Hugo
Cruchade
,
Y.
Pouilloux
,
R.
Beauchet
and
Ludovic
Pinard
*
Institut de Chimie des Milieux et Matériaux de Poitiers (IC2MP), UMR 7285 CNRS, 4 rue Michel Brunet, Bâtiment B27, TSA 51106, 86073 Poitiers Cedex 9, France. E-mail: ludovic.pinard@univ-poitiers.fr
First published on 18th January 2022
The oxidative cracking of n-decane, n-dodecane, n-tetradecane and n-hexadecane was assessed at millisecond contact times on a platinum catalyst at a C/O molar ratio of 1.8. The thermal mapping of the reactor showed the similar thermal behaviour of the millisecond reactor at the steady-state for all reactants, corresponding to the autothermal operation of the combustion catalyst in the range of 440–550 °C. The heat provided led to a thermal gradient in the post-catalytic gas-phase and sustained the endothermic formation of valuable linear α-olefins (LAOs). The LAO yields increased with the carbon chain length of the reactant from 11.4 wt% starting from n-decane to 20.2 wt% starting from n-hexadecane. Furthermore, the LAO carbon chain length tends to be higher when feeding the MSR with larger n-alkanes. Two mathematical models are able to predict the distributions of organic products: (i) the Anderson-Schultz-Flory law for cracking products, i.e. LAO and n-aldehydes and (ii) a model based on the hydrogen atom abstraction probability for oxygenated compounds, the formation of which does not involve carbon–carbon bond cleavage, i.e. tetrahydrofurans, oxiranes and ketones.
The oxidative cracking (OC) of hydrocarbons in a millisecond reactor (MSR) appears as a promising alternative to synthesise these raw materials in one step at atmospheric pressure.9–13 Hydrocarbons react at millisecond contact times with a heterogeneous combustion catalyst (e.g. Pt/Al2O3) to produce LAOs through an autothermal way.11,14 In this homogeneous process assisted by heterogeneous catalysis, complete and partial catalysed combustion of a part of the reactant provides the required heat for the gas-phase formation of olefins by oxidative and thermal cracking.10,11,13,15–19 The MSR is then a 2-zone reaction system involving consideration of both the thermal equilibrium and chemical transformation.
The studies of Schmidt et al. of various reactants highlight the dependence of the chemical nature of the organic products on the reactant structure. Alkanes produce mostly olefins,9,11,12,19–21 while cyclic reactants produce aromatics22–24 and oxygenated reactants result in oxygenated compounds.25–27 In some studies of diesel n-paraffin OC in a MSR,10,11 Schmidt et al. showed the relevance of this technology to produce LAOs. They highlight an increase in the length and the yield of LAOs with n-alkane length. Nevertheless, the impact of the reactant carbon chain length on olefin formation and MSR behaviour still requires clarification. It is well established that the reactivity of n-alkanes increases with their carbon chain length when the conversion occurs through gas-phase oxidation,28 catalytic combustion,29 acidic-catalysed reaction30,31 or thermal cracking.32–34 In the case of thermal cracking, heavier hydrocarbons lead to higher yields of ethylene. The complex reaction system involved in a MSR with various chemical transformations requires a thorough study of the different reactivities of the diesel n-alkanes.
The MSR is a chemical process combining several reactions leading to products with a wide range of chemical natures.18 Peroxyalkyl radicals were identified as key intermediates for the formation of organic products from the n-decane OC.18 Their formation involves a random secondary hydrogen atom abstraction from the n-alkane followed by molecular oxygen addition. The peroxyalkyl radical then undergoes an internal secondary hydrogen atom transfer (HT) to form a hydroperoxyalkyl radical. The nature of the final organic product depends on the hydrogen atom position abstracted during the internal transfer step. A HT on the third carbon atom from the peroxyradical position leads to the formation of an olefin and an n-aldehyde after a β-scission of a C–C bond and a HO˙ elimination; the olefin production occurs mainly from this path and in smaller amounts from the thermal cracking of the n-alkane. A HT occurring on the same position, or on the second or fourth carbon atom from the peroxyradical position, leads respectively to the formation of a ketone, an oxirane or a tetrahydrofuran (THF) after the HO˙ elimination. These three oxygenated compounds are obtained with the same carbon atom number as the reactant. A mathematical model was established18 to predict the distributions of THF, oxiranes and ketones resulting from the n-decane OC. It is based on the hydrogen atom abstraction probability (HAAP); the distribution is calculated as the sum of the probabilities to abstract the correct secondary hydrogen atom at the two mechanism steps (abstraction from n-alkane and internal transfer), leading to the formation of the considered compound. Each secondary hydrogen atom is considered to have similar reactivity.
