The coupling of propane and methanol: enhancing hydrocarbon conversion and stability through integrated catalytic processes

Abstract

The integration of endothermic alkane activation and exothermic methanol conversion presents a promising strategy for enhancing energy efficiency and economic viability in hydrocarbon processing. Herein, we systematically investigate the propane-methanol co-reaction using a ZSM-5 catalyst, focusing on the effects of reaction conditions and the synergistic interactions between propane and methanol. The results reveal that at an optimized temperature of 475 °C and a 1:1 M ratio of propane to methanol, the introduction of methanol substantially enhances propane activation. Notably, the conversion mechanism shifts from monomolecular cleavage to bimolecular hydrogen transfer, effectively reducing the selectivity of by-products methane and ethylene from 66.8 % to 24.4 %, and increasing the selectivity of aromatics from 1.5 % to 25.9 %. Additionally, the co-feeding of propane and methanol extends the catalyst lifetime by promoting alkene-based cycles during methanol conversion. Comprehensive characterization of the spent catalysts indicates that the enhanced catalytic stability is attributed to the suppression of high carbonization and ordered coke species. These findings provide valuable insights into the catalytic mechanisms involved and highlight the potential for optimizing sustainable chemical production pathways.