Single vs. dual-binder surface design of spray-dried Si–Al-sol-bound kaolin-matrixed SAPO-34 nanocatalyst for conversion of methanol to light-olefins in fluidized bed reactor

Abstract

This study investigates shaping and characterization of fluidizable methanol to olefins catalysts using single-binder or dual-binder. Physicochemical and mechanical properties were investigated with different methods likewise FESEM, XRD, TGA, FTIR, TPD-NH3 and BET-BJH. Furthermore, MTO process tests were accomplished to investigate the catalytic activity in the fluidized bed and fixed bed reactor and revealed that the sample shaped using dual-binder has larger surface area than the shaped one using single-binder (alumina sol or silica sol). Catalysts with silica sol and alumina-silica sol binder show relatively lower attrition resistance than the catalysts with alumina sol binder. Furthermore, implementation of alumina-silica sol provides increased acidity of the MTO catalyst which led to the increased selectivity and life time in fluidized bed reactor compared to alumina sol and silica sol binder. In addition, the MTO catalyst shaped with alumina-silica sol exhibited slightly lower coke deposition compared to the one made with single binder.