X-ray Fluorescence Tomography of Aged Fluid-Catalytic-Cracking Catalyst Particles Reveals Insight into Metal Deposition Processes

Unravelling potential reaction intermediates during catalytic pyrolysis of polypropylene with microscopy and spectroscopy

While plastics-to-plastics recycling via melting and re-extrusion is often the preferred option due to a relatively low CO2 footprint, this technique requires a highly sorted waste stream and plastic properties can often not be maintained. Obtaining aromatics, such as benzene, toluene, and xylene (BTX), via catalytic pyrolysis of polyolefins, such as polypropylene and polyethylene, offers another attractive recycling technology. In this process, a discarded crude oil refinery catalyst (ECAT) was previously shown to lower the unwanted formation of deactivating coke species compared to a fresh crude oil refinery catalyst (FCC-cat), while yielding 20 wt% aromatics from polypropylene. In this work, we study the underlying reaction mechanism for this chemical recycling process over the fresh and used refinery catalyst as well as a model system, not containing any zeolite material, using a combination of microscopy and spectroscopy. More specifically, by using in situ fluorescence microscopy, in situ infrared spectroscopy, in situ ultraviolet-visible spectroscopy as well as ex situ solid-state nuclear magnetic resonance, we observe highly fluorescent methylated aromatic intermediates that differ for the three catalyst materials under study both in their fluorescence, IR, UV-vis, and NMR spectroscopy features. This detailed micro-spectroscopic comparison informs which potential reaction intermediates lead to increased coke formation. Our results suggests that a next generation of catalyst materials for this process would profit from a higher accessibility and a milder acidity compared to an FCC-cat and shows the great potential of using ECAT to reduce coking and obtain a BTX stream, which could be become the chemical building blocks for the manufacturing of e.g., plastics and coating materials.

Visualizing the Structure, Composition and Activity of Single Catalyst Particles for Olefin Polymerization and Polyolefin Decomposition

The structural and morphological characterization of individual catalyst particles for olefin polymerization, as well as for the reverse process of polyolefin decomposition, can provide an improved understanding for how these catalyst materials operate under relevant reaction conditions. In this review, we discuss an emerging analytical toolbox of 2D and 3D chemical imaging techniques that is suitable for investigating the chemistry and reactivity of related catalyst systems. While synchrotron-based X-ray microscopy still provides unparalleled spatial resolutions in 2D and 3D, a number of laboratory-based techniques, most notably focused ion beam-scanning electron microscopy, confocal fluorescence microscopy, infrared photoinduced force microscopy and laboratory-based X-ray nano-computed tomography, have helped to significantly expand the arsenal of analytical tools available to scientists in heterogeneous catalysis and polymer science. In terms of future research, the review outlines the role and impact of in situ and operando (spectro-)microscopy experiments, involving sophisticated reactors as well as online reactant and product analysis, to obtain real-time information on the formation, decomposition, and mobility of polymer phases within single catalyst particles. Furthermore, the potential of fluorescence microscopy, X-ray microscopy and optical microscopy is highlighted for the high-throughput characterization of olefin polymerization and polyolefin decomposition catalysts. By combining these chemical imaging techniques with, for example, chemical staining methodologies, selective probe molecules as well as particle sorting approaches, representative structure-activity relationships can be derived at the level of single catalyst particles.

Migration and emission characteristics of metal pollutants in fluid catalytic cracking (FCC) process

Fluid catalytic cracking (FCC) is the core unit for heavy oil conversion in refineries. In the FCC process, the metal contaminants from the feedstock are deposited on the catalysts, causing catalyst deactivation and metal particulate matter (PM) emission. However, the migration and emission characteristics of metal pollutants in FCC units are still unclear. Here, the stack tests of three FCC units were carried out to monitor metal PM emissions, and the metal contents of the feedstock oil and spent catalyst were detected. For the metal migration from the feedstock to the catalysts, Ni, Fe, and V have high concentrations and migration rates while other metals perform much lower. The metal distribution on the spent catalysts profoundly determines the metal mobility to the flue gas and the regeneration process affects the catalyst attrition, leading to metal PM emissions discrepancy. The migration rate and emission concentration of V in the deeper layers of the catalysts are much lower than those of Ni at the particle's exterior. Finally, the stack data was used to calculate the emission factors and ratio factors of the metal PM. This work is expected to advance metal migration cognition and metal pollutants emissions estimation in FCC units.

