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

Implanting Colloidal Nanoparticles into Single-Crystalline Zeolites for Catalytic Dehydration

The encapsulation of functional colloidal nanoparticles (100 nm) into single-crystalline ZSM-5 zeolites, aiming to create uniform core-shell structures, is a highly sought-after yet formidable objective due to significant lattice mismatch and distinct crystallization properties. In this study, we demonstrate the fabrication of a core-shell structured single-crystal zeolite encompassing an Fe3O4 colloidal core via a novel confinement stepwise crystallization methodology. By engineering a confined nanocavity, anchoring nucleation sites, and executing stepwise crystallization, we have successfully encapsulated colloidal nanoparticles (CN) within single-crystal zeolites. These grafted sites, alongside the controlled crystallization process, compel the zeolite seed to nucleate and expand along the Fe3O4 colloidal nanoparticle surface, within a meticulously defined volume (1.5×107≤V≤1.3×108 nm3). Our strategy exhibits versatility and adaptability to an array of zeolites, including but not restricted to ZSM-5, NaA, ZSM-11, and TS-1 with polycrystalline zeolite shell. We highlight the uniformly structured magnetic-nucleus single-crystalline zeolite, which displays pronounced superparamagnetism (14 emu/g) and robust acidity (~0.83 mmol/g). This innovative material has been effectively utilized in a magnetically stabilized bed (MSB) reactor for the dehydration of ethanol, delivering an exceptional conversion rate (98 %), supreme ethylene selectivity (98 %), and superior catalytic endurance (in excess of 100 hours).

Comparative study on Al-SBA-15 prepared by spray drying and traditional methods for bulky hydrocarbon cracking: Properties, performance and influencing factors

Mesoporous aluminosilicates Al-SBA-15 with large pore sizes and suitable acid properties are promising substitutes to zeolites for catalytic cracking of bulky hydrocarbons without molecular diffusion limitation. The conventional processes to synthesize Al-SBA-15 are time-consuming and often suffer from low "framework" Al contents. Herein, Al-SBA-15 microspheres are synthesized using the rapid and scalable microfluidic jet spray drying technique. They possess uniform particle sizes (45-60 μm), variable surface morphologies, high surface areas (264-340 m2/g), uniform mesopores (3.8-4.9 nm) and rich acid sites (126-812 μmol/g) and high acid strength. Their physicochemical properties are compared with the counterparts synthesized using traditional hydrothermal and evaporation-induced self-assembly methods. The spray drying technique results in a higher incorporation of aluminum (Al) atoms into the silica "framework" compared to the other two methods. The catalytic cracking efficiencies of 1,3,5-triisopropylbenzene (TIPB) on the Al-SBA-15 materials synthesized using the three different methods and nanosized ZSM-5 are compared. The optimal spray-dried Al-SBA-15 exhibits the best performance with 100 % TIPB conversion, excellent selectivity (about 75 %) towards the formation of deeply cracked products (benzene and propylene) and high stability. The catalytic performances of the spray-dried Al-SBA-15 with varying Si/Al ratios are also compared. The reasons for the different performances of the different materials are discussed, where the mesopores, high acid density and strength are observed to play the most critical role. This work might provide a basis for the synthesis of mesoporous rich metal-substituted silica materials for different catalytic applications.

A reactive neural network framework for water-loaded acidic zeolites

Under operating conditions, the dynamics of water and ions confined within protonic aluminosilicate zeolite micropores are responsible for many of their properties, including hydrothermal stability, acidity and catalytic activity. However, due to high computational cost, operando studies of acidic zeolites are currently rare and limited to specific cases and simplified models. In this work, we have developed a reactive neural network potential (NNP) attempting to cover the entire class of acidic zeolites, including the full range of experimentally relevant water concentrations and Si/Al ratios. This NNP has the potential to dramatically improve sampling, retaining the (meta)GGA DFT level accuracy, with the capacity for discovery of new chemistry, such as collective defect formation mechanisms at the zeolite surface. Furthermore, we exemplify how the NNP can be used as a basis for further extensions/improvements which include data-efficient adoption of higher-level (hybrid) references via Δ-learning and the acceleration of rare event sampling via automatic construction of collective variables. These developments represent a significant step towards accurate simulations of realistic catalysts under operando conditions.

Conversion of Polypropylene into Light Hydrocarbons and Aromatics by Metal Exchanged Zeolite Catalysts

Polyolefins can be converted into C2-C5 hydrocarbons and benzene-toluene-xylene (BTX) aromatics as high-demand petrochemical feedstocks via catalytic pyrolysis on acidic zeolites. Bro̷nsted and Lewis acid sites are responsible for cracking polyolefins into olefins and subsequent aromatic formation. In this study, we have subjected the parent HZSM-5 zeolite to postsynthetic partial metal exchange with Fe, Co, Ni, Cu, and Ce cations to perturb Bro̷nsted/Lewis acidity. We have investigated these metal-modified HZSM-5 on the catalytic pyrolysis of polypropylene (PP) in a micropyrolyzer connected to a two-dimensional gas chromatograph coupled to a time-of-flight mass spectrometer and flame ionization detector (Tandem Pyrolyzer-GC × GC-TOF-MS/FID setup). Whereas Fe-, Co-, Cu-, and Ce-exchanged zeolites (with 2.5, 2.3, 1.9, and 0.8 wt % metal, respectively) had comparable product yields with the parent zeolite, Ni-exchanged zeolites with Ni content of 0.5 to 2 wt % were associated with enhanced BTX formation (28-38 wt %) compared to that of the parent zeolite (22 wt %). Pyridine-FTIR indicated that the Bro̷nsted/Lewis acid ratio of the parent zeolite decreased upon metal ion exchange. According to Pyridine-TPD, the parent zeolite's medium-strength acid sites were redistributed into weak and strong acid sites in Ni-exchanged zeolites. The higher amount of carbon deposits on Ni-exchanged zeolites compared to the parent and other metal ion exchanged zeolites was attributed to the enhanced aromatization activity by the simultaneous decrease in the Bro̷nsted/Lewis acid ratio and emergence of strong acid sites.

