Kinetic and catalytic performance of a BI‐porous composite material in catalytic cracking and isomerisation reactions

Catalytic behaviour of pure zeolite ZSM‐5 and a bi‐porous composite material (BCM) were investigated in transformation of m‐xylene, while zeolite HY and the bi‐porous composite were used in the cracking of 1,3,5‐triisopropylbenzene (TIPB). The micro/mesoporous material was used to understand the effect of the presence of mesopores on these reactions. Various characterisation techniques, that is, XRD, SEM, TGA, FT‐IR and nitrogen sorption measurements were applied for complete characterisation of the catalysts. Catalytic tests using CREC riser simulator showed that the micro/mesoporous composite catalyst exhibited higher catalytic activity as compared with the conventional microporous ZSM‐5 and HY zeolite for transformation of m‐xylene and for the catalytic cracking of TIPB, respectively. The outstanding catalytic reactivity of m‐xylene and TIPB molecules were mainly attributed to the easier access of active sites provided by the mesopores. Apparent activation energies for the disappearance of m‐xylene and TIPB over all catalysts were found to decrease in the order: E_BCM > E_ZSM‐5 and E_BCM > E_HY, respectively. © 2012 Canadian Society for Chemical Engineering     

WO3-ZSM-5/MCM-41催化剂的合成 及其催化氧化脱硫研究

以氢氧化钠溶液处理微孔沸石ZSM-5来提供硅铝源,合成了ZSM-5/MCM-41复合结构型分子筛。采用XRD、N2吸附脱附、TEM等方法对其进行了表征,考察了其水热稳定性。实验结果表明,碱处理合成的ZSM-5/MCM-41同时具有微孔孔道和介孔孔道结构,并具有优于介孔MCM-41分子筛的水热稳定性。以ZSM-5/MCM-41为载体负载三氧化钨后应用于噻吩/正辛烷模拟油体系,双氧水为氧化剂,催化氧化脱硫,WO3-ZSM-5/MCM-41（三氧化钨质量分数为10%）表现出良好的催化性能,脱硫率可达到93.6%。     

Synthesis and characterization of MCM-41-type composite materials prepared from ZSM-5 zeolite

Micro/mesoporous composite materials with microporous and mesoporous double pores-size distribution were hydrothermally synthesized by using slurry or filtrate of alkali-treated ZSM-5 zeolite and were characterized by XRD, N₂ adsorption, FT-IR, TEM and so on. The XRD and TEM patterns indicate the composite materials possess ordered hexagonal structure. The sample MZ-B using filtrate of alkali-treated ZSM-5 zeolite hardly contains raw ZSM-5 particles. However, sample MZ-A originated from the slurry of alkali-treated ZSM-5 zeolite may contain some ZSM-5 crystallites, owing to the differences in concentration and time of alkaline treatment for ZSM-5 zeolite.     

Synthesis of ZSM-5/SAPO-11 composite and its application in FCC gasoline hydro-upgrading catalyst

This article describes the synthesis, characterization and application of a novel aluminosilicate/silicoaluminophosphate composite zeolite ZSM-5/SAPO-11. The composite was synthesized by the in situ overgrowth of SAPO-11 on ZSM-5 and was characterized by means of X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transformed infrared (FT-IR) spectrometry, N₂ adsorption and infrared spectroscopy of adsorbed pyridine. The results were compared with those of the mechanical mixture composed of individual ZSM-5 and SAPO-11. In the mechanical mixture, the ZSM-5 phase was morphologically separate from the SAPO-11 phase, while the ZSM-5/SAPO-11 composite existed in a form of a core-shell structure, with the ZSM-5 phase as the core and the SAPO-11 phase as the shell. Compared with the mechanical mixture, the composite had more mesopores and moderate acidity distribution, which could accelerate the diffusion of substances and enhance the synergetic effect between Brönsted and Lewis acids. The comparison of the catalytic performances of the mechanical mixture and the composite-based Ni–Mo catalysts for FCC gasoline hydro-upgrading showed that, due to the above advantages of the composite, the corresponding catalyst yielded improved gasoline research octane number, high liquid yield, good desulfurization activity and lower coke amount and thus could be considered as a potential catalyst system for hydro-upgrading FCC gasoline.     

