Due to cost and energy consumption constraints, converting
benzene
into ethylbenzene using low-cost syngas instead of ethylene as an
alkylation reagent is significant. However, when using syngas as the
reaction raw material, generating ethylated side chains on the benzene
ring is challenging. Instead, toluene/xylene becomes the primary product.
We used a three-bed series connection method in a reactor, achieving
one-step high selectivity of syngas and benzene to produce ethylbenzene.
In the first bed layer (ZnAl2O4/SAPO-34), the
syngas was first converted into methanol/dimethyl ether (DME) on ZnAl2O4. Then, it was further converted into low-carbon
olefins on SAPO-34, with the microporous shape-selective effect of
SAPO-34, inhibiting the generation of toluene/xylene in the alkylation
of benzene with methanol/DME. At the same time, we proved that the
absence of microporous shape-selective effect acid sites on the outer
surface of S34 can lead to the occurrence of side reactions of benzene
and methanol/DME methylation. In the second bed layer, SAPO-34 could
continue to convert unconverted methanol/DME in the first bed layer
into low-carbon olefins. In the third layer (ZSM-5), ethylene and
benzene underwent highly selective alkylation on ZSM-5 to convert
it into ethylbenzene. We found a “volcanic” curve relationship
between the selectivity of ethylbenzene and the Brønsted acid
site density of ZSM-5. On the one hand, Brønsted acid could catalyze
the formation of ethylbenzene from benzene and ethylene; On the other
hand, excessive Brønsted acid could lead to the isomerization
of ethylbenzene to toluene/xylene. When the Brønsted acid showed
a site density of 0.7 mmol/g, the selectivity of ethylbenzene was
as high as 87%, with a byproduct of xylene showing only 0.3%, which
is usually difficult to separate from ethylbenzene. Finally, the three-bed
catalytic system showed no deactivation after 100 h.