Formation of a Porous Crystalline Mg1-xAl2Oy Overlayer on Metal Catalysts via Controlled Solid-State Reactions for High-temperature Stable Catalysis

Catalyst deactivation by sintering and coking is a long-standing issue in metal-catalyzed harsh high-temperature hydrocarbon reactions. Ultrathin oxide coatings of metal nanocatalysts have recently appeared attractive to address this issue, while the porosity of the overlayer is difficult to control to preserve the accessibility of embedded metal nanoparticles, thus often leading to a large decrease in activity. Here, we report that a nanometer-thick alumina coating of MgAl2O4-supported metal catalysts followed by high-temperature reduction can transform a nonporous amorphous alumina overlayer into a porous Mg1-xAl2Oy crystalline spinel structure with a pore size of 2-3 nm and weakened acidity. The high porosity stems from the restrained Mg migration from the MgAl2O4 support to the alumina overlayer through solid-state reactions at high temperatures. The resulting Ni/MgAl2O4 and Pt/MgAl2O4 catalysts with a porous crystalline Mg1-xAl2Oy overlayer achieved remarkably high stability while preserving much higher activity than the corresponding alumina-coated Ni and Pt catalysts on MgO and Al2O3 supports in the reactions of dry reforming of methane and propane dehydrogenation, respectively.

The refinery of the future

Fossil fuels-coal, oil and gas-supply most of the world's energy and also form the basis of many products essential for everyday life. Their use is the largest contributor to the carbon dioxide emissions that drive global climate change, prompting joint efforts to find renewable alternatives that might enable a carbon-neutral society by as early as 2050. There are clear paths for renewable electricity to replace fossil-fuel-based energy, but the transport fuels and chemicals produced in oil refineries will still be needed. We can attempt to close the carbon cycle associated with their use by electrifying refinery processes and by changing the raw materials that go into a refinery from fossils fuels to carbon dioxide for making hydrocarbon fuels and to agricultural and municipal waste for making chemicals and polymers. We argue that, with sufficient long-term commitment and support, the science and technology for such a completely fossil-free refinery, delivering the products required after 2050 (less fuels, more chemicals), could be developed. This future refinery will require substantially larger areas and greater mineral resources than is the case at present and critically depends on the capacity to generate large amounts of renewable energy for hydrogen production and carbon dioxide capture.

Enhanced Bio-BTX Formation by Catalytic Pyrolysis of Glycerol with In Situ Produced Toluene as the Cofeed

The catalytic coconversion of glycerol and toluene (93/7 wt %) over a technical H-ZSM-5/Al2O3 (60-40 wt %) catalyst was studied, aiming for enhanced production of biobased benzene, toluene, and xylenes (bio-BTX). When using glycerol/toluene cofeed with a mass ratio of 93/7 wt %, a peak BTX carbon yield of 29.7 ± 1.1 C.% (at time on stream (TOS) of 1.5-2.5 h), and an overall BTX carbon yield of 28.7 C.% (during TOS of 8.5 h) were obtained, which are considerably higher than those (19.1 ± 0.4 C.% and 11.0 C.%) for glycerol alone. Synergetic effects when cofeeding toluene on the peak and overall BTX carbon yields were observed and quantified, showing a relative increase of 3.1% and 30.0% for the peak and overall BTX carbon yield (based on the feedstock). These findings indicate that the strategy of cofeeding in situ produced toluene for the conversion of glycerol to aromatics has potential to increase BTX yields. In addition, BTX production on the catalyst (based on the fresh catalyst during the first run for TOS of 8.5 h and without regeneration) is significantly improved to 0.547 ton ton-1catalyst (excluding the 76% of toluene product that is 0.595 ton ton-1catalyst for the recycle in the cofeed) for glycerol/toluene cofeed, which was 0.426 ton ton-1catalyst for glycerol alone. In particular, this self-sufficient toluene product recycling strategy is advantageous for the production and selectivity (relative increase of 84.4% and 43.5% during TOS of 8.5 h) of biobased xylenes.

Constrained and Open Mesoporosity in Polypropylene Cracking: Insight From Spectroscopic Investigations of Acidity, Diffusion, and Activity

The outcome of the demetalation process of zeolites depends on applied treatment conditions and can lead to the formation of either open or constrained mesopores. The quaternary ammonium cations as pore-directing agents during desilication are responsible for developing constrained mesoporosity with bottleneck entrances. However, higher mesopore surface area and higher accessibility of acid sites are often found for the hierarchical zeolites with constrained mesopores. This is followed by better catalytic activity in the cracking of vacuum gas oil and polymers. For desilication with pure NaOH, a realumination process is observed and an additional acid-wash step is required to reach their full catalytic potential. Thus, this study aims to analyze the acidic and catalytic properties of hierarchical ZSM-5 zeolites of different mesoporosity types employing in situ and operando FT-IR spectroscopic evaluation of polypropylene cracking. The suitability of constrained mesoporosity is studied by assessing the neopentane diffusion in kinetic adsorption, Monte Carlo calculations, and rapid scan FT-IR spectroscopic measurement analyzed by Crank solution for diffusion. The FT-IR spectroscopic results of in situ and operando studies are supported by two-dimensional correlation analysis, allowing to establish the direction of changes seen on spectra and their order.