ZSM-5/MCM-41复合分子筛的制备及对乙醇脱水的催化活性

以微孔ZSM-5分子筛为母体,采用NaOH溶液对其进行预处理,再在水热条件下以十六烷基三甲基溴化铵（CTMAB）为模板剂制备了ZSM-5/MCM-41介微孔复合分子筛,考察了预处理温度、晶化温度等因素对复合分子筛结构和形貌的影响。进一步考察了该复合分子筛催化剂在乙醇脱水反应中的催化活性。结果表明,ZSM-5分子筛在2.0 mol/L NaOH溶液中于110℃预处理20 h,再于110℃水热晶化20 h制备的分子筛具有良好的介微孔复合结构;该复合分子筛经NH4NO3溶液离子交换制备的氢型催化剂在乙醇脱水催化反应中表现出良好的性能。当乙醇WHSV=0.5 h-1时,最佳反应温度为240～255℃,乙醇转化率〉99%,乙烯选择性〉96%。     

Hybrid zeolitic-mesostructured materials as supports of metallocene polymerization catalysts

The potential application of hybrid ZSM-5/Al-MCM-41 zeolitic-mesostructured materials as supports of metallocene polymerization catalysts has been investigated and compared with the behaviour of standard mesoporous Al-MCM-41 and microporous ZSM-5 samples. Hybrid zeolitic-mesostructured solids were prepared from zeolite seeds obtained with different Si/Al molar ratios (15, 30 and 60), which were assembled around cetyltrimethylammonium bromide (CTAB) micelles to obtain hybrid materials having a combination of both zeolitic and mesostructured features. (nBuCp)₂ZrCl₂/MAO catalytic system was impregnated onto the above mentioned solid supports and tested in ethylene polymerization at 70 °C and 5 bar of ethylene pressure. Supports and heterogeneous catalysts were characterized by X-ray powder diffraction, nitrogen adsorption-desorption isotherms at 77 K, transmission electron microscopy, ²⁷Al-MAS-NMR, ICP-atomic emission spectroscopy and UV-vis spectroscopy.Catalysts supported over hybrid ZSM-5/Al-MCM-41 (Si/Al = 30-60) exhibited the best catalytic activity followed by those supported on Al-MCM-41 (Si/Al = 30-60). However, catalyst supported on ZSM-5 gave lower polymerization activity because of its microporous structure with narrower pores and lower textural properties than hybrid and mesoporous materials.Although higher acid site population shown by hybrid materials could contribute to the stabilization of the metallocene system on the support, in this case their better catalytic performance is mainly ascribed to the larger textural properties.     

甲醇制烃反应ZSM-5催化剂微孔孔道控制的最新研究进展

甲醇在ZSM-5分子筛催化作用下,定向转化为低碳烯烃、汽油和芳烃等产品,是现代煤化工的重要技术。虽然ZSM-5结构规整有序,酸性强且水热稳定性好,具备优异的择形催化效应,但其孔结构以微孔为主,反应产物不能快速扩散出微孔,易形成积炭,导致催化剂活性降低而快速失活。缩短微孔孔道促进产物扩散成为甲醇定向转化催化剂研究的关键问题。本文总结了近十年来关于ZSM-5微孔孔道控制的最新研究进展,归纳了通过控制其晶粒尺寸、形貌和介孔结构,调控微孔孔道长度,提升反应分子在微孔内扩散性能的方法,特别分析了上述控制因子的关键调控机制;提出对纳米尺度的ZSM-5进一步精准构筑介孔结构,是获得高稳定性催化剂的重要途径;而在控制孔结构的基础上,优化表面酸性,有望提升甲醇制烃反应的产物选择性。本综述期望为甲醇制烃领域研究提供相关理论基础。     

Alkylphosphonic acid- and small amine-templated synthesis of hierarchical silicoaluminophosphate molecular sieves with high isomerization selectivity to di-branched paraffins

This article proposes a one-step strategy to hydrothermally synthesize SAPO-11 with hierarchical micro- and meso-porous structure. The structure and acidity properties and the isomerization performance of the resulting hierarchical SAPO-11 were extensively characterized and assessed, respectively, and compared with those of a microporous SAPO-11. The results showed that the SAPO-11 with mutually interpenetrating micropores and mesopores had been obtained by introducing tetradecylphosphoric acid into the synthesis system of microporous SAPO-11. Compared with microporous SAPO-11, the hierarchical SAPO-11 had much higher external surface and mesoporous volume, and more active sites with suitable Brönsted acid strength. These advantages endowed the hierarchical SAPO-11-based catalyst with superior isomerization activity, enhanced selectivity to di-branched products, and decreased cracking selectivity. The strategy proposed opens a new route to synthesizing a variety of hierarchical mesoporous SAPO molecular sieves for size-selective catalytic conversions of relatively large hydrocarbon molecules.     