Correlated x-ray fluorescence and ptychographic nano-tomography on Rembrandt's The Night Watch reveals unknown lead "layer"

The Night Watch, one of the most famous masterpieces by Rembrandt, is the subject of a large research and conservation project. For the conservation treatment, it is of great importance to understand its current condition. Correlated nano-tomography using x-ray fluorescence and ptychography revealed a-so far unknown-lead-containing "layer", which likely acts as a protective impregnation layer applied on the canvas before the quartz-clay ground was applied. This layer might explain the presence of lead soap protrusions in areas where no other lead components are present. In addition to the three-dimensional elemental mapping, ptychography visualizes and quantifies components not detectable by hard x-ray fluorescence such as the organic fraction and quartz. The first-time use of this combination of synchrotron-based techniques on a historic paint micro-sample shows it to be an important tool to better interpret the results of noninvasive imaging techniques operating on the macroscale.

Emission characteristics of condensable particulate matter (CPM) from FCC flue gas

Particulate matter (PM) as a major air pollutant, generally includes filterable particulate matter (FPM) and condensable particulate matter (CPM). CPM has gradually attracted widespread attention recently, due to its increasing proportion in total PM emissions. Fluid catalytic cracking (FCC) units, the main emission source in refineries, mostly use wet flue gas desulfurization (WFGD), which will produce a large amount of CPM. However, CPM emission and composition of FCC units are actually unclear. In this work, we aimed to understand the emission characteristics of CPM in FCC flue gas and provide some potential control strategies. Here, the stack tests of three typical FCC units were conducted to monitor FPM and CPM, and the field monitoring FPM results are higher than the concentration provided by Continuous Emission Monitoring System (CEMS). The emission of CPM is at a high-level concentration from 28.88 to 86.17 mg/Nm³, divided into inorganic fraction and organic fraction. The inorganic fraction is mainly composed in CPM, where water-soluble ions including SO₄^2-, Na⁺, NH₄⁺, NO₃^-, CN^-, Cl^-, and F^-, are the major contributors. Moreover, a variety of organic compounds are detected as qualitative analysis of organic fraction in CPM, which can be roughly classified into alkanes, esters, aromatics, and others. Finally, on the basis of the understanding of the characteristics of CPM, we have proposed two strategies for CPM control. This work is expected to advance CPM emission regulation and control in FCC units.

Plastic Waste Conversion over a Refinery Waste Catalyst

Polypropylene (PP) makes up a large share of our plastic waste. We investigated the conversion of PP over the industrial Fluid Catalytic Cracking catalyst (FCC-cat) used to produce gasoline from crude oil fractions. We studied transport limitations arising from the larger size of polymers compared to the crude oil-based feedstock by testing the components of this catalyst separately. Infrared spectroscopy and confocal fluorescence microscopy revealed the role of the FCC matrix in aromatization, and the zeolite Y domains in coking. An equilibrium catalyst (ECAT), discarded during FCC operation as waste, produced the same aromatics content as a fresh FCC-cat, while coking decreased significantly, likely due to the reduced accessibility and activity of the zeolite domains and an enhanced cracking activity of the matrix due to metal deposits present in ECAT. This mechanistic understanding provides handles for further improving the catalyst composition towards higher aromatics selectivity.