Water structures on acidic zeolites and their roles in catalysis

The local reaction environment of catalytic active sites can be manipulated to modify the kinetics and thermodynamic properties of heterogeneous catalysis. Because of the unique physical-chemical nature of water, heterogeneously catalyzed reactions involving specific interactions between water molecules and active sites on catalysts exhibit distinct outcomes that are different from those performed in the absence of water. Zeolitic materials are being applied with the presence of water for heterogeneous catalytic reactions in the chemical industry and our transition to sustainable energy. Mechanistic investigation and in-depth understanding about the behaviors and the roles of water are essentially required for zeolite chemistry and catalysis. In this review, we focus on the discussions of the nature and structures of water adsorbed/stabilized on Brønsted and Lewis acidic zeolites based on experimental observations as well as theoretical calculation results. The unveiled functions of water structures in determining the catalytic efficacy of zeolite-catalyzed reactions have been overviewed and the strategies frequently developed for enhancing the stabilization of zeolite catalysts are highlighted. Recent advancement will contribute to the development of innovative catalytic reactions and the rationalization of catalytic performances in terms of activity, selectivity and stability with the presence of water vapor or in condensed aqueous phase.

Recycling of Spent FCC Catalysts: Conversion of Leached Residues to Zeolite ZSM-5

The commercial recycling of spent FCC catalyst typically focuses on recovering only 1-3 % of rare-earth elements, with the remaining residues often disposed of in landfills. Here, we present a novel method to close a recycling loop for spent FCC catalyst. The method involves a series of leaching steps: Firstly, the spent catalyst material is leached with HNO3 to remove rare-earth elements such as La; second, solvothermal leaching with HCl removes most of Al and impurities like Fe, Ni and V; finally, a third leaching with H2SO4 removes Ti. The solid residues are then used to synthesize ZSM-5 without the addition of any extra silicon or aluminum sources after mild activation. The impurities in the synthesis gel strongly modify the properties of the zeolite, with ZSM-5 crystals containing higher levels of impurities exhibiting lower crystallinities, surface areas, acidities, cracking activities, as well as larger particle sizes.

An insight into REEs recovery from spent fluorescent lamps: Evaluation of the affinity of an NH4-13X zeolite towards Ce, La, Eu and Y

The constantly increasing demand of Rare Earth Elements (REEs) made them to be part of the so-called "critical elements" indispensable for the energy transition. The monopoly of only a few countries, the so-called balance problem between demand and natural abundance, and the need to limit the environmental costs of their mining, stress the necessity of a recycling policy of these elements. Different methods have been tested for REEs recovery. Despite the well-known ion-exchange properties of zeolites, just few preliminary works investigated their application for REEs separation and recycle. In this work we present a double ion exchange experiment on a NH4-13X zeolite, aimed at the recovery of different REEs from solutions mimicking the composition of liquors obtained from the leaching of spent fluorescent lamps. The results showed that the zeolite was able to exchange all the REEs tested, but the exchange capacity was different: despite Y being the more concentrated REE in the solutions, the cation exchange was lower than less concentrated ones (16 atoms p.u.c. vs 21 atoms for Ce and La solutions), suggesting a possible selectivity. In order to recover REEs from the zeolite, a second exchange with an ammonium solution was performed. The analyses of the zeolites show that almost all of Ce and Eu remain in the zeolite, while nearly half of La and Y are released. This, once again, suggests a possible selective release of REEs and open the possibility for a recovery process in which Rare Earths can be effectively separated.

Catalytic Strategies for the Upcycling of Polyolefin Plastic Waste

Chemical upgrading of waste plastics is currently one of the most important methods for addressing plastic pollution. In comparison to the current methods of incineration or landfill, chemical upgrading enables the utilization of carbon and hydrogen elements in waste plastics as resources. This process strongly relies on efficient catalysts and reaction systems. Through catalyst design, waste plastics can be converted into fuels or chemicals under the optimized reaction conditions, extending their life cycles. In this review, we systematically discuss various chemical conversion methods for polyolefin waste plastics, which account for a large proportion of waste plastics. We further explore the remaining challenges and future development trends in this field, including improving product value through product engineering and shifting research perspectives to exploring the tolerance of catalysts toward impurities in practical waste plastic waste rather than using pure plastic feedstock.

Study on the Regeneration of Waste FCC Catalyst by Boron Modification

Regeneration has been considered as an ideal way for the post-treatment of waste FCC catalyst (ECat). In this work, the degeneration mechanism of ECat was firstly researched and attributed to the increasing of strong acid sites accessibility of ECat in contrast with fresh FCC catalyst by adsorption FTIR. Based on the proposed degeneration mechanism, ECat was successfully regenerated through suitable weakening for strong acid sites by boron modification. Characterization and evaluation results suggested that, the strong acid sites of regenerated ECat (R-ECat) were apparently decreased by boron modification which had significantly improve the heavy oil catalytic cracking performance of R-ECat. Because of the excellent performance, R-ECat in this work could successfully substitute for partial fresh FCC catalyst in FCC unit, which would provide a practicable way for the reutilization of ECat.

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.

