Mechanistic differences between methanol and dimethyl ether in zeolite-catalyzed hydrocarbon synthesis.

Water influences critically the kinetics of the autocatalytic conversion of methanol to hydrocarbons in acid zeolites. At very low conversions but otherwise typical reaction conditions, the initiation of the reaction is delayed in presence of H2O. In absence of hydrocarbons, the main reactions are the methanol and dimethyl ether (DME) interconversion and the formation of a C1 reactive mixture-which in turn initiates the formation of first hydrocarbons in the zeolite pores. We conclude that the dominant reactions for the formation of a reactive C1 pool at this stage involve hydrogen transfer from both MeOH and DME to surface methoxy groups, leading to methane and formaldehyde in a 1:1 stoichiometry. While formaldehyde reacts further to other C1 intermediates and initiates the formation of first C-C bonds, CH4 is not reacting. The hydride transfer to methoxy groups is the rate-determining step in the initiation of the conversion of methanol and DME to hydrocarbons. Thus, CH4 formation rates at very low conversions, i.e., in the initiation stage before autocatalysis starts, are used to gauge the formation rates of first hydrocarbons. Kinetics, in good agreement with theoretical calculations, show surprisingly that hydrogen transfer from DME to methoxy species is 10 times faster than hydrogen transfer from methanol. This difference in reactivity causes the observed faster formation of hydrocarbons in dry feeds, when the concentration of methanol is lower than in presence of water. Importantly, the kinetic analysis of CH4 formation rates provides a unique quantitative parameter to characterize the activity of catalysts in the methanol-to-hydrocarbon process.

Hydrogen Transfer Pathways during Zeolite Catalyzed Methanol Conversion to Hydrocarbons.

Hydrogen transfer is the major route in catalytic conversion of methanol to olefins (MTO) for the formation of nonolefinic byproducts, including alkanes and aromatics. Two separate, noninterlinked hydrogen transfer pathways have been identified. In the absence of methanol, hydrogen transfer occurs between olefins and naphthenes via protonation of the olefin and the transfer of the hydride to the carbenium ion. A hitherto unidentified hydride transfer pathway involving Lewis and Brønsted acid sites dominates as long as methanol is present in the reacting mixture, leading to aromatics and alkanes. Experiments with purely Lewis acidic ZSM-5 showed that methanol and propene react on Lewis acid sites to HCHO and propane. In turn, HCHO reacts with olefins stepwise to aromatic molecules on Brønsted acid sites. The aromatic molecules formed at Brønsted acid sites have a high tendency to convert to irreversibly adsorbed carbonaceous deposits and are responsible for the critical deactivation in the methanol to olefin process.

Critical role of formaldehyde during methanol conversion to hydrocarbons.

Formaldehyde is an important intermediate product in the catalytic conversion of methanol to olefins (MTO). Here we show that formaldehyde is present during MTO with an average concentration of ~0.2 C% across the ZSM-5 catalyst bed up to a MeOH conversion of 70%. It condenses with acetic acid or methyl acetate, the carbonylation product of MeOH and DME, into unsaturated carboxylate or carboxylic acid, which decarboxylates into the first olefin. By tracing its reaction pathways of 13C-labeled formaldehyde, it is shown that formaldehyde reacts with alkenes via Prins reaction into dienes and finally to aromatics. Because its rate is one order of magnitude higher than that of hydrogen transfer between alkenes on ZSM-5, the Prins reaction is concluded to be the major reaction route from formaldehyde to produce dienes and aromatics. In consequence, formaldehyde increases the yield of ethene by enhancing the contribution of aromatic cycle.