Controlling product selectivity and catalyst lifetime by altering acid strength, cavity size of SAPO, and diffusion rate of methanol in the MTO reaction: DFT and MD calculations.

The initiation mechanisms of the MTO process over silicoaluminophosphate (SAPO) catalysts with zeolite-like structures using first-principles calculations have been investigated. The supramolecular system of silicoaluminophosphates consisting of inorganic cages with Brønsted acid sites and trapped organic compounds was used as a catalyst in the MTO reaction. To study the structure-property relationship in more detail, the effect of acidity and cage size of different types of SAPOs (SAPO-18, SAPO-34, and SAPO-17 with CHA, AEI, and ERI structures, respectively) in the aromatic cycle of hydrocarbon pool mechanism was investigated. The differences in reaction barriers can be explained by the cage size, pore topology, and environment of framework protons of materials. Product selectivity was controlled by using cavity-type zeolite, the steric constraint of the cavity for the formation of critical intermediates, and acidic strength. The results show that ethylene selectivity increases as the cavity size decreases, and the elliptical pore size of the structures decreases, thereby decreasing the acidity of the zeolite structure, leading to an increase in propylene selectivity. SAPO-18 exhibits the longest reaction lifetime and has the highest amount of carbonaceous material after reaction completion. SAPO-17 with small pore and cavity size is selective to ethylene, although it shows a rapid catalyst deactivation rate.

Effect of CNT over structural properties of SAPO-34 in MTO process: Experimental and molecular simulation studies.

The hierarchical silicoaluminophosphate (SAPO-34) catalyst was synthesized using the mixtures of diethylamine (D) and butylamine (B) as a structure-directing agent (SDA), and carbon nanotube (CNT) as a secondary template in the hydrothermal method. The catalysts were characterized by Fourier-transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM), transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy (EDX), N2 physisorption, and temperature-programmed desorption of ammonia (NH3-TPD) techniques and evaluated for the catalytic activity in the Methanol to Olefins (MTO) process. The results showed that the use of CNT as the secondary template improved the hierarchical structure of SAPO-34 due to increasing the external surface area and mesoporosity and decreasing the particle size and as a result, made better the performance of the prepared SAPO-34 zeolite in the MTO process. Among all the prepared samples, the CNT-B-D catalyst synthesized by mixing three templates displayed the highest ethylene and propylene selectivity of 49% and 34%, respectively. Also, using CNT in the synthesis of samples increased the catalytic stability. In addition, pure, binary, and ternary adsorption isotherms and diffusivities of the main products and reactants over the SAPO-34 were investigated by theoretical measurements, because sorption and diffusion affect the catalyst stability and C2-C3 selectivity in the MTO reaction. The higher diffusion rate of ethylene leads to following the aromatic-based cycle in the MTO process.