transport and thus cause rapid deactivation of the catalyst. Fabrication of hierarchical SAPO-34 zeolite is one of the most effective strategies to address the intrinsic diffusion limitation. As simple, inexpensive, and efficient approach, the post-synthetic route has attracted considerable attention and widely used to introduce secondary meso-/macropores into the microporous SAPO-34 material. Significant effort has been dedicated to the development of post-synthesis strategies to prepare hierarchical SAPO-34 zeolite, thereby enhancing its catalytic performance in the MTO process. This mini-review addresses the post-synthesis preparation of hierarchical SAPO-34 catalysts and their MTO performance. Furthermore, some current problems and prospects of the post-synthesis route to hierarchical SAPO-34 catalysts are also revised. We expect this minireview to inspire the more efficient preparation of hierarchical SAPO-34 catalysts for the MTO process.     

用于甲醇制烯烃SAPO-34分子筛的研究进展

具有CHA结构的SAPO-34分子筛因其优异的理化性质被认为是甲醇制烯烃(MTO)工艺的最佳催化剂,但CHA结构中狭窄的八元环孔会限制扩散,使催化剂易于失活降低使用寿命.本文从构建多级孔结构和减小分子筛粒径入手,综述了具有优异的MTO催化性能的多级孔和纳米级SAPO-34分子筛的最新进展,分析不同制备方法对SAPO-3...     

甲醇制烯烃反应机理和动力学研究进展

甲醇制烯烃（MTO）反应是重要的生产低碳烯烃技术，对于其反应机理的研究，尤其是第一个C—C键生成过程的探讨备受争论。近年来，Hydrocarbon Pool平行反应机理逐渐得到较广泛的认可，并在此基础上出现了很多MTO反应动力学的研究报道以及对该快速失活反应的催化剂积炭与失活现象的研究。针对在SAPO-34等分子筛催化剂的MTO反应情况，综述了近些年来国内外对于其反应机理、反应动力学、积炭和失活动力学的研究进展情况。     

甲醇制烯烃催化剂SAPO-34分子筛的改性研究进展

甲醇制烯烃（MTO）被认为是最有希望以煤或天然气为原料替代石油制取烯烃的技术路线。具有CHA结构的SAPO-34分子筛是MTO反应生产乙烯和丙烯最理想的催化剂,但在甲醇转化过程中,芳香烃类中间体受到SAPO-34分子筛八元环微孔结构的限制,使催化剂孔道堵塞并覆盖其酸性位点,造成催化剂积炭失活。为了提高SAPO-34分子筛催化剂的寿命和低碳烯烃的选择性,改善传质并延缓焦炭的沉积至关重要。从构建多级孔结构、减小晶粒尺寸及调控分子筛酸性3个方面出发,总结了SAPO-34分子筛在MTO反应中的研究进展,并对今后催化剂的粒度、孔尺寸、酸性质等方向的改进及发展进行了展望。     

甲醇制烯烃催化剂SAPO-34分子筛的制备和喷雾成型

SAPO-34分子筛用于催化甲醇转化制烯烃,乙烯和丙烯选择性高,是很好的甲醇制烯烃催化剂。由于SAPO-34分子筛失活速率快,甲醇制烯烃反应器通常是连续循环再生的流化床反应器,SAPO-34分子筛必须喷雾成型并达到一定抗磨强度后才能使用。在50 L反应釜合成了SAPO-34分子筛,并在中试喷雾装置上,以SAPO-34为活性组分喷雾成型甲醇制烯烃催化剂。结果表明,喷雾成型甲醇制烯烃催化剂的抗磨损指数为1.58%·h-1,抗磨性能达到工业应用要求,与两种工业甲醇制烯烃催化剂对比,喷雾成型甲醇制烯烃催化剂寿命最长,达260 min,乙烯、丙烯选择性以及乙烯+丙烯总选择性在对应的各个反应时间点均最高,260 min分别达到49.09%、35.05%和84.98%。     

分子筛催化剂上催化裂化汽油掺混甲醇的改质研究

以实现甲醇制取低碳烯烃转化工艺和FCC汽油降烯烃工艺的有效组合为目的,在固定床微型反应装置上,使用SAPO-34、ZSM-5、DOCO以及分子筛组合催化剂,对FCC汽油掺混甲醇改质进行了研究。主要对反应温度、空速和混炼比等影响因素进行了考察。结果表明,SAPO-34分子筛上甲醇制取低碳烯烃效果较好,高烯烃含量汽油在SAPO-34分子筛上的氢转移和芳构化效果显著,ZSM-5分子筛上的芳构化反应效果和DOCO的异构化反应效果较显著,甲醇转化与汽油转化反应间的相互协同作用,既有利于甲醇转化成低碳烯烃又能提高汽油降烯烃转化深度。适宜的混炼条件:反应温度400℃,m(甲醇):m(汽油)=0.05,空速3h~(-1),组合催化剂上,产物汽油中烯烃含量较FCC粗汽油下降23%以上。     

