Aldol Condensation of Acetone Over Basic Zeolite Catalysts for Production of Mesityl Oxide Intermediate

Abstract

Aldol condensation of acetone is an important catalytic process for the production of mesityl oxide, a valuable intermediate widely utilized in solvent manufacturing, fine chemicals, pharmaceuticals, and fuel additive synthesis. The present study investigates the catalytic performance of basic zeolite catalysts for acetone aldol condensation under controlled reaction conditions, with emphasis on mesityl oxide selectivity, catalyst activity, and process optimization. Various zeolite-based catalysts possessing different pore structures, surface basicity, and active site distributions were evaluated to determine their influence on acetone conversion and product formation pathways. Experimental observations demonstrate that the presence of strong and accessible basic active sites significantly enhances aldol condensation reactions and promotes selective formation of mesityl oxide while minimizing undesirable side reactions and heavy byproduct generation. The effects of reaction temperature, catalyst loading, feed composition, and residence time on catalytic efficiency and product yield were systematically analyzed. Results indicate that optimized operating conditions improve acetone conversion and mesityl oxide selectivity, contributing to enhanced process stability and reduced energy consumption. The study further examines catalyst regeneration behavior and long-term operational performance, revealing that zeolite catalysts maintain substantial catalytic activity after repeated reaction cycles. Comparative analysis with conventional homogeneous catalysts confirms the advantages of heterogeneous zeolite systems, including simplified product separation, lower corrosion risk, and improved environmental sustainability.