多级孔道ZSM-5分子筛的合成及其催化应用

多级孔道ZSM-5分子筛具有微孔沸石分子筛良好的择形催化性能和介孔材料优异的传质扩散性能,在催化领域显示出良好的应用前景。本文综述了近年来多级孔道ZSM-5分子筛的研究进展,重点介绍了多级孔道ZSM-5分子筛的不同合成方法,包括后处理法、硬模板法和软模板法等,同时介绍了不同方法得到的多级孔道ZSM-5分子筛在催化反应中的应用,分析表明多级孔道ZSM-5分子筛以其良好的扩散性能和适宜的酸性提高了反应转化率和目标产物选择性。最后对多级孔道ZSM-5分子筛的发展方向进行了展望,指出研发简单、经济和环保的新合成路线是多级孔道ZSM-5分子筛发展中的重大挑战,深入研究多级孔道分子筛中介孔的形成机理和开发具有多级孔道整体式催化剂以及负载型多级孔道ZSM-5分子筛是今后的研究重点。     

Exploring suitable ZSM-5/MCM-41 zeolites for catalytic cracking of n-dodecane: Effect of initial particle size and Si/Al ratio

In this study, various ZSM-5/MCM-41 micro/mesoporous zeolite composites have been prepared by alkalidesilication and surfactant-directed recrystallization of ZSM-5. The effects of particle size and Si/Al ratio of initial ZSM-5 zeolites on the structure and catalytic performance of ZSM-5/MCM-41 composites are studied. The results of XRD, TEM N₂-adsorption-desorption, NH₃-TPD and in situ FT-IR revealed that ordered hexagonal MCM-41 mesopores with 3-4 nm pore size were formed around ZSM-5 crystals, and the specific surface area and mesopore volume of composites increased with increasing the Si/Al ratio of initial ZSM-5. Catalytic cracking of n-dodecane (550 ℃, 4 MPa) showed that the ZSM-5/MCM-41 composites obtained from the high Si/Al ratio and nano-sized initial ZSM-5 zeolites exhibited superior catalytic performance, with the improvement higher than 87% in the catalytic activities and 21% in the deactivation rate compared with untreated zeolites. This could be ascribed to their suitable pore structure, which enhanced the diffusion of reactant molecules in pores of catalysts.     

Synthesis of hierarchical ZSM-5 microspheres with superior performance for catalytic methanol-to-olefin conversion

Methanol-to-olefin (MTO) conversion on zeolites has encountered severe coke deposition and rapid deactivation. Creating different levels of porosity is essential to mitigate such issues. Herein, we demonstrate a facile and green strategy to synthesize uniform and hierarchically macro/mesoporous ZSM-5 microspheres by combining spray-freeze drying and steaming-assisted crystallization (SAC). The structure, crystallinity, and porosity of the zeolite microspheres are controlled by adjusting the water/gel mass ratio and time in the SAC process. The structure evolution during the SAC process is revealed. In the catalytic MTO reaction, the representative hierarchically porous ZSM-5 catalyst exhibits superior catalytic performance. At a very high weight hourly space velocity of 18 h⁻¹, it shows a dramatically prolonged lifetime (47 h at >99% conversion) and much-improved selectivity to ethylene and propylene compared with the conventional microporous ZSM-5 and nano-sized ZSM-5. The enhanced performance is originated from the hierarchical structure and suitable acidity of the ZSM-5 microspheres.     

Study of cracking of large molecules over a new type meso-ZSM-5 composite zeolite

A new type meso-ZSM-5 composite zeolite with interconnected macropores and skeletons under hydrothermal conditions was prepared through zeolite degraded method. The skeletons can be templated to the morphology of network in different conditions. The physical properties of the meso-ZSM-5 composite zeolite were characterized by XRD, IR, SEM and nitrogen sorption techniques. Catalytic tests show that the meso-ZSM-5 composite zeolite catalyst exhibits high catalytic activity compared with the conventional microporous ZSM-5 zeolites for catalytic cracking of 1,3,5-triisopropylbenzene. The high 1,3,5-triisopropylbenzene conversion are mainly assigned to the presence of the hierarchical porosity of the pore walls. The macropores offer easier transport and access to the active sites and the macroporous walls built by ZSM-5 crystals provide the acidic sites for reaction.     