One-Shot Dual-Detection-Based Single-Molecule Super-Resolution Imaging Method for Real-Time Observation of Spatiotemporal Catalytic Activity Variations on the Plasmonic Gold Nanoparticle Surface

Understanding the relationship between the surface properties of a single plasmonic nanoparticle and its catalytic performance is critical for developing highly efficient nanocatalysts. In this study, a one-shot dual-detection-based single-molecule super-resolution imaging method in the evanescent field was developed to observe real-time spatiotemporal catalytic activity on a single plasmonic gold nanoparticle (AuNP) surface. The scattering intensity of AuNPs and the fluorescence of resorufin molecules produced on the AuNP surface were obtained simultaneously to investigate the relationship between nanoparticles and catalytic reactions at a single-molecule level. Chemisorbed adsorbates (i.e., catalytic product and resorufin) changed the electron density of individual AuNPs throughout the catalytic cycle, resulting in the fluctuation of the scattering intensity of individual AuNPs, which was attributed to the electron transfer between reactant resazurin molecules and AuNPs. The increase in the electron density of individual AuNPs affected the catalytic reaction rate. Furthermore, sequential mapping of individual catalytic events at the subdiffraction limit resolution was completed for real-time surface dynamics and spatiotemporal activity variations on the single AuNP surface. The developed method can aid in understanding surface-property-dependent catalytic kinetics and facilitate the development of nanoparticle-based heterogeneous catalysts at subdiffraction limit resolution.

Bioseparation of rare earth elements and high value-added biomaterials applications

Rare earth elements (REEs) are a group of critical minerals and extensively employed in new material manufacturing. However, separation of lanthanides is difficult because of their similar chemical natures. Current lanthanide leaching and separation methods require hazardous compounds, resulting in severe environmental concerns. Bioprocessing of lanthanides offers an emerging class of tools for REE separation due to mild leaching conditions and highly selective separation scenarios. In the course of biopreparation, engineered microbes not only dissolve REEs from ores but also allow for selective separation of the lanthanides. In this review, we present an overview of recent advances in microbes and proteins used for the biomanufacturing of lanthanides and discuss high value-added applications of REE-derived biomaterials. We begin by introducing the fundamental interactions between natural microbes and REEs. Then we discuss the rational design of chassis microbes for bioleaching and biosorption. We also highlight the investigations on REE binding proteins and their applications in the synthesis of high value-added biomaterials. Finally, future opportunities and challenges for the development of next generation lanthanide-binding biological systems are discussed.

Rare Earths-The Answer to Everything

Rare earths, scandium, yttrium, and the fifteen lanthanoids from lanthanum to lutetium, are classified as critical metals because of their ubiquity in daily life. They are present in magnets in cars, especially electric cars; green electricity generating systems and computers; in steel manufacturing; in glass and light emission materials especially for safety lighting and lasers; in exhaust emission catalysts and supports; catalysts in artificial rubber production; in agriculture and animal husbandry; in health and especially cancer diagnosis and treatment; and in a variety of materials and electronic products essential to modern living. They have the potential to replace toxic chromates for corrosion inhibition, in magnetic refrigeration, a variety of new materials, and their role in agriculture may expand. This review examines their role in sustainability, the environment, recycling, corrosion inhibition, crop production, animal feedstocks, catalysis, health, and materials, as well as considering future uses.

Fluorescent-Probe Characterization for Pore-Space Mapping with Single-Particle Tracking

Porous solids often contain complex pore networks with pores of various sizes. Tracking individual fluorescent probes as they diffuse through porous materials can be used to characterize pore networks at tens of nanometers resolution. However, understanding the motion behavior of fluorescent probes in confinement is crucial to reliably derive pore network properties. Here, we introduce well-defined lithography-made model pores developed to study probe behavior in confinement. We investigated the influence of probe-host interactions on diffusion and trapping of confined single-emitter quantum-dot probes. Using the pH-responsiveness of the probes, we were able to largely suppress trapping at the pore walls. This enabled us to define experimental conditions for mapping of the accessible pore space of a one-dimensional pore array as well as a real-life polymerization-catalyst-support particle.

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.

Crystal-Phase Engineering in Heterogeneous Catalysis

The performance of a chemical reaction is critically dependent on the electronic and/or geometric structures of a material in heterogeneous catalysis. Over the past century, the Sabatier principle has already provided a conceptual framework for optimal catalyst design by adjusting the electronic structure of the catalytic material via a change in composition. Beyond composition, it is essential to recognize that the geometric atomic structures of a catalyst, encompassing terraces, edges, steps, kinks, and corners, have a substantial impact on the activity and selectivity of a chemical reaction. Crystal-phase engineering has the capacity to bring about substantial alterations in the electronic and geometric configurations of a catalyst, enabling control over coordination numbers, morphological features, and the arrangement of surface atoms. Modulating the crystallographic phase is therefore an important strategy for improving the stability, activity, and selectivity of catalytic materials. Nonetheless, a complete understanding of how the performance depends on the crystal phase of a catalyst remains elusive, primarily due to the absence of a molecular-level view of active sites across various crystal phases. In this review, we primarily focus on assessing the dependence of catalytic performance on crystal phases to elucidate the challenges and complexities inherent in heterogeneous catalysis, ultimately aiming for improved catalyst design.

Current State and Perspectives of Exfoliated Zeolites

Zeolites are highly efficient industrial catalysts and sorbents with microporous framework structures. Approximately 10% of the frameworks, but eventually all in the long run, have produced both 3D crystals and 2D layers. The latter can be intercalated and expanded like all 2D materials but proved difficult to exfoliate directly into suspensions of monolayers in solution as precursors for unique synthetic opportunities. Successful exfoliations have been reported recently and are overviewed in this perspective article. The discussion highlights 3 primary challenges in this field, namely finding suitable 2D zeolite preparations that exfoliate directly in high yield, proving uniform layer thickness in solution and identifying applications to exploit the unique synthetic capabilities and properties of exfoliated zeolite monolayers. Four zeolites have been confirmed to exfoliate directly into monolayers: 3 with known structures-MWW, MFI, and RWR and one unknown, bifer with a unit cell close to ferrierite. The exfoliation into monolayers is confirmed by the combination of 5-6 characterization techniques including AFM, in situ and in-plane XRD, and microscopies. The promising areas of development are oriented films and membranes, intimately mixed zeolite phases, and hierarchical nanoscale composites with other active species like nanoparticles and clusters that are unfeasible by solid state processes.

