Fluid catalytic cracking: recent developments on the grand old lady of zeolite catalysis

A Bottom-Up Strategy for the Synthesis of Highly Siliceous Faujasite-Type Zeolite

High-silica zeolite Y is a desired catalytic material for oil refining and the petrochemical industry. However, its direct synthesis remains a symbolic challenge in the field of zeolite synthesis, with a limited improvement of the framework SiO₂ /Al₂ O₃ ratio (SAR) from ≈5 to 9 over the past 60 years. Here, the synthesis of highly siliceous zeolite Y with tunable SAR up to 15.6 through a cooperative strategy is reported, which involves the use of FAU nuclei, a bulky organic structure-directing agent (OSDA), and a gel system with low alkalinity (named NOA-co strategy). A series of quaternary alkylammonium ions is discovered as effective OSDAs based on the NOA-co strategy, and the relevant crystallization mechanism is elucidated. Moreover, the high-silica products are demonstrated to have greatly improved (hydro)thermal stability, high concentration of strong acid sites, and uniform acid distribution, which lead to superior catalytic performance in the cracking of bulky hydrocarbons. It is anticipated that this synthetic strategy will benefit the synthesis and development of zeolitic catalysts in a wide range of reaction processes.

Renewable Aromatics from Tree-Borne Oils over Zeolite Catalysts Promoted by Transition Metals

Despite the ever-growing demand for benzene-toluene-xylene (BTX), the alternative route of production from tree-borne oils is rarely investigated and poorly understood. Here, we have synthesized a Zn-loaded Y-zeolite catalyst for the continuous production of bio-BTX from tree-borne oils (nonedible seed oil), e.g., neem oil. Our approach involves low-temperature selective cracking-dehydrogenation-aromatization of neem oil over metal-supported catalysts to xylene-rich aromatics. The physicochemical properties of the prepared catalyst were characterized using powder XRD, N₂ physisorption, TEM, NH₃-TPD, XPS, Py-FTIR, solid-NMR, and TG analyses. Mesoporous Y-zeolites with a pore diameter of 7.4 Å showed better selectivity toward aromatics and were found to be the most effective catalyst for the aromatization process, especially for BTX. The aromatic yield was found to increase with the addition of Zn, and the highest conversion of 90-94% with an ∼75% BTX yield was achieved with the ZnY catalyst. During aromatization, a sizable number of short alkanes and olefins were also obtained on acidic Y-zeolites. The off-gas composition shows the presence of ∼45% C₂-C₄ olefins with 8.9% H₂. The incorporation of Zn species can promote the dehydrogenation activity, and the subsequent aromatization required a suitable pore network. The optimized ZnY catalyst inspires the formation of toluene and xylenes, inhibiting the formation of benzene and gaseous alkanes.

Effects of ultrasonic irradiation on crystallization kinetics, morphological and structural properties of zeolite FAU

In this work, NaX zeolite was synthesized and the effect of ultrasound irradiation on reaction kinetics, morphological and structural properties was investigated. Ultrasound was applied, by using a plate transducer (91.8 kHz), for the first time during the crystallization of zeolite NaX, at high temperature, varying the irradiation moment and its duration. Furthermore, ultrasound was applied after the crystallization by a horn-type transducer (20-24 kHz) at low temperature. The effects of irradiated volume (100-300 mL), sonication time (2-10 min) and ultrasound power (10-200 W) were studied with a power intensity up to 100 W/cm². It was found that the application of ultrasound during the first hour of crystallization resulted in 20% reduction of reaction time compared to a standard crystallization. Ultrasound can also reduce the agglomeration degree of the final powder by combining high power and long sonication time. After 5 min sonication time at 0.3 W/mL, the tapped density of the powder was increased by 10%, from 0.37 to 0.41 g/mL. Finally, by scanning electron microscopy (SEM) it was demonstrated that ultrasound can disrupt the agglomerates without affecting the morphology of individual crystals.

A variable temperature infrared spectroscopy study of NaY zeolite dehydration

Variable temperature diffuse reflection infrared spectroscopy is used to monitor molecular vibration changes associated with water molecules and zeolite framework during thermal dehydration of NaY zeolite. Absorbance bands are assigned to three unique water molecule environments. These three water types exhibit different temperature-dependent band intensity profiles. A band at 3700 cm^-1 is assigned to framework acid sites. The intensity of this band was found to vary with temperature in a manner consistent with the occupancy of sodium cations in II' unit cell locations. Specific framework vibrations exhibit temperature-dependent intensity change profiles. Band intensities at 1190, 1060, and 960 cm^-1, associated with Si-O-Si and Si-O-Al asymmetric stretching vibrations, are sensitive to water content. Band intensity at 800 cm^-1, assigned to Si-O-Si symmetric stretching, is inversely correlated with temperature-dependent unit cell volume changes. All framework band intensity changes detected during heating are reversible after re-hydration during sample cooling.

