Catalyst Modification Strategies and Reactor Engineering for Enhanced p‐Xylene Production via Toluene Methylation: A Review

Abstract p ‐Xylene is a key industrial chemical with increasing demand due to the shift in global markets toward petrochemicals. While most p ‐xylene is currently produced through naphtha cracking, naphtha reforming, toluene disproportionation, and trans‐alkylation, alternative and cost‐effective manufacturing techniques are needed. Catalytic methylation of toluene using shape‐selective catalysts is a potential route to yield xylenes with great para selectivity. Recent research has focused on key challenges in modifying catalysts to increase surface acidity, pore channels, and crystallinity, improving para selectivity, and reactor set‐up used for the toluene methylation reaction. However, challenges remain in designing effective shape‐selective catalysts without sacrificing catalytic activity and maximizing methanol utilization for increased p ‐xylene productivity. This review discusses recent developments in catalyst design and modification strategies for improved shape selectivity, including the influence of reaction conditions. The review concludes with a forward‐looking perspective on developing, designing, and modifying catalysts and the commercialization of the toluene methylation process to address gaps in the related research field.