Acidity: A Key Parameter in Zeolite-Templated Carbon Formation

This work reveals the crucial role of zeolite acidity in the synthesis of zeolite-templated carbons (ZTCs). While textural and chemical properties appear to be independent from acidity at a given synthesis temperature, the spin concentration in hybrid materials appears to be strongly impacted by the zeolite acid site concentration. The electrical conductivity of the hybrids and resulting ZTCs are closely related to the spin concentration in the hybrid materials. The amount of zeolite acid sites hence fundamentally impacts the electrical conductivity of the samples that spans over a range of four magnitudes. Electrical conductivity reveals as key parameter to describe the quality of ZTCs.

Transport limitations in polyolefin cracking at the single catalyst particle level

Catalytic cracking is a promising approach to chemically recycle polyolefins by converting them into smaller hydrocarbons like naphtha, and important precursors of various platform chemicals, such as aromatics. Cracking catalysts, commonly used in the modern refinery and petrochemical industry, are tailored to process gaseous or liquid feedstock. Polyolefins, however, are very large macromolecules that form highly viscous melts at the temperatures required to break their backbone C-C bonds. Therefore, mass transport is expected to limit the performance of traditional cracking catalysts when applied to the conversion of polymers. In this work, we study these effects during the cracking of polypropylene (PP) over catalysts utilized in the fluid catalytic cracking (FCC) process. Thermogravimetric experiments using PP of varying molecular weight (Mw) and catalysts of varying accessibility showed that low Mw model polymers can be cracked below 275 °C, while PP of higher Mw required a 150 °C higher temperature. We propose that this difference is linked to different degrees of mass transport limitations and investigated this at length scales ranging from milli- to nanometers, utilizing in situ optical microscopy and electron microscopy to inspect cut open catalyst-polymer composites. We identified the main cause of transport limitations as the significantly higher melt viscosity of high Mw polymers, which prohibits efficient catalyst-polymer contact. Additionally, the high Mw polymer does not enter the inner pore system of the catalyst particles, severely limiting utilization of the active sites located there. Our results demonstrate that utilizing low Mw polymers can lead to a significant overestimation of catalyst activity, and suggest that polyolefins might need to undergo a viscosity reducing pre-treatment in order to be cracked efficiently.

Direct Detection of Paired Aluminum Heteroatoms in Chabazite Zeolite Catalysts and Their Significance for Methanol Dehydration Reactivity

The distributions of heteroatoms within zeolite frameworks have important influences on the locations of exchangeable cations, which account for the diverse adsorption and reaction properties of zeolite catalysts. In particular for aluminosilicate zeolites, paired configurations of aluminum atoms separated by one or two tetrahedrally coordinated silicon atoms are important for charge-balancing pairs of H+ cations, which are active for methanol dehydration, or divalent metal cations, such as Cu2+, which selectively catalyze the reduction of NOx, both technologically important reactions. Such paired heteroatom configurations, however, are challenging to detect and probe, due to the typically nonstoichiometric compositions and nonperiodic distributions of aluminum atoms within aluminosilicate zeolite frameworks. Nevertheless, distinct configurations of paired framework aluminum atoms are unambiguously detected and resolved in solid-state 2D 27Al-29Si and 29Si-29Si NMR spectra, which are sensitive to the local environments of covalently bonded 27Al-O-29Si and 29Si-O-29Si moieties, respectively. Specifically, two H+-chabazite zeolites with the same bulk framework aluminum contents are shown to have different types and populations of closely paired aluminum species, which correlate with higher activity for methanol dehydration. The methodologies and insights are expected to be broadly applicable to analyses of heteroatom sites, their distributions, and adsorption and reaction properties in other zeolite framework types.

Dynamic Behavior of Droplet Impact on Laminar Superheated Particles

The impact of droplets on particles involves a wide range of complex phenomena and mechanisms, including bubble nucleation, crater formation, fluidization, and more intricate changes in the boiling regime when impacting superheated particles. In this study, we focus on droplet impact behavior on superheated laminar particles at various temperatures and define six typical characteristic patterns of a single droplet impact on superheated laminar particles, including film evaporation, bubbly boiling, immersion boiling, sputter boiling, transition boiling, and film boiling. It is worth noting that the variations of inertial force FI caused by gravity, the capillary force FC generated by the pores of the droplets, and the dewetting force by the vapor phase FV are the main contributors to different evaporation regimes. Interestingly, we find that the Leidenfrost point (LFP) of droplets on the laminar superheated particles decreases with particle size, which is related to the effect of the pore space generated between the laminar particles. Finally, the effect of temperature, particle size, and Weber number (We) on the dynamic behavior of droplet impact is revealed. Experimental results show that the instantaneous diameter of droplets is inversely proportional to the change of height, with different patterns of maximum spreading diameter and maximum bounce height at different particle sizes, while the maximum spreading velocity and maximum bounce velocity are independent of particle size. We believe the present work would provide a broader knowledge and comprehension of the droplet impact on heated particles and promote the development of the safety and productivity of industrial processes such as fluid catalytic cracking, spray drying, and spray cooling.

