Ethanol transformation into gasoline range hydrocarbons by a one-step heterogeneous catalysis was studied using a metal-exchanged zeolite catalyst at ambient pressure. Here, we successfully show full conversion of ethanol to a drop-in fuel product and that water concentration shows no effect on the catalyst or final product distribution. This suggests that fermentation stream can also be used as a reactant.  We optimized the reaction temperature and liquid hourly space velocity to increase the yield of drop-in fuel product. The results for pure ethanol are as follows: Optimal temperature of 350 �C and LHSV of 4.5 hr-1 provided full ethanol conversion with a 45% yield. Catalyst was observed to become coked after three hours and the yield of drop-in fuel dramatically decreased. Thermogravimetric experiments suggested that the catalyst could be regenerated at 450 �C within 35 minutes. After regeneration catalyst recovered its full performance suggesting that catalyst inactivation was due to coking only and dealumination did not occur. The products were collected, separated from water, and dried before detailed hydrocarbon analysis and engine experiments.  Fuel product consists of a mixture of C3 � C16 hydrocarbons containing paraffin, iso-parrafins, olefins, aromatic compounds, and < 500 ppm of oxygen containing compounds.  The physical properties were similar to certified gasoline with a research octane number and motor octane number of 112 and 95, respectively.  Successful engine experiments were performed on a variable valve actuation engine showing comparable performance and emission data to certified gasoline.

Direct catalytic conversion of ethanol stream into fuel

243rd National Meeting (2012)

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