Vapor Phase Alkylation of Isomeric Cresols with Tert-Butyl Alcohol over Perlite Supported Sulfated Zirconia Catalyst

In the present study, perlite was thermally activated and then modified desirably to generate super acidity by loading different weight percentages of sulfated zirconia (SZ) via the two-step sol-gel method. As-prepared sulfated zirconia perlite (SZP) catalysts showed suitable catalytic potential in the vapor phase alkylation of o, m, and p-cresols with tert-butyl alcohol. The presence of crystalline phases in SZP catalysts was confirmed by XRD and FT-IR studies. TEM images revealed the nano size of the catalysts in the range of 9–25 nm. The presence of SZ on the surface of perlite was further confirmed by N2 adsorption–desorption, SEM, SEM-EDX, TGA, and UV-Vis DRS techniques. The pyridine FT-IR results confirmed the existence of Brønsted, Lewis acidic sites and their combination as super acidic catalytic active centers on the surface of catalyst utilized in the vapor phase alkylation of o, m, and p-cresols with tert-butyl alcohol. The regeneration and reusability of the preferred catalyst until the 5th reaction cycle without any considerable loss in catalytic activity demonstrated the stability of the catalyst. Comparative studies show that SZP can be regenerated and is superior compared to other catalysts previously used for other alkylation reactions with the potential for use on a large scale.