Methanol-to-gasoline conversion over ZSM-5 catalysts, a non-petroleum carbon fuel process, is significantly impacted by coke deposition, which deactivates the catalyst by blocking zeolite pores during the reaction and diffusion process. This study investigated the differences in coke species development and deactivation using a non-linear kinetic model, comparing microcrystalline ZSM-5 with longer pore lengths to nanocrystalline ZSM-5 with shorter pores, both tested at 350°C. Catalyst and coke were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), temperature-programmed oxidation (TPO), thermogravimetric analysis (TGA), and an elemental analyzer. Micro ZSM-5 initially achieved 99 % conversion but rapidly dropped to 61 % due to coke buildup, while nano ZSM-5 maintained over 98 % conversion for 24 hours before declining, highlighting the superior catalytic durability of shorter pores. Micro ZSM-5 showed faster coking, accumulating 7.19 % coke with higher temperature-resistant graphitic coke, whereas nano ZSM-5 exhibited a lower coke buildup of 4.56 %, forming primarily amorphous coke. A two-step non-linear kinetic model for soft and hard coke oxidation was applied, with the second-order model providing the highest correlation coefficient. The activation energy for coke decomposition was influenced by pore length, revealing distinct kinetic behaviors for hydrogen-deficient graphitic coke and amorphous coke. This study underscores the importance of zeolite pore structure on coke formation, deposition patterns, and catalytic durability, offering deeper insights into the methanol-to-gasoline conversion process.
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