Heterogeneity in the Fragmentation of Ziegler Catalyst Particles during Ethylene Polymerization Quantified by X-ray Nanotomography

Ziegler-type catalysts are the grand old workhorse of the polyolefin industry, yet their hierarchically complex nature complicates polymerization activity-catalyst structure relationships. In this work, the degree of catalyst framework fragmentation of a high-density polyethylene (HDPE) Ziegler-type catalyst was studied using ptychography X-ray-computed nanotomography (PXCT) in the early stages of ethylene polymerization under mild reaction conditions. An ensemble consisting of 434 fully reconstructed ethylene prepolymerized Ziegler catalyst particles prepared at a polymer yield of 3.4 g HDPE/g catalyst was imaged. This enabled a statistical route to study the heterogeneity in the degree of particle fragmentation and therefore local polymerization activity at an achieved 3-D spatial resolution of 74 nm without requiring invasive imaging tools. To study the degree of catalyst fragmentation within the ensemble, a fragmentation parameter was constructed based on a k-means clustering algorithm that relates the quantity of polyethylene formed to the average size of the spatially resolved catalyst fragments. With this classification method, we have identified particles that exhibit weak, moderate, and strong degrees of catalyst fragmentation, showing that there is a strong heterogeneity in the overall catalyst particle fragmentation and thus polymerization activity within the entire ensemble. This hints toward local mass transfer limitations or other deactivation phenomena. The methodology used here can be applied to all polyolefin catalysts, including metallocene and the Phillips catalysts to gain statistically relevant fundamental insights in the fragmentation behavior of an ensemble of catalyst particles.

Visualizing defects and pore connectivity within metal-organic frameworks by X-ray transmission tomography

Metal-Organic Frameworks (MOFs) have the potential to change the landscape of molecular separations in chemical processes owing to their ability of selectively binding molecules. Their molecular sorting properties generally rely on the micro- and meso-pore structure, as well as on the presence of coordinatively unsaturated sites that interact with the different chemical species present in the feed. In this work, we show a first-of-its-kind tomographic imaging of the crystal morphology of a metal-organic framework by means of transmission X-ray microscopy (TXM), including a detailed data reconstruction and processing approach. Corroboration with Focused Ion Beam-Scanning Electron Microscopy (FIB-SEM) images shows the potential of this strategy for further (non-destructively) assessing the inner architecture of MOF crystals. By doing this, we have unraveled the presence of large voids in the internal structure of a MIL-47(V) crystal, which are typically thought of as rather homogeneous lattices. This challenges the established opinion that hydrothermal syntheses yield relatively defect-free material and sheds further light on the internal morphology of crystals.

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.

Quantitative Visual Characterization of Contaminant Metals and their Mobility in Fluid Catalytic Cracking Catalysts

A new approach for characterization of fluid catalytic cracking (FCC) catalysts is proposed. This approach is based on computational visual analyses of images originating from field emission scanning electron microscopy (FE-SEM) studies coupled with elemental mapping via electron dispersive x-ray spectroscopy (EDX) analyses. The concept of contaminant metal mobility is defined and systematically studied through quantification of interparticle transfer and intraparticle penetration of the most common FCC contaminant metals (nickel, vanadium, iron, and calcium). This novel methodology was employed for practical quantification of intraparticle mobility via the Peripheral Deposition Index (PDI). For analyzing and quantifying interparticle mobility, a new index was developed and coined “Interparticle Mobility Index” or IMI. With the development and practical application of these two indices, this study offers the first standardized methodology for quantification of metals mobility in FCC. This novel systematic approach for analyzing metals mobility allows for improved troubleshooting of refinery-specific case studies and for more effective research and development in contaminant metals passivation in FCC catalysts.

Transformations of FCC catalysts and carbonaceous deposits during repeated reaction-regeneration cycles

Transformations of an industrial zeolite-based fluid catalytic cracking (FCC) catalyst and its coke deposits during regeneration following FCC reactions of a representative refinery stream are investigated.