Chemical reactivity under nanoconfinement

Confining molecules can fundamentally change their chemical and physical properties. Confinement effects are considered instrumental at various stages of the origins of life, and life continues to rely on layers of compartmentalization to maintain an out-of-equilibrium state and efficiently synthesize complex biomolecules under mild conditions. As interest in synthetic confined systems grows, we are realizing that the principles governing reactivity under confinement are the same in abiological systems as they are in nature. In this Review, we categorize the ways in which nanoconfinement effects impact chemical reactivity in synthetic systems. Under nanoconfinement, chemical properties can be modulated to increase reaction rates, enhance selectivity and stabilize reactive species. Confinement effects also lead to changes in physical properties. The fluorescence of light emitters, the colours of dyes and electronic communication between electroactive species can all be tuned under confinement. Within each of these categories, we elucidate design principles and strategies that are widely applicable across a range of confined systems, specifically highlighting examples of different nanocompartments that influence reactivity in similar ways.

Operando X-Ray Spectroscopic Techniques: A Focus on Hydrogen and Oxygen Evolution Reactions

The study of structural as well as chemical properties of an electrocatalyst in its reaction environment is a challenge in electrocatalysis. This is very important for the better understanding of the dynamic changes in the reactivity with respect to the structure of catalysts to give insight into the reaction mechanism. The in situ/operando investigation of electrode/electrolyte interface has been increasingly explored in recent days due to the significant developments in technology. The review focus on operando X-ray spectroscopic techniques to understand the behavior of electrocatalysts in hydrogen evolution and oxygen evolution reactions (HER and OER). Some recent studies on the application of operando X-ray spectroscopic methods to study the dynamic nature as well as the evaluation of structural and chemical changes of the electrocatalysts for HER and OER in different reaction environment are discussed.

Using ultrasound to improve the sequential post-synthesis modification method for making mesoporous Y zeolites

Mesoporous Y zeolites were prepared by the sequential chemical dealumination (using chelating agents such as ethylenediaminetetraacetic acid, H4EDTA, and citric acid aqueous solutions) and alkaline desilication (using sodium hydroxide, NaOH, aqueous solutions) treatments. Specifically, the ultrasound-assisted alkaline treatment (i.e., ultrasonic treatment) was proposed as the alternative to conventional alkaline treatments which are performed under hydrothermal conditions. In comparison with the hydrothermal alkaline treatment, the ultrasonic treatment showed the comparatively enhanced efficiency (with the reduced treatment time, i.e., 5 min vs. 30 min, all with 0.2 mol·L−1 NaOH at 65°C) in treating the deal-uminated Y zeolites for creating mesoporosity. For example, after the treatment of a dealuminated zeolite Y (using 0.1 mol·L−1 H4EDTA at 100°C for 6 h), the ultrasonic treatment produced the mesoporous zeolite Y with the specific external surface area (Sexternal) of 160 m2·g·−1and mesopore volume (Vmeso) of 0.22 cm3·g−1, being slightly higher than that by the conventional method (i.e., Sextemal= 128 m2·g−1 and Vmeso = 0.19 cm3·g−1). The acidic property and catalytic activity (in catalytic cracking of n-octane) of mesoporous Y zeolites obtained by the two methods were comparable. The ultrasonic desilication treatment was found to be generic, also being effective to treat the dealuminated Y zeolites by citric acid. Additionally, the first step of chemical dealumination treatment was crucial to enable the effective creation of mesopores in the parent Y zeolite (with a silicon-to-aluminium ratio, Si/Al = 2.6) regardless of the subsequent alkaline desilication treatment (i.e., ultrasonic or hydrothermal). Therefore, appropriate selection of the condition of the chemical dealumination treatment based on the property of parent zeolites, such as Si/Al ratio and crystallinity, is important for making mesoporous zeolites effectively.

Understanding the Loading Dependence of Adsorbate Diffusivities in Hierarchical Metal-Organic Frameworks

Using atomistic simulations, we studied the diffusion of n-hexane in a series of isoreticular hierarchical metal-organic frameworks (MOFs) NU-100x. Nonmonotonic diffusivity-loading relationships that depend on the pore sizes were observed, which can be explained by the spatial distribution of adsorbates at different loadings. For one of the MOFs in the series, NU-1000-M, the diffusivity-loading relationship is almost identical to the previously reported results of n-hexane diffusion in the hierarchical self-pillared pentasil (SPP) zeolite. Detailed analysis revealed that the similarity results from their similar micropore and window sizes, which was confirmed by free-energy mapping. The effects of temperature and adsorbate chain length on the diffusion were also studied, which supported our conclusion that the diffusivity in hierarchical nanoporous materials is primarily controlled by the sizes of the micropores and the connecting windows, particularly at relatively low loadings.

