Directed transforming of coke to active intermediates in methanol-to-olefins catalyst to boost light olefins selectivity

Jibin Zhou, Mingbin Gao, Jinling Zhang, Wenjuan Liu, Tao Zhang, Hua Li, Zhaochao Xu, Mao Ye () and Zhongmin Liu ()
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Jibin Zhou: Chinese Academy of Sciences
Mingbin Gao: Chinese Academy of Sciences
Jinling Zhang: Chinese Academy of Sciences
Wenjuan Liu: University of Chinese Academy of Sciences
Tao Zhang: Chinese Academy of Sciences
Hua Li: Chinese Academy of Sciences
Zhaochao Xu: Chinese Academy of Sciences
Mao Ye: Chinese Academy of Sciences
Zhongmin Liu: Chinese Academy of Sciences

Nature Communications, 2021, vol. 12, issue 1, 1-11

Abstract: Abstract Methanol-to-olefins (MTO), the most important catalytic process producing ethylene and propylene from non-oil feedstocks (coal, natural gas, biomass, CO2, etc.), is hindered by rapid catalyst deactivation due to coke deposition. Common practice to recover catalyst activity, i.e. removing coke via air combustion or steam gasification, unavoidably eliminates the active hydrocarbon pool species (HCPs) favoring light olefins formation. Density functional theory calculations and structured illumination microscopy reveal that naphthalenic cations, active HCPs enhancing ethylene production, are highly stable within SAPO-34 zeolites at high temperature. Here, we demonstrate a strategy of directly transforming coke to naphthalenic species in SAPO-34 zeolites via steam cracking. Fluidized bed reactor-regenerator pilot experiments show that an unexpectedly high light olefins selectivity of 85% is achieved in MTO reaction with 88% valuable CO and H2 and negligible CO2 as byproducts from regeneration under industrial-alike continuous operations. This strategy significantly boosts the economics and sustainability of MTO process.

Date: 2021
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DOI: 10.1038/s41467-020-20193-1

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