甲醇制烯烃反应工艺、反应机理及其动力学研究进展

甲醇制烯烃工艺近年来已成为煤化工领域的研究热点。不同的甲醇制烯烃催化剂将导致不同的反应过程,以SAPO-34为催化剂时,甲醇主要遵循烃池机理,通过快速的平行反应直接生产乙烯和丙烯(MTO)等低碳烯烃;以ZSM-5为催化剂时,甲醇主要遵循双循环机理中的烯烃循环机理,通过甲基化-裂解等多步反应间接生产丙烯(MTP)。这种反应特征的不同也决定着反应器类型和工艺条件的不同:SAPO-34催化剂易失活的特性决定了工业MTO过程通常采用易再生的流化床反应器从甲醇一步生成乙烯和丙烯,而具有良好抗结焦能力的ZSM-5催化剂使得工业MTP过程通常选择易放大的固定床反应器,通过大量烯烃循环与分离逐步获得丙烯。针对SAPO-34催化剂上MTO过程以及ZSM-5催化剂上MTP过程的不同反应情况,综述了近年来甲醇制烯烃代表性的反应工艺、反应机理以及反应动力学等方面的研究进展,并根据其存在的问题提出了相应的发展方向。     

高岭土微球原位合成SAPO-34分子筛及其在流化床甲醇/二甲醚制烯烃过程中的应用(英文)

SAPO-34 zeolite is considered to be an effective catalyst for methanol or dimethyl ether conversion to olefins. In this study, we developed the in situ synthesis technology to prepare SAPO-34 zeolite in kaolin microspheres as a catalyst for fluidized methanol or dimethyl ether to olefins process. The silicoaluminophosphate zeolite was first time reported to be synthesized in kaolin microspheres. The SAPO-34 content of synthesized catalyst was about 22% as measured by three different quantitative methods (micropore area, X-ray fluorescence and energy dispersive spectroscopy element analysis). Most of the SAPO-34 zeolites were in nanoscale size and distributed uniformly inside the spheres. The catalytic performance was evaluated in fixed bed and fluidized bed reactors. Compared with the conventional spray-dry catalyst, SAPO/kaolin catalyst showed superior catalytic activities, better olefin selectivities (up to 94%, exclusive coke), and very good hydrothermal stability. The in situ synthesis of SAPO-34 in kaolin microspheres is a facile and economically feasible way to prepare more effective catalyst for fluidized MTO/DTO (methanol to olefins/dimethyl ether to olefins) process.     

甲醇制低碳烯烃技术发展研究现状

由甲醇制低碳烯烃(Methanol-to-olefins,简称MTO)是非常有希望替代石油路线的新工艺。选择性能优良的分子筛催化剂并深入认识反应机理是MTO工艺发展的关键环节。SAPO-34分子筛因其对MTO反应具有良好的催化性能而得到广泛认可;该反应过程的机理大致可分为氧鎓离子机理和碳池机理等。从长远来看,MTO工艺对我国具有重要的意义。     

碱金属改性对SAPO-34分子筛催化性能的影响

通过等体积浸渍法,制备得到碱金属(Li、Na、K、Rb、Cs)改性的SAPO-34催化剂。并在常压连续固定床反应器上评价了各催化剂的甲醇制低碳烯烃(MTO)的性能,同时对催化剂进行了XRD、FT-IR、NH₃-TPD等表征分析。结果表明,碱金属负载量为2%时,除Cs离子改性的催化剂低碳烯烃的选择性和寿命有所降低外,其他碱金属离子改性的SAPO-34催化剂低碳烯烃的选择性和寿命都有了明显的提高,尤其是Li离子改性的催化剂乙烯+丙烯的选择性达77%左右,寿命相对延长了2.5倍;将该催化剂再生3次后乙烯、丙烯的选择性几乎保持不变。     

One-step conversion of syngas to light olefins over bifunctional metal-zeolite catalyst

