Research and development of catalytic processes for petroleum and natural gas conversions in the Dalian Institute of Chemical Physics

The Dalian Institute of Chemical Physics (DICP) of the Chinese Academy of Sciences has a long history in the R&D of catalysts and catalytic processes for petroleum and natural gas conversions in China. In this paper, results and features of some commercialized petrochemical catalysts and processes as well as newly developed processes for natural gas conversion in the pilot-plant stage are described. (C) 1999 Elsevier Science B.V. All rights reserved.

Methane aromatization in the absence of an added oxidant and the bench scale reaction test

A bench scale reaction test for methane aromatization in the absence of an added oxidant was performed and its reaction result evaluated based on the carbon balance of the system. The result was compared with those obtained from the micro-reaction test to ensure the accuracy of the internal standard analyzing method employed in this paper. The catalytic performances of modified Mo/HZSM-5 catalysts were examined. It was found that pre-treatment by steam on HZSM-5 weakened the serious deposition of coke, and pre-impregnation of n-ethyl silicate on HZSM-5 could improve the conversion of CH4, but had little effect on coke formation. A low temperature activation procedure including pre-reduction of the catalyst with methane prevents the zeolite lattice from being seriously destroyed by high valence state Mo species when the Mo loading is high. It was suggested that Mo2C species detected by XRD spectra was the active phase for CH4 aromatization.

A study on reduction behaviors of the supported platinum-iron catalysts

The reduction behaviors of the supported platinum-iron catalysts and their comparison with supported iron catalysts were studied by TPR (temperature-programmed reduction)-in situ Fe-57 MBS (Mossbauer spectroscopy). The results indicated that the TPR processes of all Fe-containing catalysts were different from that of bulk alpha-Fe2O3. There were interactions between Pt, Fe and the gamma-Al2O3 or SiO2 support for the Pt-Fe/gamma-Al2O3 and Pt-Fe/SiO2 catalysts. All the iron-containing catalysts show that Fe3+ was highly dispersed on the support (gamma-Al2O3 and SiO2) before reduction. No Fe-0 was found in the reduction processes. The Fe3+ was reduced to Fe2+ in tetrahedral vacancy first for the reduction of the Pt-Fe/gamma-Al2O3 catalyst. No Fe2+ in octahedral vacancy was found in the reduction of the Pt-Fe/SiO2 catalyst. Adding Pt to Fe/support (gamma-Al2O3 or SiO2) could promote the reduction of the Fe species. (C) 1999 Elsevier Science B.V. All rights reserved.

Regeneration behaviors of Fe/Si-2 and Fe-Mn/Si-2 catalysts for C2H6 dehydrogenation with CO2 to C2H4

The catalytic performance of Fe/Si-2 and Fe-Mn/Si-2 catalysts for conversion of C2H6 with CO2 to C2H4 was examined in a continuous-flow and fixed-bed reactor. The results show that the Fe-Mn/Si-2 catalyst exhibits much better reaction activity and selectivity to C2H4 than those of the Fe/Si-2 catalyst. Furthermore, the coking-decoking behaviors of these catalysts were studied through TG. The catalytic performances of the catalysts after regeneration for conversion of C2H6 or dilute C2H6 in FCC off-gas with CO2 to C2H4 were also examined. The results show that both activity and selectivity of the Fe-Mn/Si-2 catalyst after regeneration reached the same level as those of the fresh catalyst, whereas it is difficult for the Fe/Si-2 catalyst to refresh its reaction behavior after regeneration.

Kinetics of the selective reduction of NO with CH4 over an In-Fe2O3/HZSM-5 catalyst

A kinetic model presented for the selective reduction of NO with CH4 over an InFe2O3/HZSM-5 catalyst by considering the process as a combination of two simultaneous reactions: NO+O2CH4 (reaction 1) and O-2+CH4 (reaction 2). Linear regression calculation was employed to find the kinetic parameters. It was found that although the activation energies of the two reactions were almost identical, the reaction rate constants were dramatically different, namely, k(1)much greater than k(2), indicating that the NO+O-2+CH4 reaction was more preferable to take place on the In-Fe2O3/HZSM-5 catalyst as compared with the O-2+CH4 reaction.

Synthesis of a high-permeance NaA zeolite membrane by microwave heating

Zeolite membranes with high permeance and separation factors are highly desirable for practical applications. Although, in the past, very good separation factors have been obtained, it has proved difficult to achieve a high permeance. Ken a comparative study of microwave versus conventional heating in the hydrothermal synthesis of NaA zeolite membranes is made. It is demonstrated that membranes prepared by microwave heating have not only a higher permeance but also a considerably shorter synthesis time. These observations are rationalized by examining the mechanism of membrane formation.