This study aims to assess the impact of the carbon chain length of the reactant on the performance of the MSR dedicated to LAO production and the transposition of the model of the organic compound distributions to higher n-alkanes. The thermal mapping of the reactor and the online quantification (through gas-phase chromatography) of products obtained during the oxidative cracking of model molecules, n-decane (n-C10), n-dodecane (n-C12), n-tetradecane (n-C14) and n-hexadecane (n-C16), will allow the characterisation and deep understanding of the thermal and chemical phenomena involved in the MSR. Oxidative cracking will be carried out on new platinum-based catalysts at a C/O molar ratio of 1.8, with a similar heat flow at the reactor inlet for all the studied reactants.
The flow at the outlet of the reactor was analysed through online GPC after 10, 70 and 135 min to quantify the products.
The molar flow of a compound i (Fi in mol min−1) was determined from the calibrations with inert nitrogen as the internal standard:
![]() | (1) |
The conversion of n-alkane (Xn–alkane) was determined as follows:
![]() | (2) |
Dioxygen conversion (XO2) was calculated from the inlet molar flow (FO2,0) provided by the mass flow controller:
![]() | (3) |
The yield of the hydrocarbon product j (Yj) was reported on a carbon atom basis as follows:
![]() | (4) |
The oxygen atom balance was closed to calculate the water molar flow rate. Carbon and hydrogen atom balances were typically closed within ± 8%, close to L.D. Schmidt et al.10,12
The catalyst temperature increases immediately after feeding the reactor with the air–hydrocarbon mixture, which corresponds to a TOS of 1 min. After some minutes, the MSR reaches an autothermal steady-state. The catalyst temperature equilibrates then at 490 to 550 °C for the n-decane and 440 °C for the other n-alkanes. A thermal gradient establishes within the post-catalytic gas-phase during the operation, from the catalyst back face to 235 mm below. The hydrocarbon flow stop results in an exotherm on the catalyst surface and 20 mm below inside the gas phase, followed by the fast cooling of the reactor. The thermal behaviours of the MSR for the four n-alkanes (Fig. 1) are similar to the previous one observed during n-decane oxidative cracking.18
The yields of carbonaceous products and dioxygen conversion are depicted in Fig. 2 for n-decane, n-dodecane, n-tetradecane and n-hexadecane at TOS of 10, 70 and 135 min. Hydrocarbon conversions, i.e. the sum of yields is close to 50% and the oxygen conversion is higher than 75% for each of the reactants.
The OC of these n-paraffins produces compounds with similar chemical natures: partial and total oxidation compounds, i.e. CO and CO2, small amounts of methane (yields ≤ 1.5%) and organic products. Organic products are oxygenated compounds with n-aldehydes, THF, oxiranes, ketones and olefins. Olefins are mainly light olefins, i.e. ethylene and propylene, and α-olefins. Small amounts of positional isomers of the alkene function having the same number of carbon atoms as the reactive n-alkane (yields ≈ 3 wt%) are produced. The typical chromatograms of heavy organic products obtained during the four n-alkanes OC are depicted in the ESI† in Fig. S1. The increase of the carbon chain length of the reactant induces a broadening of the number of compounds in these organic product families. Heavier α-olefins and n-aldehydes are produced, and their formation involves C–C bond cracking.18 The number of position isomers increases for THF, oxiranes, ketones and olefins with the same carbon atom number as the parent n-alkane. They result from peroxy radical decomposition.
Their size range extends from ethylene to olefins having the same number of carbon atoms as the evaluated n-alkane.
The yields show the same asymmetrical appearance, with a more significant amount of light olefins (ethylene and propylene) than that of LAOs. In the case of LAOs, the yield profiles flatten out with the increase in the size of the carbon chain of the reactant, and then the production of LAOs tends towards equimass formation.
The Anderson-Schultz-Flory (ASF) law5,6 allows modelling the evolution of the molar distributions of LAOs resulting from cracking according to the following equation:
![]() | (5) |
The ASF law is usually used to describe the distribution of LAOs synthesised from chain growing processes such as ethylene oligomerisation5,6 or Fisher–Tropsh.36 It reports competition between twin reactions: propagation of the chain growth and termination of the polymerisation process. The term α in eqn (5) corresponds to the probability of chain growth, defined as the ratio of the rate of the propagation reaction (kp) and the sum of the rates of the propagation and termination reactions (kt):
![]() | (6) |
In the MSR process, the LAO results from chain cleavage; by analogy with these chain-growth processes, the term α can transcribe a possible over-cracking. A low value of α corresponds to the most light olefin formation, i.e. significant over-cracking by homolytic cleavage or β-scission of C–C bonds. A value close to 1 corresponds to a balanced distribution, i.e. stabilization of terminal alkyl radicals by β-scission of a C–H bond and preservation of olefins formed from possible over-cracking reactions, such as new initiations by the homolytic cleavage of C–C bonds.