Magnetophoretic Sorting of Single Catalyst Particles

A better understanding of the deactivation processes taking place within solid catalysts is vital to design better ones. However, since inter-particle heterogeneities are more a rule than an exception, particle sorting is crucial to analyse single catalyst particles in detail. Microfluidics offers new possibilities to sort catalysts at the single particle level. Herein, we report a first-of-its-kind 3D printed magnetophoretic chip able to sort catalyst particles by their magnetic moment. Fluid catalytic cracking (FCC) particles were separated based on their Fe content. Magnetophoretic sorting shows that large Fe aggregates exist within 20 % of the FCC particles with the highest Fe content. The availability of Brønsted acid sites decreases with increasing Fe content. This work paves the way towards a high-throughput catalyst diagnostics platform to determine why specific catalyst particles perform better than others.

2D/3D Microanalysis by Energy Dispersive X-ray Absorption Spectroscopy Tomography

X-ray spectroscopic techniques have proven to be particularly useful in elucidating the molecular and electronic structural information of chemically heterogeneous and complex micro- and nano-structured materials. However, spatially resolved chemical characterization at the micrometre scale remains a challenge. Here, we report the novel hyperspectral technique of micro Energy Dispersive X-ray Absorption Spectroscopy (μED-XAS) tomography which can resolve in both 2D and 3D the spatial distribution of chemical species through the reconstruction of XANES spectra. To document the capability of the technique in resolving chemical species, we first analyse a sample containing 2-30 μm grains of various ferrous- and ferric-iron containing minerals, including hypersthene, magnetite and hematite, distributed in a light matrix of a resin. We accurately obtain the XANES spectra at the Fe K-edge of these four standards, with spatial resolution of 3 μm. Subsequently, a sample of ~1.9 billion-year-old microfossil from the Gunflint Formation in Canada is investigated, and for the first time ever, we are able to locally identify the oxidation state of iron compounds encrusting the 5 to 10 μm microfossils. Our results highlight the potential for attaining new insights into Precambrian ecosystems and the composition of Earth's earliest life forms.

A three-dimensional view of structural changes caused by deactivation of fluid catalytic cracking catalysts

Since its commercial introduction three-quarters of a century ago, fluid catalytic cracking has been one of the most important conversion processes in the petroleum industry. In this process, porous composites composed of zeolite and clay crack the heavy fractions in crude oil into transportation fuel and petrochemical feedstocks. Yet, over time the catalytic activity of these composite particles decreases. Here, we report on ptychographic tomography, diffraction, and fluorescence tomography, as well as electron microscopy measurements, which elucidate the structural changes that lead to catalyst deactivation. In combination, these measurements reveal zeolite amorphization and distinct structural changes on the particle exterior as the driving forces behind catalyst deactivation. Amorphization of zeolites, in particular, close to the particle exterior, results in a reduction of catalytic capacity. A concretion of the outermost particle layer into a dense amorphous silica-alumina shell further reduces the mass transport to the active sites within the composite.Catalyst deactivation in fluid catalytic cracking processes is unavoidably associated with structural changes. Here, the authors visualize the deactivation of zeolite catalysts by ptychography and other imaging techniques, showing pronounced amorphization of the outer layer of the catalyst particles.

Localization and Speciation of Iron Impurities within a Fluid Catalytic Cracking Catalyst

Fluid catalytic cracking is a chemical conversion process of industrial scale. This process, utilizing porous catalysts composed of clay and zeolite, converts heavy crude-oil fractions into transportation fuel and petrochemical feedstocks. Among other factors iron-rich reactor and feedstream impurities cause these catalyst particles to permanently deactivate. Herein, we report tomographic X-ray absorption spectroscopy measurements that reveal the presence of dissimilar iron impurities of specific localization within a single deactivated particle. Whereas the iron natural to clay in the composite seems to be unaffected by operation, exterior-facing and feedstream-introduced iron was found in two forms. Those being minute quantities of ferrous oxide, located near regions of increased porosity, and impurities rich in Fe³⁺ , preferentially located in the outer dense part of the particle and suggested to contribute to the formation of an isolating amorphous silica alumina envelope.

