SBIR Phase I: Engineered Zeolite Catalyst for Paraffin Alkylation

这个小型企业创新研究（SBIR）一期项目旨在为石化和炼油行业开发一种新型的工程沸石催化剂。一股即将到来的重新配方汽油热潮正在推动固体酸催化剂通往烷基酸盐的发展。其目的是在6000万吨/年的烷基酸市场上，用更安全、更环保的固体酸催化剂取代硫酸和氢氟酸。虽然沸石已经作为潜在的候选材料进行了试验，但它们在生产过程中会迅速失活。失活主要是由于“焦炭”沉积物的形成堵塞了气孔开口并阻塞了活性部位。新型沸石催化剂使用智能结构导向剂来创建高度有序的微观和宏观孔隙。较大的孔提供了试剂进入微孔系统的高效通道和快速扩散，而较小的孔提供了高表面积和尺寸选择性；因此具有特殊的催化和筛分功能。作为第一阶段研究的一部分，工程沸石催化剂将被合成、表征并测试其活性和稳定性。预计与传统的沸石体系相比，独特的孔隙结构将减少孔内扩散障碍，从而提高产物选择性和显着延长催化剂寿命。这种新型工程沸石可以有效地用作固体-酸催化剂，用于快速液相反应，如异辛烷、异丙烯和EB的生产。

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.