Modeling and analysis of air combustion and steam regeneration in methanol to olefins processes

Light olefins is the incredibly important materials in chemical industry.Methanol to olefins(MTO),which provides a non-oil route for light olefins production,received considerable attention in the past decades.However,the catalyst deactivation is an inevitable feature in MTO processes,and regeneration,therefore,is one of the key steps in industrial MTO processes.Traditionally the MTO catalyst is regenerated by removing the deposited coke via air combustion,which unavoidably transforms coke into carbon dioxide and reduces the carbon utilization efficiency.Recent study shows that the coke species over MTO catalyst can be regenerated via steam,which can promote the light olefins yield as the deactivated coke species can be essentially transferred to industrially useful synthesis gas,is a promising pathway for further MTO processes development.In this work,we modelled and analyzed these two MTO regeneration methods in terms of carbon utilization efficiency and technology economics.As shown,the steam regeneration could achieve a carbon utilization efficiency of 84.31%,compared to 74.74%for air combustion regeneration.The MTO processes using steam regeneration can essentially achieve the near-zero carbon emission.In addition,light olefins production of the MTO processes using steam regeneration is 12.81%higher than that using air combustion regeneration.In this regard,steam regeneration could be considered as a potential yet promising regeneration method for further MTO processes,showing not only great environmental benefits but also competitive economic performance.

Significant Breakthrough in Industrial Test of the "Methanol to Olefins" Process Developed by Dalian Institute of Chemical Physics,Chinese Academy of Sciences

A process of ＂Methanol or Dimethylether to Olefins＂ developed by Dalian Institute of Chemical Physics （DICP）, designated as the DMTO process, has attained great success in industrial scaling up testing. DICP, by collaborating with the Xinxing Coal Chemical Co., Ltd. of Shaanxi Province and the Luoyang Petrochemical Engineering Co. of the SINOPEC Group, operated successfully a 50t（methanol）/d unit for the conversion of methanol to lower olefins, with a methanol conversion of close to 100%, and a selectivity to lower olefins（ethylene, propylene and butylenes） of higher than 90%. On 23rd August, the industrial test project has passed a state appraisal. The experts of the Appraisal Group, headed by Prof. YUAN Qingtang, academician of Chinese Academy of Engineering, drew the conclusions that the DMTO process, by utilizing a proprietary SAPO-34 catalyst system and a recycling fluidized bed reaction system for the production of lower olefins from methanol, is the first unit in the world having a capacity of producing nearly ten thousand tons lower olefins per year. The technological level of the industrial test is at a leading position internationally. This accomplishment will provide a sound base for the subsequent commercialization of the DMTO process.

In situ Synthesis of SAPO-34 Zeolites in Kaolin Microspheres for a Fluidized Methanol or Dimethyl Ether to Olefins Process

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 micro-spheres 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,bet-ter 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.

Kinetics of steam regeneration of SAPO-34 zeolite catalyst in methanol-to-olefins(MTO) process

Methanol-to-olefins(MTO)is industrially applied to produce ethylene and propylene using methanol converted from coal,synthetic gas,and biomass.SAPO-34 zeolites,as the most efficient catalyst in MTO process,are subject to the rapid deactivation due to coke deposition.Recent work shows that steam regeneration can provide advantages such as low carbon dioxide emission and enhanced light olefins yield in MTO process,compared to that by air regeneration.A kinetic study on the steam regeneration of spent SAPO-34 catalyst has been carried out in this work.In doing so,we first investigated the effect of temperature on the regeneration performance by monitoring the crystal structure,acidity,residual coke properties and other structural parameters.The results show that with the increase of regeneration temperature,the compositions of residual coke on the catalyst change from pyrene and phenanthrene to naphthalene,which are normally considered as active hydrocarbon pool species in MTO reaction.However,when the regeneration temperature is too high,nitrogen oxides can be found in the residual coke.Meanwhile,as the regeneration temperature increases,the quantity of residual coke reduces and the acidity,BET surface area and pore structure of the regenerated samples can be better recovered,resulting in prolonging catalyst lifetime.We have further derived the kinetics of steam regeneration,and obtained an activation energy of about 177.8 kJ·mol^(-1).Compared that with air regeneration,the activation energy of steam regeneration is higher,indicating that the steam regeneration process is more difficult to occur.

Synthesis and characterization of an unusual snowflake-shaped ZSM-5 zeolite with high catalytic performance in the methanol to olefin reaction

The ZSM-5 zeolite with an unusual snowflake-shaped morphology was hydrothermally synthesized for the first time,and compared with common ellipsoidal and boat-like shaped samples.These samples were characterized by N2 adsorption-desorption,X-ray fluorescence spectroscopy,scanning electron microscopy,X-ray diffraction,magic angle spinning nuclear magnetic resonance,temperature-programmed desorption of ammonia,and infrared spectroscopy of pyridine adsorption.The results suggest that the BET surface area and SiO2/Al2O3 ratio of these samples are similar,while the snowflake-shaped ZSM-5 zeolite possesses more of the（101） face,and distortion,dislocation,and asymmetry in the framework,resulting in a larger number of acid sites than the conventional samples.Catalysts for the methanol to olefin（MTO） reaction were prepared by loading Ca on the samples.The snowflake-shaped Ca/ZSM-5 zeolite exhibited excellent selectivity for total light olefin（72%） and propene（39%） in MTO.The catalytic performance influenced by the morphology can be mainly attributed to the snowflake-shaped ZSM-5 zeolite possessing distortion,dislocation,and asymmetry in the framework,and lower diffusion limitation than the conventional samples.