Single-Molecule Fluorescence Microscopy Reveals Local Diffusion Coefficients in the Pore Network of an Individual Catalyst Particle

We used single-molecule fluorescence microscopy to study self-diffusion of a feedstock-like probe molecule with nanometer accuracy in the macropores of a micrometer-sized, real-life fluid catalytic cracking (FCC) particle. Movies of single fluorescent molecules allowed their movement through the pore network to be reconstructed. The observed tracks were classified into three different states by machine learning and all found to be distributed homogeneously over the particle. Most probe molecules (88%) were immobile, with the molecule most likely being physisorbed or trapped; the remainder was either mobile (8%), with the molecule moving inside the macropores, or showed hybrid behavior (4%). Mobile tracks had an average diffusion coefficient of D = 8 × 10-14 ± 1 × 10-13 m2 s-1, with the standard deviation thought to be related to the large range of pore sizes found in FCC particles. The developed methodology can be used to evaluate, quantify and map heterogeneities in diffusional properties within complex hierarchically porous materials.

Stability of a Bifunctional Cu-Based Core@Zeolite Shell Catalyst for Dimethyl Ether Synthesis Under Redox Conditions Studied by Environmental Transmission Electron Microscopy and In Situ X-Ray Ptychography

When using bifunctional core@shell catalysts, the stability of both the shell and core-shell interface is crucial for catalytic applications. In the present study, we elucidate the stability of a CuO/ZnO/Al2O3@ZSM-5 core@shell material, used for one-stage synthesis of dimethyl ether from synthesis gas. The catalyst stability was studied in a hierarchical manner by complementary environmental transmission electron microscopy (ETEM), scanning electron microscopy (SEM) and in situ hard X-ray ptychography with a specially designed in situ cell. Both reductive activation and reoxidation were applied. The core-shell interface was found to be stable during reducing and oxidizing treatment at 250°C as observed by ETEM and in situ X-ray ptychography, although strong changes occurred in the core on a 10 nm scale due to the reduction of copper oxide to metallic copper particles. At 350°C, in situ X-ray ptychography indicated the occurrence of structural changes also on the µm scale, i.e. the core material and parts of the shell undergo restructuring. Nevertheless, the crucial core-shell interface required for full bifunctionality appeared to remain stable. This study demonstrates the potential of these correlative in situ microscopy techniques for hierarchically designed catalysts.

A DNP-supported solid-state NMR study of carbon species in fluid catalytic cracking catalysts

A combination of solid-state NMR techniques supported by EPR and SEM-EDX experiments was used to localize different carbon species (coke) in commercial fluid catalytic cracking catalysts. Aliphatic coke species formed during the catalytic process and aromatic coke species deposited directly from the feedstock respond differently to dynamic nuclear polarization signal enhancement in integral and crushed FCC particles, indicating that aromatic species are mostly concentrated on the outside of the catalyst particles, whereas aliphatic species are also located on the inside of the FCC particles. The comparison of solid-state NMR data with and without the DNP radical at low and ambient temperature suggests the proximity between aromatic carbon deposits and metals (mostly iron) on the catalyst surface. These findings potentially indicate that coke and iron deposit together, or that iron has a role in the formation of aromatic coke.

Fast X-ray microfluorescence imaging with submicrometer-resolution integrating a Maia detector at beamline P06 at PETRA III

The high brilliance of third-generation synchrotron sources increases the demand for faster detectors to utilize the available flux. The Maia detector is an advanced imaging scheme for energy-dispersive detection realising dwell times per image-pixel as low as 50 µs and count rates higher than 10 × 10⁶ s^-1. In this article the integration of such a Maia detector in the Microprobe setup of beamline P06 at the storage ring PETRA III at the Deutsches Elektronen-Synchrotron (DESY) in Hamburg, Germany, is described. The analytical performance of the complete system in terms of rate-dependent energy resolution, scanning-speed-dependent spatial resolution and lower limits of detection is characterized. The potential of the Maia-based setup is demonstrated by key applications from materials science and chemistry, as well as environmental science with geological applications and biological questions that have been investigated at the P06 beamline.