Novel and ideal zirconium-based dense membrane reactors for partial oxidation of methane to syngas

A novel and ideal dense catalytic membrane reactor for the reaction of partial oxidation of methane to syngas (POM) was constructed from the stable mixed conducting perovskite material of BaCo0.4Fe0.4Zr0.2O3-delta and the catalyst of LiLaNiO/gamma-Al2O3. The POM reaction was performed successfully. Not only was a short induction period of 2 h obtained, but also a high catalytic performance of 96-98% CH4 conversion, 98-99% CO selectivity and an oxygen permeation flux of 5.4-5.8 ml cm(-2) min(-1) (1.9-2.) mumol m(-2) S-1 Pa-1) at 850 degreesC were achieved. Moreover, the reaction has been steadily carried out for more than 2200 h, and no interaction between the membrane material and the catalyst took place.

Preparation of zeolite-metal composite membrane

A NaA zeolite membrane was synthesized on the surface of the stainless steel stab. The membrane was characterized by XRD and SEM. The membrane was continuous and highly intergrown. The size of NaA zeolite crystals was about 5 similar to 6 mum.

Titanium-based perovskite-type mixed conducting ceramic membranes for oxygen permeation

A titanium-based perovskite-type oxide was synthesized by an improved method of combining EDTA acid and citric acid complexes. High structural stability, good sintering ability, and relatively high oxygen permeation flux were obtained simultaneously for disks synthesized from this ceramic oxide. (C) 2002 Elsevier Science B.V All rights reserved.

Synthesis of NaA zeolite membranes from clear solution

NaA zeolite membranes were successfully synthesized on a porous alpha -Al2O3 support from clear solution. The synthesis parameters, such as surface seeding, synthesis time, synthesis stages, etc. were investigated. Surface seeding can not only accelerate the formation of NaA zeolite on the support surface, but can also inhibit the transformation of NaA zeolite into other types of zeolites. A continuous NaA zeolite membrane formed on the seeded support after 2 h of synthesis. Gas permeation results showed that a synthesis time of 3 h produced the best NaA zeolite membrane. When the synthesis time was longer than 4 h, the NaA zeolite on the support surface began to transform into other types of zeolites, and the quality of the NaA zeolite membrane decreased. The quality of the NaA zeolite membrane can be improved by employing the multi-stage synthesis method. The NaA zeolite membrane with a synthesis time of 2 h after a two-stage synthesis showed the best gas permeation performance. The permeances of H-2, O-2, N-2, and n-C4H10 decreased as the molecular kinetic diameter of the gases increased. which showed the molecular sieving effect of the NaA zeolite membrane. The permselectivities of H-2/n-C4H10 and O-2/N-2 were 19.1 and 1.8, respectively. These values are higher than the Knudsen diffusion ratios of 5.39 and 0.94. However, the permeation of n-C4H10 also indicated that the NaA zeolite membrane had certain defects with diameters larger than the pore size of NaA zeolite. A synthesis model was proposed to clarify the effect of surface seeding. (C) 2001 Elsevier Science B.V. All rights reserved.

Synthesis of NaA zeolite membrane by microwave heating

The synthesis of NaA zeolite membrane on a porous alpha -Al2O3 support by microwave heating (MH) was investigated. The formation of a NaA zeolite membrane was drastically promoted by MH. The synthesis time was reduced from 3 h for conventional heating (CH) to 15 min for MH. Surface seeding cannot only promote the formation of NaA zeolite on the support, but also inhibit the transformation of NaA zeolite into other types of zeolites. The thickness of the NaA zeolite membrane synthesized by MH was about 4 mum, thinner than that of NaA zeolite membrane synthesized by CH. The permeance of NaA zeolite membrane synthesized by MH was four times higher than that of the NaA zeolite membrane synthesized by CH, while their permselectivities were comparable. Multi-stage synthesis resulted in the transformation of NaA zeolite into other types of zeolites, and the perfection of the as-synthesized membrane decreased.

Synthesis and perfection evaluation of NaA zeolite membrane

The synthesis of NaA zeolite membrane on a porous alpha -Al2O3 support from clear solution and the evaluation of the perfection of the as-synthesized membrane by gas permeation were investigated. When an unseeded support was used, the NaA zeolite began to transform into other types of zeolites before a continuous NaA zeolite membrane formed. When the support was coated with nucleation seeds, not only the formation of NaA zeolite on the support surface was accelerated, but also the transformation of NaA zeolite into other types of zeolites was inhibited. A continuous NaA zeolite membrane can be formed. Perfection evaluation indicated that the NaA zeolite membrane with the synthesis time of 3 h showed the best perfection after a one-stage synthesis. The perfection of NaA zeolite membrane can be improved by employing the multi-stage synthesis method. The NaA zeolite membrane with a synthesis time of 2 h after a two-stage synthesis showed the best gas permeation performance, The permselectivity of H-2/n-C4H10 and O-2/N-2 were 19.1 and 1.8, respectively, higher than those of the corresponding Knudsen diffusion selectivity of 5.39 and 0.94, which showed the molecular sieving effect of NaA zeolite. However, the permeation of n-C4H10 also indicated that the NaA zeolite membrane had certain defects, the diameter of which were larger than the NaA zeolite channels. (C) 2001 Elsevier Science B.V. All rights reserved.