Nickel Poisoning of a Cracking Catalyst Unravelled by Single-Particle X-ray Fluorescence-Diffraction-Absorption Tomography

Ni contamination from crude oil in the fluid catalytic cracking (FCC) process is one of the primary sources of catalyst deactivation, thereby promoting dehydrogenation-hydrogenation and speeding up coke growth. Herein, single-particle X-ray fluorescence, diffraction and absorption (μXRF-μXRD-μXAS) tomography is used in combination with confocal fluorescence microscopy (CFM) after thiophene staining to spatially resolve Ni interaction with catalyst components and study zeolite degradation, including the processes of dealumination and Brønsted acid sites distribution changes. The comparison between a Ni-lean particle, exposed to hydrotreated feedstock, and a Ni-rich one, exposed to non-hydrotreated feedstock, reveals a preferential interaction of Ni, found in co-localization with Fe, with the γ-Al₂ O₃ matrix, leading to the formation of spinel-type hotspots. Although both particles show similar surface zeolite degradation, the Ni-rich particle displays higher dealumination and a clear Brønsted acidity drop.

Differentiating the role of organic additives to assemble open framework aluminosilicates using INS spectroscopy

Uneasy lies a pore that bears a crown – INS study on crown-ether containing zeolites.

A core–shell Y zeolite with a mono-crystalline core and a loosely aggregated polycrystalline shell: a hierarchical cracking catalyst for large reactants

Increased external surface areas promote the pre-cracking of reactants, and the core–shell structure guarantees that reactants undergo a hierarchical cracking process.

Mechanism of tetralin conversion on zeolites for the production of benzene derivatives

The influences of acidity and textural properties of the zeolites on the activity and selectivity were revealed in tetralin conversion.

Aromatization of ethylene over zeolite-based catalysts

Elucidating the role of metal modification and confined hydrocarbon species in the aromatization of ethylene on zeolite catalysts.

Microfluidics and catalyst particles

In this review article, we discuss the latest advances and future perspectives of microfluidics for micro/nanoscale catalyst particle synthesis and analysis. In the first section, we present an overview of the different methods to synthesize catalysts making use of microfluidics and in the second section, we critically review catalyst particle characterization using microfluidics. The strengths and challenges of these approaches are highlighted with various showcases selected from the recent literature. In the third section, we give our opinion on the future perspectives of the combination of catalytic nanostructures and microfluidics. We anticipate that in the synthesis and analysis of individual catalyst particles, generation of higher throughput and better understanding of transport inside individual porous catalyst particles are some of the most important benefits of microfluidics for catalyst research.

A time- and cost-effective synthesis of CHA zeolite with small size using ultrasonic-assisted method

In this paper, the ultrasonic-assisted method has been used to the rapid hydrothermal synthesis of CHA zeolite in the absence of expensive organic template. The influence of different sonicated time on the crystallinity and micromorphology of CHA-type crystals has been studied in detail. The bath-type ultrasound processor produces acoustic waves at the frequency of 20 kHz and the power of ultrasound wave is 150 W. The synthesized products have been characterized by XRD, SEM, EDX, TG and N₂ adsorption analyses. Due to the acceleration on homogeneous nucleation caused by acoustic cavitation cracks during the ultrasonic vibrative process, the crystallization time can be shorten from 48 h to 10 h and the crystal size can be reduced from about 20 μm to 5 μm. The SEM observations of samples with different ultrasonic treatment time distinctly revealed the morphology evolution of the walnut-like CHA zeolites. From EDX, TG and N₂ adsorption comparisons, it is clear that untreated sample and ultrasonic sample both have similar element distribution, thermal stability, and pore size distribution. The research work in this paper has demonstrated the ultrasonic treatment can significantly improve crystallinity degree, reduce crystallization time and crystal size of CHA zeolite.

Synthesis of ZSM-5 Zeolite Using Coal Fly Ash as an Additive for the Methanol to Propylene (MTP) Reaction

Using ZSM-5 zeolites as catalysts for the methanol to propylene (MTP) reaction is being widely investigated and has been industrially applied. In this study, pure ZSM-5 zeolite was successfully synthesized by a direct hydrothermal method using the fly ash of coal gasification as an additional raw material. Various analysis methods such as X-ray diffraction, N2 sorption, scanning electron microscopy, and infrared spectroscopy, were employed to characterize the physicochemical properties of parent and modified zeolites. Then, the prepared ZSM-5 catalysts were tested in the MTP reaction. The results showed that pure ZSM-5 could be directly synthesized in the optimized conditions using fly ash as additional silicon and aluminum sources, and those ZSM-5 catalysts turned out to be candidate catalysts for the MTP reaction. Whereas their catalytic lifetimes were not good enough due to the strong acid sites and needed improving.

