MOR-MFI Heterostructural Zeolite Catalyst for Heavy Aromatic Transalkylation
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Solution Overview
Problem
Current catalyst systems face challenges in efficiently converting heavy aromatics (C8+ aromatics) to lighter aromatic products like benzene, toluene, and xylenes, particularly in maintaining activity and catalyst life as the amount of C8+ aromatics in the feed increases.
Innovation Solution
A catalyst composition is developed by adding heterostructural seeds with MFI and/or MEL framework structures, such as ZSM-5 and ZSM-11, to the synthesis mixture for preparing a zeolite with a MOR framework structure, combined with metals from Group 10 and optionally Group 11-15 of the IUPAC Periodic Table, resulting in a catalyst with improved performance for converting C8+ aromatic hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical mixing of two zeolites is used in the same catalyst particle, then both transalkylation and dealkylation activities are achieved, but the catalyst complexity increases and manufacturing precision decreases
Solution Approach 1:
The patent combines two different zeolite structures (MOR framework and MFI framework) into a single synthesized catalyst particle with heterogeneous structure. This merging approach allows both transalkylation (from MOR) and dealkylation (from MFI) activities to coexist in one catalyst, eliminating the need for physical mixing of separate zeolite particles while maintaining dual functionality.
Solution Approach 2:
The invention creates a composite zeolite material with heterogeneous structure containing both MOR and MFI framework types within the same particle. This composite structure integrates the beneficial properties of both zeolite types, achieving multiple catalytic functions in a single material system with improved manufacturing precision.
2Ease of manufacture
If physical mixing of zeolites with binder is used, then catalyst particle formation is achieved, but manufacturing precision and catalyst performance are limited
Solution Approach 1:
The patent replaces the mechanical mixing process (physical mixing of zeolites with binder) with a chemical synthesis process. By using hydrothermal synthesis methods, the zeolite structures are formed in-situ with precise control over their framework types, compositions, and spatial distribution, achieving superior manufacturing precision and catalyst performance.
Solution Approach 2:
The invention controls synthesis parameters (temperature, pressure, pH, precursor ratios, additives) during hydrothermal synthesis to precisely regulate the formation of heterogeneous zeolite structures. By optimizing these parameters, the patent achieves controlled crystallization of MOR and MFI frameworks within the same particle, enhancing manufacturing precision and catalytic performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the conversion of C8+ aromatic hydrocarbons to lighter aromatic products, improving activity and catalyst longevity compared to conventional methods, and eliminates the need for physical mixing of zeolites, achieving higher toluene/C9/C10 conversion and benzene purity.
Implementation Method 1
A catalyst composition is developed by adding heterostructural seeds with MFI and/or MEL framework structures, such as ZSM-5 and ZSM-11, to the synthesis mixture for preparing a zeolite with a MOR framework structure, combined with metals from Group 10 and optionally Group 11-15 of the IUPAC Periodic Table, resulting in a catalyst with improved performance for converting C8+ aromatic hydrocarbons.
Data Source
AI summary
Disclosed are catalyst compositions and their use in a process for the conversion of a feedstock containing C8+ aromatic hydrocarbons to produce light aromatic products, comprising benzene, toluene and xylene. The catalyst composition comprises a zeolite which comprises a MOR framework structure and a MFI and/or MEL framework structure, (b) at least one first metal of Group 10 of the IUPAC Periodic Table, and (c) optionally at least one second metal of Group 11 to 15 of the IUPAC Periodic Table. In one or more embodiments, the MOR framework structure comprises mordenite, preferably a mordenite zeolite having small particle size. The MFI framework structure preferably comprises ZSM-5, and the MEL framework structure preferably comprises ZSM-11.