Imaging of Oxygen Diffusion in Individual Platinum/Ce2 Zr2 Ox Catalyst Particles During Oxygen Storage and Release

The spatial distribution of Ce(3+) and Ce(4+) in each particle of Ce2 Zr2 Ox in a three-way conversion catalyst system was successfully imaged during an oxygen storage/release cycle by scanning X-ray absorption fine structure (XAFS) using hard X-ray nanobeams. For the first time, nano-XAFS imaging visualized and identified the modes of non-uniform oxygen diffusion from the interface of Pt catalyst and Ce2 Zr2 Ox support and the active parts in individual catalyst particles.

Visualizing Dealumination of a Single Zeolite Domain in a Real-Life Catalytic Cracking Particle

Fluid catalytic cracking (FCC) catalysts play a central role in the chemical conversion of crude oil fractions. Using scanning transmission X-ray microscopy (STXM) we investigate the chemistry of one fresh and two industrially deactivated (ECAT) FCC catalysts at the single zeolite domain level. Spectro-microscopic data at the Fe L3 , La M5 , and Al K X-ray absorption edges reveal differing levels of deposited Fe on the ECAT catalysts corresponding with an overall loss in tetrahedral Al within the zeolite domains. Using La as a localization marker, we have developed a novel methodology to map the changing Al distribution of single zeolite domains within real-life FCC catalysts. It was found that significant changes in the zeolite domain size distributions as well as the loss of Al from the zeolite framework occur. Furthermore, inter- and intraparticle heterogeneities in the dealumination process were observed, revealing the complex interplay between metal-mediated pore accessibility loss and zeolite dealumination.

Relating structure and composition with accessibility of a single catalyst particle using correlative 3-dimensional micro-spectroscopy

To understand how hierarchically structured functional materials operate, analytical tools are needed that can reveal small structural and chemical details in large sample volumes. Often, a single method alone is not sufficient to get a complete picture of processes happening at multiple length scales. Here we present a correlative approach combining three-dimensional X-ray imaging techniques at different length scales for the analysis of metal poisoning of an individual catalyst particle. The correlative nature of the data allowed establishing a macro-pore network model that interprets metal accumulations as a resistance to mass transport and can, by tuning the effect of metal deposition, simulate the response of the network to a virtual ageing of the catalyst particle. The developed approach is generally applicable and provides an unprecedented view on dynamic changes in a material's pore space, which is an essential factor in the rational design of functional porous materials.

Nanoscale Chemical Imaging of an Individual Catalyst Particle with Soft X-ray Ptychography

Understanding Fe deposition in fluid catalytic cracking (FCC) catalysis is critical for the mitigation of catalyst degradation. Here we employ soft X-ray ptychography to determine at the nanoscale the distribution and chemical state of Fe in an aged FCC catalyst particle. We show that both particle swelling due to colloidal Fe deposition and Fe penetration into the matrix as a result of precracking of large organic molecules occur. The application of ptychography allowed us to provide direct visual evidence for these two distinct Fe-based deactivation mechanisms, which have so far been proposed only on the basis of indirect evidence.

