Characterization of catalysts
The wide angle XRD patterns obtained from the HNZ–5 specimens are shown in Fig. 1. The diffraction peaks at 7.78°, 8.80°, 23.10° and 23.74° are related to an MFI structure and are attributed to the (101), (200), (501) and (303) crystal planes, respectively. [22] As the Si/Al molar ratio was increased, the intensity of each peak was also increased, suggesting that the materials became more crystalline. However, an excess of NaAlO2 produced a greater number of aluminum oxide tetrahedral (AlO4–), reducing the probability that Si–O–Al bonds would be formed and providing HNZ–5 with a lower degree of crystallinity. [23]
Figure 1 XRD patterns of HNZ–5 specimens having different Si/Al molar ratios.
Figure 2 demonstrates that the HNZ–5 crystals synthesized in this work each had a structure comprising typical nanocrystalline aggregates. The surfaces of these HNZ–5 samples were composed of uneven crystal particles, as opposed to the coffin–like morphologies of conventional ZSM–5 crystals. The HNZ–5–15 evidently had a low degree of crystallinity and contained a high proportion of the amorphous aluminosilicate precursor. Increasing the Si/Al molar ratio to 30 or 45 provided more ordered crystal structures along with aggregated nanoparticles. The crystal size of the HNZ–5–45 was larger than those of the other two specimens, possibly because the greater number of silicon oxide tetrahedra (SiO4–) in this material promoted crystal growth to give larger particle sizes. It is evident from these data that the Si/Al molar ratio greatly affected the morphology of material by modifying the nanocrystalline stacking pattern. [24]
Figure 2 SEM images of HNZ–5 specimens having different Si/Al molar ratios. (a) HNZ–5–15, (b) HNZ–5–30, and (C) HNZ–5–45.
Figure 3a presents the adsorption–desorption isotherms obtained from the HNZ–5 samples. The rapid increase in the quantity of adsorbed N2 at low relative pressures (P/P0 < 0.1) indicates the presence of numerous micropores. In the medium relative pressure region (0.3 < P/P0 < 0.8), N2 was condensed and accumulated in the mesopores, resulting in the formation of a hysteresis loop. [25] Moreover, the HNZ–5–45 isotherm exhibits an H3 type hysteresis loop, suggesting the presence of mesopores formed by particle stacking. In the corresponding SEM image (Fig. 2c), crystal particles with lengths on the order of 50 nm can be seen on the surface of the HNZ–5–45. From this image, it is apparent that a mesoporous structure was formed between nanocrystalline aggregates in this material. Figure 3b demonstrates that the HNZ–5–45 contained both mesopores (2–80 nm in size) and micropores (0–2 nm in size). In contrast, the HNZ–5–15 did not generate a significant hysteresis loop in the medium relative pressure region, indicating a low number of mesopores in this sample. The corresponding SEM image (Fig. 2a) confirms that this material had a low degree of crystallinity with many amorphous structures, resulting in fewer intergranular mesopores. The pore size distribution of the HNZ–5–15 shows a wide range of pore sizes and is uneven.
Table 1 summarizes the BET surface areas of the catalysts and confirms that increasing the Si/Al ratio increased the area. The BET surface area of the HNZ–5–15 was much lower than those of the HNZ–5–30 and HNZ–5–45 because the former material underwent limited nanocrystal aggregation.
Figure 3 Adsorption–desorption curves and pore size distributions of HNZ–5 specimens having different Si/Al molar ratios.
Table 1
BET surface areas, pore volumes, average pore diameters and acidity of HNZ–5.
