SBIR Phase I: Engineered Zeolite Catalyst for Paraffin Alkylation

该小型企业创新研究（SBIR）第一阶段项目旨在为石化和炼油行业开发一种新型工程沸石催化剂。 一个迫在眉睫的新配方汽油热潮正在推动固体酸催化剂路线的烷基化的发展。其目的是在6000万吨/年的烷基化物市场中用更安全、更环保的固体酸催化剂取代硫酸和氢氟酸。 尽管沸石已被尝试作为潜在的候选物，但它们在生产中迅速失活。失活主要是由于形成“焦炭”沉积物，堵塞孔隙开口并阻塞活性位点。 新型沸石催化剂使用智能结构导向剂来产生高度有序的微孔和大孔。较大的孔提供试剂到微孔系统的有效进入和快速扩散，而较小的孔可以提供高表面积和尺寸选择性;因此具有特定的催化和筛分功能。 作为第一阶段研究的一部分，工程沸石催化剂将进行合成、表征和活性和稳定性测试。与传统的沸石体系相比，这种独特的孔结构将减少孔内扩散障碍，从而提高产物选择性，延长催化剂的使用寿命。这种新型的工程沸石可有效地用作快速液相反应的固体酸催化剂，如生产异辛烷、异丙苯和乙苯。

This Small Business Innovation Research (SBIR) Phase I project aims to develop a new class of engineered zeolite catalysts for the petrochemical and refining industry. A looming reformulated gasoline boom is driving the development of solid-acid catalysts routes to alkylates. The intent is to replace sulfuric and hydrofluoric acids with safer and more environmentally benign solid-acid catalysts in the 60-million tons/year alkylates market. Although zeolites have been tried as a potential candidate, they deactivate rapidly on stream. The deactivation is mainly due to the formation of 'coke' deposits that plug up pore mouth openings and block the active sites. The novel zeolite catalyst uses smart structure-directing agents to create highly ordered micro and macro-pores. The larger pores provide efficient access and quick diffusion of reagents to the micro-porous system, while the smaller pores can offer high-surface area and size selectivity; thus specific catalytic and sieving functions. Engineered zeolite catalysts will be synthesized, characterized and tested for activity and stability as part of the Phase I research. It is expected that the unique pore architecture will reduce intra-pore diffusive barriers leading to higher product selectivity and a significantly longer catalyst life compared to conventional zeolitic systems.This new class of engineered zeolites can be used effectively as a solid-acid catalyst for fast liquid phase reactions such as the production of iso-octanes, cumene and EB.