Photo-spectroscopy of mixtures of catalyst particles reveals their age and type

Within a fluid catalytic cracking (FCC) unit, a mixture of catalyst particles that consist of either zeolite Y (FCC-Y) or ZSM-5 (FCC-ZSM-5) is used in order to boost the propylene yield when processing crude oil fractions. Mixtures of differently aged FCC-Y and FCC-ZSM-5 particles circulating in the FCC unit, the so-called equilibrium catalyst (Ecat), are routinely studied to monitor the overall efficiency of the FCC process. In this study, the age of individual catalyst particles is evaluated based upon photographs after selective staining with substituted styrene molecules. The observed color changes are linked to physical properties, such as the micropore volume and catalytic cracking activity data. Furthermore, it has been possible to determine the relative amount of FCC-Y and FCC-ZSM-5 in an artificial series of physical mixtures as well as in an Ecat sample with unknown composition. As a result, a new practical tool is introduced in the field of zeolite catalysis to evaluate FCC catalyst performances on the basis of photo-spectroscopic measurements with an off-the-shelf digital single lens reflex (DSLR) photo-camera with a macro lens. The results also demonstrate that there is an interesting time and cost trade-off between single catalyst particle studies, as performed with e.g. UV-vis, synchrotron-based IR and fluorescence micro-spectroscopy, and many catalyst particle photo-spectroscopy studies, making use of a relatively simple DSLR photo-camera. The latter approach offers clear prospects for the quality control of e.g. FCC catalyst manufacturing plants.

The curious case of zeolite–clay/binder interactions and their consequences for catalyst preparation

Zeolite-based catalyst bodies are commonly employed in a range of important industrial processes. Depending on the binder and shaping method chosen, vast differences in the reactivity, selectivity and stability are obtained. Here, three highly complementary micro-spectroscopic techniques were employed to study zeolite ZSM-5–binder interactions in SiO₂-, Al₂O₃-, SiO₂ : Al₂O₃- (2 : 1 mix) and kaolinite-bound catalyst pellets. We establish how their preparation influences the zeolite–clay/binder interactions. Using thiophene as an acid-catalyzed staining reaction, light absorbing oligomers produced in each sample were followed. To our surprise, kaolinite decreased the overall reactivity of the sample due to the phase change of the binder, creating a hard impenetrable outer layer. Aluminum migration to the zeolite was observed when Al₂O₃ was selected as a binder, creating additional Brønsted acid sites, which favored the formation of ring-opened thiophene oligomers compared to the larger oligomer species produced when SiO₂ was used as a binder. In the latter case, the interaction of the Si–OH groups in the binder with thiophene was revealed to have a large impact in creating such large oligomer species. Furthermore, the combination of a SiO₂ : Al₂O₃ mix as a binder enhanced the reactivity, possibly due to the creation of additional Brønsted acid sites between the two binder components during pellet preparation. It is evident that, independent of the shaping method, the intimate contact between the zeolite and binder heavily impacts the reactivity and product selectivity, with the type of binder playing a vital role.

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

Fluid catalytic cracking (FCC) is one of the major conversion technologies in the oil refinery industry, and the largest commercial catalytic process that uses zeolite materials.

Fluid catalytic cracking (FCC) is one of the major conversion technologies in the oil refinery industry. FCC currently produces the majority of the world's gasoline, as well as an important fraction of propylene for the polymer industry. In this critical review, we give an overview of the latest trends in this field of research. These trends include ways to make it possible to process either very heavy or very light crude oil fractions as well as to co-process biomass-based oxygenates with regular crude oil fractions, and convert these more complex feedstocks in an increasing amount of propylene and diesel-range fuels. After providing some general background of the FCC process, including a short history as well as details on the process, reactor design, chemical reactions involved and catalyst material, we will discuss several trends in FCC catalysis research by focusing on ways to improve the zeolite structure stability, propylene selectivity and the overall catalyst accessibility by (a) the addition of rare earth elements and phosphorus, (b) constructing hierarchical pores systems and (c) the introduction of new zeolite structures. In addition, we present an overview of the state-of-the-art micro-spectroscopy methods for characterizing FCC catalysts at the single particle level. These new characterization tools are able to explain the influence of the harsh FCC processing conditions (e.g. steam) and the presence of various metal poisons (e.g. V, Fe and Ni) in the crude oil feedstocks on the 3-D structure and accessibility of FCC catalyst materials.