Approaching High-Performance TS-1 Zeolites in the Presence of Alkali Metal Ions via Combination of Adjusting pH Value and Modulating Crystal Size

Lewis acid zeolites play an important role in industrially important green reactions closely related to fine chemical and biomass conversion. Titanium-doped TS-1 zeolite is a milestone Lewis acid zeolite widely used in industrially significant green oxidation processes with hydrogen peroxide as an oxidant under mild conditions. TS-1 zeolites are normally synthesized in basic conditions under hydrothermal treatment. Up to now, there has still been no success in synthesizing active TS-1 Lewis acid zeolites by using inorganic alkali, e.g., NaOH or KOH as base, which is cheaper and more stable compared to the quaternary ammonium hydroxide or organic amines used in traditional synthesis. Here, an inorganic base of NaOH was employed in synthesizing active TS-1 zeolites for the first time. The crucial factor was the control of adverse effects of sodium cations on the incorporation of active titanium cations. Higher catalytic activity was achieved by further reducing the size of the TS-1 crystal by using the seed-added strategy, which uses the catalytic activity of a commercial catalyst, the production cost being much lower than commercial TS-1 catalysts, indicating great commercial potential and the possibility of preparing other cheap Lewis acid catalysts by using inorganic alkali.

A facile strategy to prepare ZSM-5-based composites with enhanced light olefin selectivity and stability in the HTO process

In this study, the influence of different ZSM-5 composite materials (ASA, γ-alumina, η-Al₂O₃, SiO₂, and attapulgite) and their performance in the n-hexane catalytic cracking process in a fixed bed microreactor at 550 °C under atmospheric pressure was studied. XRD, FT-IR spectroscopy, NH₃-TPD, BET, FE-SEM, and TG analyses were performed to characterize the catalysts. The result of the n-hexane to olefin process indicated that the A2 catalyst (γ-alumina composition with ZSM-5) showed the highest conversion of 98.89%, highest propylene selectivity of 68.92%, highest yield of light olefins of 83.84%, and highest propylene to ethylene ratio of 4.34. The reason for the significant increase in all these factors and the lowest amount of coke in this catalyst is the use of γ-alumina, which increased the hydrothermal stability and resistance to deactivation, improved the acidic properties with a strong to weak acid ratio of 0.382, and increased the mesoporosity to 0.242. This study indicates the effect of the extrusion process and the composition and the major effect of the properties of this material on the physicochemical properties and distribution of the product.

Machine learning-assisted crystal engineering of a zeolite

It is shown that Machine Learning (ML) algorithms can usefully capture the effect of crystallization composition and conditions (inputs) on key microstructural characteristics (outputs) of faujasite type zeolites (structure types FAU, EMT, and their intergrowths), which are widely used zeolite catalysts and adsorbents. The utility of ML (in particular, Geometric Harmonics) toward learning input-output relationships of interest is demonstrated, and a comparison with Neural Networks and Gaussian Process Regression, as alternative approaches, is provided. Through ML, synthesis conditions were identified to enhance the Si/Al ratio of high purity FAU zeolite to the hitherto highest level (i.e., Si/Al = 3.5) achieved via direct (not seeded), and organic structure-directing-agent-free synthesis from sodium aluminosilicate sols. The analysis of the ML algorithms' results offers the insight that reduced Na₂O content is key to formulating FAU materials with high Si/Al ratio. An acid catalyst prepared by partial ion exchange of the high-Si/Al-ratio FAU (Si/Al = 3.5) exhibits improved proton reactivity (as well as specific activity, per unit mass of catalyst) in propane cracking and dehydrogenation compared to the catalyst prepared from the previously reported highest Si/Al ratio (Si/Al = 2.8).

Turning Polyethylene Waste to Hydrocarbons Using a Sustainable Acidic Carbocatalyst

Careless release of plastic waste is a pressing problem for marine and other eco-environments, and materials recycling of this stream is an open problem. For this purpose, a new metal-free acidic carbocatalyst with 8 wt % sulfur is constructed from a side product of the paper industry namely Na-lignosulfonate. The catalyst shows an extraordinary performance for the fragmentation of polymer waste which smoothly occurs above the ceiling temperature of the polymers. The reaction is run without hydrogen and at ambient pressure with commercially available high-density polyethylene (HDPE) as well as a real polymer waste mixture of high and low-density polyethylene (HDPE, LDPE). In all cases, a homologous series of n-alkanes and n-alkenes are obtained. The unique sulfur-rich carbonaceous structure (transfer hydrogenation functionality) and the metal-free character of the acidic carbocatalyst makes it inert against many typical catalyst poisons, among them water, salt, polar functionalities, and sulfur species. The described performance in plastic recycling, as well as the low cost and large-scale availability of lignosulfonate from the pulp industry, makes this metal-free acidic carbocatalyst promising for real-life environmental applications.

Synergism between hierarchical MFI zeolites and alumina in alkene cross-metathesis reactions as a function of composition

Synergism between hierarchical zeolites and alumina in the preparation of active Mo catalysts, as a function of composition ratios, has been demonstrated in the cross-metathesis reaction between ethene and 2-butene. The metathesis reaction activity, reflected by ethene conversion, increases from 24.1% to 49.2% with the increase in the alumina content in composites from 10 wt% to 30 wt%. A further increase in the alumina content leads to the reduction in the metathesis activity, in which the ethene conversion decreases from 30.3% to 4.8% upon the enhanced alumina content from 50 wt% to 90 wt%. The impact of alumina content on the metathesis activity is closely associated with the interaction mode between the hierarchical ZSM-5 zeolite and alumina. TEM observation as well as EDS analysis and XPS results prove the progressive coating of alumina phase on the surface of zeolites along with the progressive enhancement of alumina content. The moderate alumina content in the composite enables the desired interaction between hierarchical zeolites and alumina, which is beneficial for the preparation of active catalysts for the alkene cross-metathesis reaction.