Samples | SBET (m2/g) | Smicro (m2/g) | Sexternal (m2/g) | Vtotal (cm3/g) | Vmicro (cm3/g) | Average pore diameter (nm) | Acid amount (mmol NH3/g) |
Weak acid | Strong acid | Total |
HNZ–5–15 | 90 | 72 | 18 | 0.12 | 0.04 | 5.18 | 0.45 | 0.02 | 0.47 |
HNZ–5–30 | 321 | 226 | 95 | 0.20 | 0.12 | 2.50 | 0.31 | 0.05 | 0.36 |
HNZ–5–45 | 329 | 241 | 88 | 0.11 | 0.09 | 2.04 | 0.23 | 0.04 | 0.27 |
Figure 4 provides the NH3–TPD curves of the HNZ–5 specimens. These materials generated NH3 desorption peaks within the ranges of 100–290 and 290–400°C, corresponding to weak and strong acid sites, respectively. [26] In general, weak acid sites can be attributed to non–framework aluminum atoms or Si–OH groups associated with structural imperfections in these materials. In contrast, strong acid sites are primarily associated with Si–O–Al groups in molecular sieves. [27] The number of weak acid sites increased with decreases in the Si/Al molar ratio (Table 1). This was a consequence of increases in the concentration of Al3+ ions in the initial gel, which in turn increased the proportion of non–framework aluminum atoms in the product. The HNZ–5–30 was found to have the highest number of strong acid sites, indicating that the use of a suitable Si/Al molar ratio promoted the formation of Si–O–Al bonds. As such, more Al3+ ions were embedded in the catalyst skeleton to act as strong acid sites. Conversely, the HNZ–5–15 had the lowest proportion of strong acid sites because of the poor crystallinity of the sample. As a result, the majority of the Al3+ ions originally present in the gel were not embedded in the HNZ–5–15 skeleton but rather became non–framework aluminum, generating more weak acid sites and fewer strong acid sites.
Figure 4 NH3–TPD profles of HNZ–5 specimens having different Si/Al molar ratios.
Figure 5 shows the 27Al magic angle spinning NMR spectra acquired from the various HNZ–5 samples. Each spectra contains a peak at approximately 54 ppm representing framework tetrahedral aluminum (FAl) along with a much weaker, broader peak at approximately 0 ppm typical of extra–framework octahedral aluminum (EFAl). [28, 29] These data confirm that Al3+ ions in these materials were present at tetrahedral sites in the same manner as Si. It should be noted that the four Al–O groups in each tetrahedra provided a net negative charge to the framework that could be compensated for by the presence of protons. These protons were situated in hydroxyl bridges next to aluminum ions, providing strong acid sites. [30] The HNZ–5–30 produced the most intense peak at 55 ppm, establishing that this specimen contained the greatest number of four–coordinated skeleton aluminum ions. The corresponding NH3–TPD results (Table 1) confirmed that the HNZ–5–30 had the largest quantity of strong acid sites.
Figure 5 27Al MAS NMR spectra of HNZ–5 specimens having different Si/Al molar ratios.
Catalytic cracking of the WCOMC
The effects of the Vmeso/Vmicro ratio on the selectivity for light olefins and the conversion of the WCOMC are summarized in Fig. 6. The total selectivity for light olefins was found to initially increase and then decrease as this ratio was increased, with the highest selectivity (71.3%) at a Vmeso/Vmicro ratio of 0.76 in the case of the HNZ–5–30. Using this material, the selectivity for butene reached the highest value of 16.8%. The HNZ–5–30 had a BET specific surface area of 321 m2/g with mesopores accounting for 29.6% of this area. The weak and strong acid sites in ZSM–5 molecular sieves are typically found in micropores while the main function of mesopores is to reduce the resistance to the diffusion of reactants. The latter effect limits the occurrence of secondary reactions of the desired products. [31, 32] An excess of mesopores will reduce the residence time of reactants at the acid sites and hence lead to an incomplete reaction such that the selectivity for light olefins is lowered. Therefore, the most suitable catalyst will have an optimal Vmeso/Vmicro ratio.
Figure 6 also summarizes the effect of the WA/SA ratio on the conversion of the WCOMC and shows that, as the WA/SA value was increased, the conversion increased. The present WCOMC was primarily composed of triglycerides and free fatty acids, and triglycerides were cracked at high temperatures to form fatty acids, acrolein and ketones. Subsequently, these compounds underwent decarbonylation and dehydration at acid sites on the catalyst to generate additional products such as C2H4 and long–chain alkanes. The latter then underwent C–C bond cleavage and isomerization to produce short–chain alkanes and olefins. [33, 34] Some of the ester groups contained in the triglycerides also participated in deoxygenation reactions at strong acid sites that produced small molecule substances such as CO2, CO, H2O and coke precursors. [35] Therefore, neither high nor low WA/SA values were conducive to the formation of light olefins through WCOMC cracking.