Fabrication of spent FCC catalyst composites by loaded V2O5 and TiO2 and their comparative photocatalytic activities

The spent fluid catalytic cracking catalyst (FCC) has been loaded with different content of V₂O₅ and TiO₂ through a modified-impregnation method. X-ray Diffraction (XRD), ultraviolet-visible spectrophotometry (UV-Vis), Scanning Electron Microscope (SEM), and Fourier Transform Infrared spectroscopy (FT-IR) are used to characterize the structure and morphology of these samples. Their photocatalytic activity was evaluated by degradation of methylene blue (MB) solution under 300 W Xenon lamp irradiation. The interplanar spacing of the zeolite Y (111) plane is affected by the amount of the loaded V₂O₅ on spent FCC catalyst. The (111) plane of spent FCC catalyst loaded with V₂O₅ and TiO₂ sample is 1.404 nm, which is higher than that of the zeolite Y (1.395 nm). The amount of adsorption of MB and the photocatalytic activity for the degradation increased with increasing the interplanar spacing of the (111) plane of sample. We fabricated of spent FCC catalyst composites by loaded V₂O₅ and TiO₂, which effectively solved the spent FCC catalyst disposal problem. The efficiency of the developed sample provides a potentially economical way of degrading MB.

Catalyst/Feedstock Ratio Effect on FCC Using Different Catalysts Samples

The present study is a follow-up to a recent authors contribution which describes the effect of the C/O (catalyst/oil) ratio on catalytic cracking activity and catalyst deactivation. This study, while valuable, was limited to one fluidized catalytic cracking (FCC) catalyst. The aim of the present study is to consider the C/O effect using three FCC catalysts with different activities and acidities. Catalysts were characterized in terms of crystallinity, total acidity, specific surface Area (SSA), temperature programmed ammonia desorption (NH3-TPD), and pyridine chemisorption. 1,3,5-TIPB (1,3,5-tri-isopropyl benzene) catalytic cracking runs were carried out in a bench-scale mini-fluidized batch unit CREC (chemical reactor engineering centre) riser simulator. All data were taken at 550 °C with a contact time of 7 s. Every experiment involved 0.2 g of 1,3,5-TIPB with the amount of catalyst changing in the 0.12–1 g range. The resulting 0.6–5 g oil/g cat ratios showed a consistent 1,3,5-TIPB conversion increasing first, then stabilizing, and finally decreasing modestly. On the other hand, coke formation and undesirable benzene selectivity always rose. Thus, the reported results show that catalyst density affects both catalyst coking and deactivation, displaying an optimum C/O ratio, achieving maximum hydrocarbon conversions in FCC units.

Elucidation of correlated disorder in zeolite IM-18

Classical crystallography is based on the translational periodicity of crystals and the analysis of discrete Bragg reflections. However, it is inadequate for determining disordered structures, of which the diffuse scattering is vital to evaluate the disorder level. The correlated disorder of IM-18 presents as zigzag chains arranged in translational periodicity and the double four-ring units randomly distributed along two dimensions. Supercell models regulated by multiple probabilities were systematically built to simulate the single-crystal and powder X-ray diffraction patterns in order to ascertain the specific disorder configuration in the single-crystal or polycrystalline samples of IM-18. The presence of defects in the polycrystalline sample was proved by combining ²⁹Si magic angle spinning (MAS) NMR and ¹H-¹H double quantum MAS NMR spectra, and was quantitatively explored by the simulation method. The method could also elucidate other disordered structures in polycrystalline or single-crystal samples, despite the presence of defects or multidimensional disorder.

Influence of desilication conditions on the shynthesis of herarchical zeolite Y

Hierarchical zeolites were synthesized by two methodologies, following desilication procedures of commercial zeolites. Starting from USY zeolite (Zeolyst CBV720,Si/Al=15), the effect of the amount of CTAB in the desilication media and the hydrothermal treatment time on the synthesized materials were analyzed.The results showed that the surfactant amount has a higher influence on relative crystallinity (%RC) and textural properties of the materials than synthesis time. All the samples showed a lower BET surface area compared with the starting zeolite, although mesopore surface area increased from 210.33 to 467.30 m2/g in the case of Z720-75sample. In the case of USY zeolite withSi/Al=2.6 (ZeolystCBV500),a previous dealumination with H4EDTA and anacid washingwith Na2H2EDTAsteps were included.It was found that the micropore and the mesopore surface areasincreased 13.96% and 11.23%, respectively, compared with the parent zeolite; furthermore, the %RC was 99% after treatmentprocedures.