Data-driven optimal operation of the industrial methanol to olefin process based on relevance vector machine

Methanol to olefin(MTO)technology provides the opportunity to produce olefins from nonpetroleum sources such as coal,biomass and natural gas.More than 20 commercial MTO plants have been put into operation.Till now,contributions on optimal operation of industrial MTO plants from a process systems engineering perspective are rare.Based on relevance vector machine(RVM),a data-driven framework for optimal operation of the industrial MTO process is established to fully utilize the plentiful industrial data sets.RVM correlates the yield distribution prediction of main products and the operation conditions.These correlations then serve as the constraints for the multi-objective optimization model to pursue the optimal operation of the plant.Nondominated sorting genetic algorithmⅡis used to solve the optimization problem.Comprehensive tests demonstrate that the ethylene yield is effectively improved based on the proposed framework.Since RVM does provide the distribution prediction instead of point estimation,the established model is expected to provide guidance for actual production operations under uncertainty.

Recent progress in the deactivation mechanism of zeolite catalysts in methanol to olefins

Methanol to olefins(MTO)as an important reaction in C1 chemistry can effectively transform non-petroleum carbon resources into value-added chemicals.Zeolites have been widely used as MTO catalysts.However,they usually suffer from a rapid deactivation due to bulky coke species production,and thus require continuous regenerations in industrial application.The key to design and develop highly stable zeolite catalysts for MTO process is to unravel the deactivation mechanism and clarify the structure–performance relationship of catalysts.Here,in this mini-review,we investigate the critical intermediate species inducing zeolite deactivation and analyze the formation and evolution pathways of polycyclic aromatic hydrocarbons(PAHs)that are the precursors of carbonaceous deposits.In addition,some methods to alleviate the coking mainly including acid regulation,morphology modification and process optimization,are also summarized.

Changing the balance of the MTO reaction dual-cycle mechanism: Reactions over ZSM-5 with varying contact times

The methanol to olefins （MTO） reaction was performed over ZSM‐5 zeolite at 300℃ under various methanol weight hourly space velocity （WHSV） values. During these trials, the catalytic perfor‐mance was assessed, in addition to the formation and function of organic compounds retained in the zeolite. Analysis of reaction effluents and confined organics demonstrated a dual‐cycle reaction mechanism when employing ZSM‐5. The extent of the hydrogen transfer reaction, a secondary reac‐tion in the MTO process, varied as the catalyst‐methanol contact time was changed. In addition, 12C/13C‐methanol switch experiments indicated a relationship between the dual‐cycle mechanism and the extent of the hydrogen transfer reaction. Reactions employing a low methanol WHSV in conjunction with a long contact time favored the hydrogen transfer reaction to give alkene products and promoted the generation and accumulation of retained organic species, such as aromatics and methylcyclopentadienes, which enhance the aromatic cycle. When using higher WHSV values, the reduced contact times lessened the extent of the hydrogen transfer reaction and limited the genera‐tion of methylcyclopentadienes and aromatic species. This suppressed the aromatic cycle, such that the alkene cycle became the dominant route during the MTO reaction.

Enhanced MTO performance over acid treated hierarchical SAPO-34

Hierarchical SAPO‐34 crystals were synthesized by a facile acid etching post‐treatment. Butterfly‐shaped porous patterns on four side faces and hierarchical pores composed of micropores,mesopores and macropores were formed after a nitric acid or oxalic acid treatment. The catalyticperformance of the hierarchical SAPO‐34 for the methanol to olefins (MTO) process showed that thesynergistic effect of the hierarchical pores and acid sites resulted in a longer catalyst lifetime (from210 to 390 min for the acid treated SAPO‐34) and higher selectivity to light olefins of 92%–94%.The ethylene selectivity can be adjusted between 37.4% and 51.5% by the pore size. No hierarchical SAPO‐34 was obtained after a treatment with butanedioic acid, and with this sample, fast deactivation was detected after 100 min.

Charge compensation dominates the distribution of silica in SAPO-34

The distribution of Si atoms in the SAPO-34 framework determines its acidity and catalytic effects.This was investigated using the charge balance between the inorganic framework and trapped template ions.Three types of templates,which yielded R~＋,2R~＋ and 2R^（2＋） positive charges in the cages of SAPO-34,were obtained from single crystal data and they were used to direct the synthesis of SAPO-34 with different Si contents and formation of isolated Si atoms and Si islands in the lattice.The concentration limits of SiO2 in the gel for constituting isolated Si atoms were calculated and verified experimentally.Si islands,including 5-Si,8-Si,11-Si,14-Si island were described on the basis of host-guest charge compensation.An overall view of the distribution of Si atoms in SAPO-34 was given and a criterion for the strength and density of acid sites in SAPO-34 for it to be an efficient catalyst for MTO was made available.