Figure 6 Influence of pore structure on the selectivity of light olefins and WA/SA on the conversion of WCOMC. Temperature = 600°C, WCOMC flow rate = 0.04 mL/min, reaction time = 500min.
Figure 7 demonstrates the effects of temperature on reactions using the HNZ–5–30 and shows that the highest yields of gaseous products and of light olefins (57.6% and 37.1%, respectively) were obtained at 550°C. The product distribution varied with temperature while the ethene and butene yields increased and decreased, respectively, along with temperature. At 650°C, the ethene yield reached 11.9% and the butene yield was only 2.7%. These data indicate that the cleavage of long carbon chains was promoted at elevated temperatures. [36] Fig. 7b also shows that higher temperatures increased the selectivity for ethene but decreased that for butene. It is possible that ethene originated from monomolecular cracking reactions while propylene was generated by bimolecular cracking reactions and that higher temperatures enhanced the former while suppressing the latter. [37]
Figure 7 Influence of the reaction temperature: (a) gas product yield (b) light olefins selectivity.
Catalyst: HNZ–5–30, WCOMC flow rate = 0.04 mL/min, Reaction time = 500 min.
Figure 8a and b show the effects of the WCOMC flow rate on the yields of and selectivities for gas phase products using the HNZ–5–30. It can be seen that the highest yield of light olefins (43.9%) was obtained at a flow rate of 0.02 mL/min. Increasing the WCOMC flow rate decreased the yields of gaseous products and of light olefins, from 43.9–31.1% in the case of the latter. Figure 8b demonstrates that the flow rate affected the ethene and butene outputs although in opposite ways. The selectivities for ethene and propylene decreased by 1.4% and 2.2%, respectively, while the selectivity for butene increased by 1.3%. These changes are attributed to decomposition of the WCOMC at high temperatures to produce pyrolysis vapors, non condensable gases (mainly CO, CO2, H2 and CH4) and carbon deposits. The pyrolysis vapors eventually contacted the catalyst surfaces and diffused into the HNZ–5 pores. In this manner, these compounds interacted with acidic sites and underwent a series of reactions such as dehydration, decarbonylation and oligomerization to generate light olefins. A high flow rate reduced the fracture rate of long–chain alkanes at catalytic sites, leading to a decrease in selectivity for ethene and propylene but an increase in selectivity for butene.[38]
Figure 8 Influence of the feed flow rate: (a) gas product yield, (b) light olefins selectivity.
Catalyst: HNZ–5–30, temperature = 550°C, reaction time = 500 min.
Figure 9 plots the product outputs over time from a reaction using the HNZ–5–30 at 550°C that proceeded for 6000 min. The yields of ethene, propylene and butylene were initially high and then remained stable as the reaction time was extended. These data also reveal a slight decrease in the cracking performance after 3500 min. This effect occurred because some active sites on the catalyst were covered by coke precursors as the reaction progressed. This would have prevented access of reactants to acidic sites in the micropore channels to some extent and thus degraded the catalytic performance.[17]
Figure 9 Influence of the reaction time. Temperature = 550°C, WCOMC flow rate = 0.04 mL/min, reaction time = 6000 min.
Figure 10 showed the thermogravimetric data acquired from fresh catalyst and spent fresh catalyst and spent catalyst. These data indicate that both specimens exhibited mass loss due to the reaction between carbon deposits and oxygen. The used HNZ–5–30 showed a mass loss of 16.67% in the range of 450–600°C, suggesting a high H/C ratio related to so–called “soft coke” in the catalyst pore system. [39] This coke corresponded to adsorbed hydrocarbon molecules inside the catalyst pores that had been generated by coke precursors. However, the spent HNZ–5–30–6000 (having been applied to the reaction for 6000 min) showed a mass loss of 28.17% within the range of 500–650°C. This result indicates the formation of “hard coke” associated with the polymerization of soft coke to produce more bulky carbonaceous compounds having low H/C ratios. [40]
Figure 10 TG curves of the spent catalysts.