Vida y comportamiento catalíticos en la conversión de metanol a hidrocarburos en condiciones cercanas a las supercríticas

Resumo

The methanol to hydrocarbons reaction was discovered at the end of the seventies by the Mobil company researchers. This reaction has to be catalysed by zeolitic catalysts, mainly by the ZSM-5 catalyst. The reaction allow converting methanol to hydrocarbons through two consecutive dehydration steps, the first one produces dimethyl ether from the methanol and the second one produces hydrocarbons, initially light olefins, form the dimethyl ether. The reaction is a refinery process, which produces a wide range of hydrocarbons from the methane to the durene. Depending on the reaction parameters (temperature, space velocity, methanol partial pressure, catalyst acidity ...) the reaction can be modified to obtain different processes as the MTG (methanol to gasoline) or the MTO (methanol to olefins). The principal problem of the methanol to hydrocarbons reaction is the zeolitic catalysts deactivation due to the coke formation inside the catalyst pores. This process can lead to the pores total blockage and to deactivate the catalyst active centres until total loss of activity. The supercritical fluids exhibit physical properties intermediate between the liquid and the gas phases, which made them an attractive medium to perform some chemical reactions. Among these properties there are increase of the solubility related to the gas phase and the increase of the mass transfer properties related to the liquid phase that permit solubilize the coke deposited on the catalyst active surface. This phenomena is particularly important in reactions, where the hydrocarbons are present as the cyclohexene isomerisation, the butene alkylation or the Fischer-Tropsch reaction. The application of the supercritical conditions or near-supercritical conditions to the methanol to hydrocarbons reaction is the main objective of this study. On this purpose, an experimental apparatus was set-up and can work at elevated temperatures (up to 400 oC) and high pressures (up to 140 bar). A gas chromatography methodology has also been established in order to analyse the reaction products. This work proceeded by the following stages: the first one was the study of the pressure influence over different thermodynamic equilibria. This influence is demonstrated to be too low to significantly alter the theoretic conversion. The next stage was to try to find a solvent to reduce the methanol critical point conditions. Nevertheless all the solvents chosen were not inert in the reaction conditions. Consequently, the feed was pure methanol. As the first step of the reaction is the methanol conversion to dimethyl ether and water, the critical point parameters of the reaction mixture (temperature, pressure and composition) has to be calculated by the Peng- Robinson equation of state in order to obtain the supercritical phase boundary conditions. After evaluating the appropriate experimental conditions a set of experiments has been perform to determine the pressure and temperature influence over the methanol and dimethyl ether conversion, when a ZSM-5 catalyst is used. As a conclusion, the pressure effect over the dimethyl ether conversion to hydrocarbons exhibits a decrease of the activation energy and the effectiveness factor as the pressure increases. The effectiveness factor increases with higher temperatures. It means that mass transport inside the catalyst pores is partially disabled, when pressure and temperature values are between 55 and 135 bar and 320 and 380oC, respectively. To determine the near critical conditions influence in the catalyst life time some experiments have been carried out with the ZSM-5 zeolite over long reaction times at atmospheric pressure and near critical pressure. The results demonstrate a catalyst lifetime prolongation of 400%, when the feed was in near critical condition related to the catalyst lifetime at atmospheric pressure. Finally, the catalysts used in the life time experiments have been analysed. The elemental analysis shows an increase in the total amount of coke deposited over the catalyst in the atmospheric conditions lifetime sample in comparison to the near-critical lifetime sample. The loss of acidity is bigger in the atmospheric conditions lifetime sample than in the near critical one due to the deposition of coke on the active centres. And the physisorption analysis shows lower decrease in the surface area of the near critical conditions lifetime than in atmospheric conditions one.