Influence of initial Si/Al ratios on the structural,acidic and catalytic properties of nanosized-ZSM-5/SBA-15 analog composites prepared from ZSM-5 precursors

Nano-ZSM-5/SBA-15 analog composites (ZSC) were prepared in a two-step process from ZSM-5 precursors with different Si/Al molar ratios (10–50) via high-temperature synthesis in mildly acidic media (200 °C, pH 3.5) aiming to evaluate the influence of the initial Si/Al ratio on their structural, acidic and catalytic properties. The resulting materials were characterized by SAXS, XRD, FTIR, TEM, N₂ sorption, ²⁷Al solid state-NMR, NH₃-TPD, FTIR spectroscopy of adsorbed pyridine, AAS and ICP-AES. Under the applied synthesis conditions, a ZSC material with controlled distribution of nano-ZSM-5 and SBA-15 analog phases can be prepared from ZSM-5 precursors by adjusting the initial Si/Al ratio in the range of 20–30. Increasing the initial Si/Al ratio to 50, only ZSM-5 nanocrystals were obtained whereas reducing the initial Si/Al ratio to 10 led to the formation of a disordered mesoporous SBA-15 analog. The total acidity increases with the crystallinity of the ZSM-5 phase as varying the Si/Al ratio from 10 to 30 despite the decreased amount of incorporated aluminum. However, the acidity declines slightly when raising the Si/Al ratio to 50 because of the low incorporated aluminum. The catalytic performance of the ZSC materials compared to the reference materials, i.e. purely mesoporous Al-SBA-15 and purely microporous H-ZSM-5 was assessed in the gas phase cracking of cumene and 1,3,5-tri-isopropylbenzene (TIPB) as test reactions. The results show that a balanced ratio of nano-ZSM-5 and SBA-15 analog phases obtained by tuning the initial Si/Al ratio is crucial to achieve superior catalytic performance of the ZSC materials in the cracking of both cumene and TIPB.     

介微孔HY/MCM-41复合分子筛的合成及应用

以微孔HY浆液为母液,合成了介-微孔复合分子筛HY/MCM-41。通过XRD、BET和NH₃-TPD等手段对复合分子筛进行表征,并考察其水热稳定性。结果表明,复合分子筛同时具有中孔分子筛MCM-41和微孔HY型沸石的特点,与纯MCM-41分子筛相比,酸性明显增强,水热稳定性提高。利用一段串联加氢裂化工艺,考察了复合分子筛的催化性能。200 mL固定床加氢装置评价结果表明,在控制原料>350 ℃馏分油转化率为75%的条件下,加氢裂化生成油C₅⁺液收98.51%,最大量柴油馏分［(140~370) ℃］收率69.09%,＜370 ℃中馏分油选择性80.5%,能满足工业装置最大量生产柴油的需要。     

Effect of Al content on the assembly of Al-MSU-S mesostructures: zeolite seed structure change from zeolite LZY to LTA with increasing Al content

Al-MSU-S mesoporous molecular sieve catalysts with Al contents ranging from 2.5 to 50 mol% have been prepared from “zeolite seed” solutions and C₁₆ TMABr templates. Hexagonal mesoporous structures are formed that exhibit significantly higher amounts of tetrahedrally coordinated Al than analogous Al-MCM-41 catalysts. The Al-MSU-S catalysts also possess smaller pores than corresponding Al-MCM-41 materials. Catalytic cumene cracking activity is very high over the low Al content materials (2.5 mol%), approaching that of zeolite ZSM-5, but the catalytic activity decreases with increasing Al. As the Al content is increased, the Al atoms remain tetrahedrally coordinated but become less accessible to the cumene reagent. This and knowledge of zeolite synthesis suggest the formation of zeolite seeds other than the large pore LZY, such as the small pore LTA structure.     

Synthesis, characterization, and catalytic properties of a hydrothermally stable Beta/MCM-41 composite from well-crystallized zeolite Beta

A Beta/MCM-41 composite has been synthesized with a new method by using well-crystallized zeolite Beta as silica and aluminum source. The prepared composite was characterized by XRD, FTIR, N₂ adsorption/desorption at 77 K, FE-SEM, DTG, ²⁹Si MAS NMR spectral techniques. It was shown that the composite consisted of a highly ordered mesoporous MCM-41 phase and a zeolite Beta phase. Its hexagonal mesoporous structure was still retained after statically treated for 120 h in boiling water. In contrast, the structure of generally synthesized Al-MCM-41 nearly completely collapsed. This might be attributed to the assembly of the dissolved fragments such as the first and/or secondary structural units of zeolite Beta into the mesoporous structure around surfactant micelles. This is supported by the catalytic result that the prepared composite showed higher activity and selectivity for medium fraction in hydrocracking of Daqing vacuum residue than the parent zeolite Beta, the Al-MCM-41 as well as the mechanical mixture of these two materials.     