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.

Mechanistic Insights Gained by High Spatial Resolution Reactivity Mapping of Homogeneous and Heterogeneous (Electro)Catalysts

The recent development of high spatial resolution microscopy and spectroscopy tools enabled reactivity analysis of homogeneous and heterogeneous (electro)catalysts at previously unattainable resolution and sensitivity. These techniques revealed that catalytic entities are more heterogeneous than expected and local variations in reaction mechanism due to divergences in the nature of active sites, such as their atomic properties, distribution, and accessibility, occur both in homogeneous and heterogeneous (electro)catalysts. In this review, we highlight recent insights in catalysis research that were attained by conducting high spatial resolution studies. The discussed case studies range from reactivity detection of single particles or single molecular catalysts, inter- and intraparticle communication analysis, and probing the influence of catalysts distribution and accessibility on the resulting reactivity. It is demonstrated that multiparticle and multisite reactivity analyses provide unique knowledge about reaction mechanism that could not have been attained by conducting ensemble-based, averaging, spectroscopy measurements. It is highlighted that the integration of spectroscopy and microscopy measurements under realistic reaction conditions will be essential to bridge the gap between model-system studies and real-world high spatial resolution reactivity analysis.

Droplet microreactor for high-throughput fluorescence-based measurements of single catalyst particle acidity

The particles of heterogeneous catalysts differ greatly in size, morphology, and most importantly, in activity. Studying these catalyst particles in batch typically results in ensemble averages, without any information at the level of individual catalyst particles. To date, the study of individual catalyst particles has been rewarding but is still rather slow and often cumbersome¹. Furthermore, these valuable in-depth studies at the single particle level lack statistical relevance. Here, we report the development of a droplet microreactor for high-throughput fluorescence-based measurements of the acidities of individual particles in fluid catalytic cracking (FCC) equilibrium catalysts (ECAT). This method combines systematic screening of single catalyst particles with statistical relevance. An oligomerization reaction of 4-methoxystyrene, catalyzed by the Brønsted acid sites inside the zeolite domains of the ECAT particles, was performed on-chip at 95 °C. The fluorescence signal generated by the reaction products inside the ECAT particles was detected near the outlet of the microreactor. The high-throughput acidity screening platform was capable of detecting ~1000 catalyst particles at a rate of 1 catalyst particle every 2.4 s. The number of detected catalyst particles was representative of the overall catalyst particle population with a confidence level of 95%. The measured fluorescence intensities showed a clear acidity distribution among the catalyst particles, with the majority (96.1%) showing acidity levels belonging to old, deactivated catalyst particles and a minority (3.9%) exhibiting high acidity levels. The latter are potentially of high interest, as they reveal interesting new physicochemical properties indicating why the particles were still highly acidic and reactive.

Molecular Views on Mechanisms of Brønsted Acid-Catalyzed Reactions in Zeolites

The Brønsted acidity of proton-exchanged zeolites has historically led to the most impactful applications of these materials in heterogeneous catalysis, mainly in the fields of transformations of hydrocarbons and oxygenates. Unravelling the mechanisms at the atomic scale of these transformations has been the object of tremendous efforts in the last decades. Such investigations have extended our fundamental knowledge about the respective roles of acidity and confinement in the catalytic properties of proton exchanged zeolites. The emerging concepts are of general relevance at the crossroad of heterogeneous catalysis and molecular chemistry. In the present review, emphasis is given to molecular views on the mechanism of generic transformations catalyzed by Brønsted acid sites of zeolites, combining the information gained from advanced kinetic analysis, in situ, and operando spectroscopies, and quantum chemistry calculations. After reviewing the current knowledge on the nature of the Brønsted acid sites themselves, and the key parameters in catalysis by zeolites, a focus is made on reactions undergone by alkenes, alkanes, aromatic molecules, alcohols, and polyhydroxy molecules. Elementary events of C-C, C-H, and C-O bond breaking and formation are at the core of these reactions. Outlooks are given to take up the future challenges in the field, aiming at getting ever more accurate views on these mechanisms, and as the ultimate goal, to provide rational tools for the design of improved zeolite-based Brønsted acid catalysts.

Methane Oxidation over the Zeolites-Based Catalysts

Zeolites have ordered pore structures, good spatial constraints, and superior hydrothermal stability. In addition, the active metal elements inside and outside the zeolite framework provide the porous material with adjustable acid–base property and good redox performance. Thus, zeolites-based catalysts are more and more widely used in chemical industries. Combining the advantages of zeolites and active metal components, the zeolites-based materials are used to catalyze the oxidation of methane to produce various products, such as carbon dioxide, methanol, formaldehyde, formic acid, acetic acid, and etc. This multifunction, high selectivity, and good activity are the key factors that enable the zeolites-based catalysts to be used for methane activation and conversion. In this review article, we briefly introduce and discuss the effect of zeolite materials on the activation of C–H bonds in methane and the reaction mechanisms of complete methane oxidation and selective methane oxidation. Pd/zeolite is used for the complete oxidation of methane to carbon dioxide and water, and Fe- and Cu-zeolite catalysts are used for the partial oxidation of methane to methanol, formaldehyde, formic acid, and etc. The prospects and challenges of zeolite-based catalysts in the future research work and practical applications are also envisioned. We hope that the outcome of this review can stimulate more researchers to develop more effective zeolite-based catalysts for the complete or selective oxidation of methane.