Light olefins(C_2–C_4) are fundamental building blocks for the manufacture of polymers, chemical intermediates,and solvents. In this work, we realized a composite catalyst, comprising Mn_xZr _yoxides and SAPO-34 zeolite,which can convert syngas(CO + H_2) into light olefins. Mn_xZr_yoxide catalysts with different Mn/Zr molar ratios were facilely prepared using the coprecipitation method prior to physical mixing with SAPO-34 zeolite. The redox properties, surface morphology, electronic state, crystal structure, and chemical elemental composition of the catalysts were examined using H_2-TPR, SEM, XPS, XRD, and EDS techniques, respectively. Tandem reactions involved activation of CO and subsequent hydrogenation over the metal oxide catalyst, producing methanol and dimethyl ether as the main reaction intermediates, which then migrated onto SAPO-34 zeolite for light olefins synthesis. Effects of temperature, pressure and reactant gas flow rate on CO conversion and light olefins selectivity were investigated in detail. The Mn_1Zr_2/SAPO-34 catalyst(Mn/Zr ratio of 1:2) attained a CO conversion of 10.8% and light olefins selectivity of 60.7%, at an optimized temperature, pressure and GHSV of 380 °C, 3MPa and 3000 h~(-1) respectively. These findings open avenues to exploit other metal oxides with CO activation capabilities for a more efficient syngas conversion and product selectivity.     

再生时间对甲醇制烯烃催化剂水蒸气再生过程的影响

对甲醇制烯烃（MTO）过程失活催化剂采用水蒸气再生不仅可以减少二氧化碳排放,而且能提高低碳烯烃选择性,具有很好的应用前景。本文针对工业MTO过程使用的SAPO-34分子筛催化剂,研究了再生时间对水蒸气再生过程的影响。采用XRD、NH₃-TPD、TGA、FTIR、GC-MS以及N₂物理吸脱附表征手段对再生催化剂样品的晶体结构、酸性、残炭性质以及结构参数进行了表征,并考察再生催化剂的MTO反应性能。结果表明,再生时间越长,再生催化剂上残炭量越低,其酸性、比表面积和孔结构等能较好地恢复,在MTO反应中表现出更长的催化寿命。在再生过程中,催化剂上的残炭物种由芘、菲等大分子量的有机物转变为对MTO具有反应活性的萘等小分子有机物;但是可溶性残炭物种随着再生时间的延长而减少,从而使得初始低碳烯烃选择性有所降低。     

Dimethyl ether conversion to light olefins over the SAPO-34/ZrO2 composite catalysts with high lifetime

The SAPO-34/ZrO₂ composite catalysts using ZrO₂ as a binder were prepared and their performance was investigated for the dimethyl ether to olefins (DTO) reaction. The composite catalysts showed higher catalytic lifetimes than the free SAPO-34 catalyst, while maintaining high selectivity toward light olefins. This suggests that the binder-filled space between the SAPO-34 crystals can provide additional diffusion paths for mass transfer. In the SAPO-34/ZrO₂ composite catalysts with different ZrO₂ contents, the SAPO-34(11 wt%)/ZrO₂ composite catalyst showed the highest catalytic lifetime. It can be concluded that ZrO₂ is one of the best binders for the preparation of SAPO-34/binder composite catalysts.     

SAPO-34分子筛催化剂制备及发展现状

乙烯和丙烯作为重要的化工原料,在经济发展中的需求量越来越大。在石油资源越来越匮乏的今天,甲醇制烯烃作为一种可以代替常规石油路线生产低碳烯烃的新工艺受到广泛关注。SAPO-34分子筛因为高甲醇转化率和优良烯烃选择性成为当前甲醇制烯烃工艺催化剂的研究重点。合成SAPO-34分子筛的影响因素有模板剂、合成原料和反应条件等。通过调节分子筛粒径尺寸、酸性、金属改性可以实现分子筛的性能优化。介绍了SAPO-34分子筛催化剂常用的制备方法和一些分子筛催化剂改进的专利。使用一定时间后催化剂由于积炭而失活,再生工艺目前主要采用烧焦再生。2011年,神华煤制烯烃示范工程进入工业化运行,近年陆续有多套甲醇制烯烃装置投产和在建,煤制烯烃正在改变中国聚烯烃市场格局。     

Preparation of SAPO-34 catalyst and presentation of a kinetic model for methanol to olefin process (MTO)

Conversion of methanol to light olefins (MTO) using acidic SAPO-34 molecular-sieve as the reaction catalyst was studied in a differential fixed bed reactor within the temperature range of 375-425 °C and under 4 bar pressure. The importance of MTO process is due to the increasing demand for light olefins in recent years. SAPO-34 was synthesized by hydrothermal method, applying morpholine as the template. The latter compound was then changed into protonated form by ion exchange method with ammonium chloride at 80 °C. A simple stoichiometric scheme has been presented for MTO. In addition a mechanism for this process based on Langmuir-Hinshelwood formulation has been put forward and the kinetic parameters have been evaluated as functions of temperature.     