多级孔ZSM-5/SAPO-34复合分子筛制备及催化MTO性能研究

为制备性能更加优异的甲醇制烯烃（MTO）催化剂及进一步探究多级孔道对MTO催化反应的影响,采用柠檬酸溶液（CA）运用后处理方法对复合分子筛进行刻蚀,成功制备了具有多级孔道结构的ZSM-5/SAPO-34复合分子筛（CA-Z-S）。对复合分子筛的晶相、骨架、孔结构等理化性质进行了表征;将复合分子筛用于催化MTO反应,考察了复合分子筛的催化性能。表征结果表明,使用CA处理对ZSM-5/SAPO-34复合分子筛的形貌、结构会产生影响,使CA-Z-S具有更紧密的复合结构、适量的弱酸中心和多级孔道复合结构。催化测试结果表明,甲醇转化率达到100%时,CA-Z-S的寿命为1 200 min,较SAPO-34提高79%,较ZSM-5/SAPO-34提高30%;CA-Z-S对轻烯烃的选择性达到90.5%,较SAPO-34提高约3.7%。研究结果表明,利用CA对复合分子筛进行后处理,有利于复合分子筛催化MTO反应性能的提升。     

A novel catalyst system based on quadruple silicoaluminophosphate and aluminosilicate zeolites for FCC gasoline upgrading

To develop a novel catalyst system that has excellent olefin reduction capability for FCC gasoline without loss in octane number, different catalysts supported on multiple composite carriers consisting of SAPO-11, Hβ, HMOR and HZSM-5 were prepared and their catalytic performances for FCC gasoline upgrading were assessed in the present investigation. The pore structure and acidity of the catalysts were characterized by N₂ adsorption and pyridine adsorption FTIR, respectively. Based on the results obtained over the catalysts supported on binary-zeolite carriers (Hβ/HZSM-5, HMOR/HZSM-5 and SAPO-11/HZSM-5) using FCC gasoline as the feedstock, various multiple-zeolite supported catalysts were developed from different combinations of the binary-zeolite systems. It was found that the SAPO-11/HMOR/β/ZSM-5 quadruple composite zeolite supported catalyst gave higher liquid yield, improved gasoline RON, and lower coke deposit amount for the hydro-upgrading of FCC gasoline and thus can be considered as a potential catalyst system. A comprehensive analysis based on the catalytic activities and acidity measurements revealed that acid strength and acid type were two very important factors influencing hydroisomerization and aromatization activities, and the difference in catalyst acid strength determined which factor predominates.     

Synthesis of a ZSM-5(core)/SAPO-5(shell) composite and its application in FCC

A core/shell structure composite was synthesized via a new method of pre-coating one raw material. The composite was characterized by X-ray diffraction, SEM, TEM and N₂ isothermal adsorption–desorption and Py-FTIR. In addition, the catalytic performance of the composite in cracking of heavy oil for producing olefin was also investigated. The characterization results show that the composite with a core/shell structure had smaller particle size, uniform SAPO-5 shell, and fewer acid sites than ZSM-5, accelerating the transport of reactant and product molecules between different zeolites. Consequently, the light olefins on the composites had high specific selectivity.     

不同结构分子筛的甲醇制丙烯催化性能

在常压、空速为1.5 h^-1、反应温度为450℃条件下,考察了4种具有不同拓扑结构的分子筛(SAPO-34、ZSM-48、ZSM-5和beta)在甲醇转化制丙烯(MTP)反应中的催化性能,并对催化剂的积炭失活行为进行了研究。结果表明,从8元环到12元环,分子筛孔口尺寸越小,低碳烯烃(乙烯+丙烯)选择性越高,积炭失活速率也越快。孔道尺寸越大,丙烯/乙烯(P/E)比越高,但产物分布向C₄以上组分偏移,丙烯选择性降低。10元环分子筛具有较高的丙烯选择性,但催化剂的积炭失活速率随孔道体系的不同有很大差异。一维直通孔道的ZSM-48容易积炭失活,而具有三维交叉孔结构的ZSM-5表现出了优异的抗积炭失活性能。不同结构分子筛在MTP反应中催化性能的差异主要归因于分子筛的过渡态择形和产物择形作用的不同。