Pairing Ga/Al-Zeolites with tailored acidity as tandem catalysts for the conversion of alcohols to olefins

This study examines Ga-zeolites as heterogeneous catalysts for alcohol dehydration and as critical components of tandem catalysts in dual bed configurations where Al-zeolites placed downstream selectively convert intermediates to light olefins. [Display omitted] •Synthesis of pure gallosilicate zeolites with CHA, MWW, and MFI topologies.•Identification of Ga-zeolites as exceptional alcohol dehydration catalysts.•Tandem Ga/Al-zeolite catalysts enhance alcohol conversion to light olefins. Zeolites are versatile catalysts owing to their tunable acidity where the active site(s) can be placed within the crystal framework or as extra-framework species in confined pores. A common approach to tailor Brønsted acidity is heteroatom exchange involving the replacement of framework aluminum with alternative elements. Introduction of heteroatoms often results in less acidic catalysts that can be used in tandem reactions for targeted reactive intermediates. In this study, we prepare a series of three different zeolites with MWW, CHA, and MFI frameworks as aluminosilicates and gallosilicates to demonstrate their performance in alcohol dehydration reactions. The two reactions examined in this study are methanol conversion to dimethyl ether and ethanol conversion to ethylene. Our findings reveal that Ga-zeolites exhibit superior performance with Ga-MCM-22 (MWW) achieving nearly 100 % alcohol conversion and selectivity to desired products at contact times that are significantly less than most dehydration catalysts reported in literature. The unique properties of Ga-zeolites are attributed to their reduced acid site strength via a direct (one-pot) synthesis that avoids conventional time-intensive, multi-step post-synthesis modifications of Al-zeolites. Here we demonstrate the use of Ga-zeolites as tandem catalysts when paired with a downstream Al-zeolite in a dual-bed reactor configuration to convert cheaper reagents (alcohols) upstream to more desired intermediates as feeds for downstream catalysts to produce light olefins. We demonstrate that dual beds using Ga-zeolite – Al-ZSM-5 (upstream–downstream) pairings outperform single bed configurations with Al-ZSM-5 or a physical mixture (Ga-/Al-zeolite) for methanol to hydrocarbons reactions, with notable improvements in catalyst lifetime and increased light olefins selectivity. Similarly, dual beds using Ga-zeolite – Al-SSZ-13 (upstream–downstream) pairings result in improved performance for ethanol to propylene reactions with