NaOH预处理对高岭土表面原位合成SAPO-34催化剂性能的影响

以高温煅烧高岭土微球(CKM)为载体,采用原位合成法制备了负载型SAPO-34催化剂(SCKM)。以质量分数2%～10%的NaOH水溶液对高岭土微球进行了预处理。采用XRD、XPS、SEM、N2吸附-脱附对NaOH处理的高岭土微球及原位合成的SAPO-34进行了表征,并在MTO固定床上对合成催化剂的活性进行了评价。结果表明,NaOH水溶液预处理对高岭土微球表面的化学组成、形貌结构以及原位合成SAPO-34负载型催化剂的性能均有显著影响。质量分数4%的NaOH水溶液处理高岭土微球表面合成的SAPO-34催化剂(4-SCKM)在MTO催化反应中的活性最佳,甲醇转化率达到100%,低碳烯烃选择性89.8%,单程寿命964 min,优于非原位合成的SAPO-34催化剂。     

Chloromethane Conversion to Higher Hydrocarbons over Zeolites and SAPOs

Chloromethane transformations were carried out over zeolites and SAPOs and the conversion and product distribution differed from the porous structure and acidity of the catalysts. Chloromethane was mainly transferred to higher hydrocarbons in gasoline range over most of zeolite catalysts, while SAPOs molecular sieves, SAPO-34 and SAPO-5, showed high selectivity for light olefins production, such as ethylene, propylene and butenes. TG analysis was used to study the coke formation during the transformation and the acid difference of the catalysts was evidenced by Temperature programmed desorption of ammonia. HZSM-5, with high activity and less coke formation, was proved to be a potential catalyst for hydrocarbons production from chloromethane conversion. It is of particular interest that SAPO-34 gave an excellent performance in light olefins production from chloromethane transformation, which may be attributed to the shape selectivity and medium strong acidity of SAPO-34.     

CuZnTiO2/SAPO-34双功能催化剂的设计、制备及其用于CO2加氢制烯烃性能

CO₂加氢经甲醇（含氧中间体）制低碳烯烃工艺路线,可实现成醇、脱水两步反应串联协同进行,打破费托合成产物Anderson-Schulz-Flory（ASF）分布限制,高选择性地制取低碳烯烃。传统甲醇合成Cu基催化剂加氢能力较强,在两步反应中产物以CH₄、低碳烷烃为主。实验设计、制备了CuZnTiO₂/(Zn-)SAPO-34复合催化剂,实现了CO₂加氢在Cu基复合催化剂上高选择性合成C₂～C₄烯烃（约60%）。研究表明,两步反应过程中甲醇体积分数较低（＜6%）,且高温下逆水煤气变换反应严重,导致催化剂酸性变化对产物分布的影响较大。调变两类活性位点比例发现,CH₄的产生与串联反应存在竞争关系,SAPO-34酸量的增加抑制了CH₄的生成,促进串联反应正向进行;合适的酸性有助于生成C₂～C₄烯烃。控制成醇、脱水两类活性位点接触距离可调变烯烃的二次反应,降低加氢能力,改善产物分布。     

草酸溶液处理对SAPO-34分子筛物性和催化性能的影响

用XRD、SEM、N₂物理吸附、XRF、ICP-AES以及NH₃-TPD、FT-IR、固体NMR和固定床甲醇制烯烃技术（MTO）反应评价等表征手段,研究了草酸溶液处理对SAPO-34分子筛的改性作用。结果表明,用草酸溶液对SAPO-34分子筛进行后处理可以通过刻蚀骨架在晶体中产生大孔,调变孔道结构,改善微孔扩散性能;选择性地降低分子筛的骨架硅含量,从而降低分子筛的酸强度和酸中心密度。将改性前后的分子筛应用于MTO反应中。评价结果表明,适度的酸处理能够在保证分子筛收率和乙烯、丙烯选择性的前提下,明显提高催化剂的单程寿命。草酸溶液处理是一种值得研究的SAPO-34分子筛后处理改性方法和MTO催化剂制备手段。     

甲醇制烯烃流化床反应器的模拟与分析

采用流化床两相模型描述甲醇制烯烃(MTO)过程,采用拉格朗日颗粒跟踪方法模拟催化剂上的积炭与反应,考察了相间传质、催化剂停留时间及返混对MTO过程的影响。结果表明,湍动流化床相间传质速率小于催化反应速率,是MTO过程的速率控制步骤;强化传质和延长催化剂停留时间都能显著提高催化剂的积炭量,有利于提高乙烯与丙烯的选择性;而减小催化剂返混或采用多级串连操作对反应选择性的改善作用不大,采用气固多级逆流操作反而会导致选择性显著下降。