Zeolite-assisted core-shell redox catalysts for efficient light olefin production via cyclohexane redox oxidative cracking

Abstract

This study reports a highly effective redox catalyst platform, i.e. composites of metal-exchanged ZSM5 and CaMn0.75Fe0.25O3@Na2WO4, for “low temperature” (<650 °C) redox oxidative cracking (ROC) of naphtha using a cyclohexane model compound. TEM-EDX showed that Na2WO4 shell covers the CaMn0.75Fe0.25O3 bulk and the zeolite + CaMn0.75Fe0.25O3@Na2WO4 composite can achieve autothermal conversion of cyclohexane under a cyclic redox scheme by selective oxidation of by-product H2 to H2O. Meanwhile, NH3-TPD and pyridine FTIR experiments confirmed that the Brönsted acidity of ZSM5 was primarily responsible for cyclohexane activation. Compared to each catalyst component alone, the synergistic effect of the composite redox catalysts resulted in substantially higher olefin yield (up to 75%), lower alkane yield (~5%), lower aromatic yield (~10%), and higher lattice oxygen utilization (up to 4 wt.cat%). Based on TGA-DSC experiments and ASPEN Plus analysis, the multi-functional redox catalysts facilitate autothermal conversion of cyclohexane with high lattice oxygen utilization from the redox catalysts. Due to the highly effective redox catalysts performance and the ease for heat integration, the novel ROC process has the potential for more energy-efficient light olefins production with significantly reduced CO2 emissions when compared to naphtha steam cracking.