The ASF plots of LAO resulting from OC of n-C10, n-C12, n-C14 and n-C16 are depicted in Fig. 3. The size distributions of LAO consecutive from breaking a bond between two secondary carbon atoms follow the ASF law (Fig. 3). The olefin with one carbon atom less than the reactive n-alkane involves a different first stage of formation, corresponding to the cleavage of a bond between the primary and secondary carbon atoms. Therefore, the ASF law cannot be used to model their molar distributions. Ethylene and propylene formation do not involve the competition step between over-cracking and stabilization. Likewise, light olefin molar distributions are not described by the ASF law.
Two models were considered to fit the molar distributions of n-aldehydes: (1) the HAAP model18 and (2) the ASF law. The plots are depicted respectively in the left panel and the right panel of Fig. 4. As observed in a previous study about n-C10 oxidative cracking,18 the HAAP model does not fit the n-aldehyde distributions. The ASF law previously used to model olefin distributions suitably fits n-aldehyde distributions.
![]() | ||
Fig. 6 Conversions of n-alkane and molecular oxygen and equilibrium catalyst temperature at a time on stream of 135 min as a function of the carbon number of the reactive n-alkane. |
The homogeneous area is larger than the heterogeneous one (several tens of millimeters and 10 mm respectively for the gas phase and the catalyst). Furthermore, the length of the homogeneous reaction area is not constant and decreases with TOS, as depicted in Fig. 1 by the post-catalytic gas-phase temperature bottom-up cooling down (235 mm). This characterization of the MSR thermal behaviour is consistent with L. D. Schmidt's observations.13,17 At a TOS of 135 min, the MSR reaches its steady-state, and the conversions of n-alkanes increase with their carbon chain length, while dioxygen conversion remains constant (Fig. 6). Therefore, the yields of partial and total combustion products (Fig. 7A) and oxygenated products (Fig. 7B) are similar. The increase of the carbon chain length of the reactant allows extending the production of LAO without the effect on light olefins and olefins having the same number of carbon atoms as the parent n-paraffin (Fig. 7C).
![]() | ||
Fig. 7 Yields of combustion products (A), oxygenated compounds (B) and olefins (C) at a time on stream of 135 min as a function of the carbon number of the reactive n-alkane. |
The n-alkane transformation through OC in a MSR involves different paths of transformation18 among the catalytic partial and total combustion, the homogeneous cracking implying molecular oxygen and the thermal cracking of the carbon chain. Olefin production can come with oxygenated compound formation (molecular oxygen implication, i.e. the peroxyalkyl pathway) or without the formation of side-products (thermal cracking, i.e. the pyrolytic pathway). In the present study, the reactivity of n-alkanes increases with their carbon chain length regarding thermal cracking and results in higher yields of LAOs.
The constant yields of olefins having the same number of carbon atoms as the reactive n-alkane (Fig. 7C) depict that the increase of initiated n-alkane occurs mainly through C–C bond cleavage (i.e. intramolecular initiation), rather than H˙ abstraction (i.e. intermolecular initiation). It agrees with the carbon–carbon bond energy decreasing with the length of the n-paraffin chain.40
The Anderson-Schulz-Flory parameters increase with the number of carbon atoms of the reagent concerning LAO and n-aldehyde distributions (Fig. 8).
![]() | ||
Fig. 8 Anderson-Schultz-Flory parameters from the α-olefin and n-aldehyde distribution modelisation at a time on stream of 135 min as a function of the carbon number of the reactive n-alkane. |
It depicts a flattening of the size distributions of cracking products and thus a formation with longer linear carbon chains. Thus, the MSR operation conditions preserve the length of the chains of terminal alkyl radicals coming from the random cleavage of the carbon chain of n-alkanes. The stable formation of light olefins (ethylene and propylene) indicates that C–H cleavage reactions predominate over C–C β-cleavage for terminal alkyl radical transformation.
In addition, the absence of di-olefinic compounds (such as 1,3-butadiene) highlights the absence of over-cracking reactions through new intramolecular initiations.
The reactivity of n-alkanes increases with their length due to a significant initiation by breaking of carbon–carbon bonds. Consequently, the yields of LAOs increase, while the oxygenated compounds and total and partial combustion products are formed in similar proportions. The experimental conditions of the MSR, i.e. temperature and residence time, preserve these primary products from secondary transformations, such as over-cracking or oxidation. Likewise, the probability of stabilizing a terminal alkyl radical into a linear α-olefin through β-scission of a C–H bond is more significant than successive ethylene elimination through β-scission of a C–C bond. Higher carbon chain n-paraffins allow longer linear α-olefin production by fast stabilization of the cracking fragments.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/d1nj05910f |
This journal is © The Royal Society of Chemistry and the Centre National de la Recherche Scientifique 2022 |