Unusual Acid Sites in LSX Zeolite: Formation Features and Physico-Chemical Properties

The advanced approach for the preparation of the NH₄ form of highly crystalline LSX zeolite under gentle drying conditions (40 °C, membrane pump dynamic vacuum) is discussed. Decationization of this form at moderate temperatures led to the formation of Brønsted acid sites (BASs), whose concentration and strength were characterized by IR spectroscopy. It was found that a maximum concentration of three BASs per unit cell can be achieved at 200 °C prior to the initiation of zeolite structure degradation. The proton affinity of BASs is unusual, and aspires 1240 kJ/mol, which is significantly higher compared to faujasites with higher moduli. The increase in temperature of the heat treatment (up to 300 °C) resulted in thermal decomposition of BASs and the manifestation of amorphous phase with corresponding Lewis acid sites (LASs) as well as terminal Si-OH groups. Both the destruction of BASs and formation of the LAS-containing amorphous phase are the key reasons for the significant decrease in the adsorption capacity in the micropore region revealed for the sample decationized at 300 °C.

Tunable hybrid zeolites prepared by partial interconversion

Zeolite interconversion is a widely used strategy due to its unique advantages in the synthesis of some zeolites. By using a long-chain quaternary amine as both a structure-directing agent and porogen, we have produced superior catalysts, which we named Hybrid Zeolites, as their structures are made of building units of different zeolite types. The properties of these materials can be conveniently tuned, and their catalytic performance can be optimized simply by stopping the interconversion at different times. For cracking the 1,3,5-triisopropylbenzene, Hybrid Zeolites made of FAU and MFI units show a 5-fold increase in selectivity towards the desired product, that is, 1,3-diisopropylbenzene, compared to the commercial FAU, and a 7-fold increase in conversion at constant selectivity compared to MFI zeolite.

Conceptual and Practical Aspects of Metal-Organic Frameworks for Solid-Gas Reactions

The presence of site-isolated and well-defined metal sites has enabled the use of metal-organic frameworks (MOFs) as catalysts that can be rationally modulated. Because MOFs can be addressed and manipulated through molecular synthetic pathways, they are chemically similar to molecular catalysts. They are, nevertheless, solid-state materials and therefore can be thought of as privileged solid molecular catalysts that excel in applications involving gas-phase reactions. This contrasts with homogeneous catalysts, which are overwhelmingly used in the solution phase. Herein, we review theories dictating gas phase reactivity within porous solids and discuss key catalytic gas-solid reactions. We further treat theoretical aspects of diffusion within confined pores, the enrichment of adsorbates, the types of solvation spheres that a MOF might impart on adsorbates, definitions of acidity/basicity in the absence of solvent, the stabilization of reactive intermediates, and the generation and characterization of defect sites. The key catalytic reactions we discuss broadly include reductive reactions (olefin hydrogenation, semihydrogenation, and selective catalytic reduction), oxidative reactions (oxygenation of hydrocarbons, oxidative dehydrogenation, and carbon monoxide oxidation), and C-C bond forming reactions (olefin dimerization/polymerization, isomerization, and carbonylation reactions).

Catalytic removal of 2-butanone with ozone over porous spent fluid catalytic cracking catalyst

To remove harmful volatile organic compounds (VOCs) including 2-butanone (methyl ethyl ketone, MEK) emitted from various industrial plants is very important for the clean air. Also, it is worthwhile to recycle porous spent fluid catalytic cracking (SFCC) catalysts from various petroleum refineries in terms of reducing industrial waste and the reuse of discharged resources. Therefore, Mn and Mn-Cu added SFCC (Mn/SFCC and Mn-Cu/SFCC) catalysts were prepared to compare their catalytic efficiencies together with the SFCC catalyst in the ozonation of 2-butanone. Since the SFCC-based catalysts have a structure similar to that of zeolite Y (Y), the Mn-loaded zeolite Y catalyst (Mn/Y) was also prepared to compare its activity for the removal of 2-butanone and ozone to that of the SFCC-based ones at room temperature. Among the five catalysts of this study (Y, Mn/Y, SFCC, Mn/SFCC, and Mn-Cu/SFCC), the Mn-Cu/SFCC and Mn/SFCC catalysts showed the better catalytic decomposition activity than the others. The increased distributions of the Mn³⁺ species and the O_vacancy sites in Mn/SFCC and Mn-Cu/SFCC catalysts which could supply more available active sites for the 2-butanone and ozone removal would enhance the catalytic activity of them.

Source and composition analysis of petroleum hydrocarbons in the refinery circulating water

Oil leakage from water coolers in refinery circulating water occurs from time to time, which affects the long-term and stable operation of refinery units. So far, workers in the refineries still adopt manual check methods, opening water coolers one by one and checking the water's smell and color to find out the spilled water coolers. In this study, a more rapid method of source appointment of oil spill in the circulating water by combining chemical fingerprinting with model recognition was developed. Firstly, chemical fingerprints including benzene/naphthalene series, and light hydrocarbon (C₃-C₅) in oil samples from all water coolers in the refinery fluid catalytic cracking (FCC) unit were analyzed by gas chromatography-mass spectrometry (GC/MS). Gasoline, diesel, and poor oil could be distinguished in terms of benzene and naphthalene distribution. The three similar types of gasolines could be distinguished by the volatile hydrocarbons especially C₃-C₄. The classification model for the spill of gasoline, diesel, and poor oil in circulating water was constructed by the partial least squares discriminant analysis algorithm with a 100% correct classification rate at the concentration more than 10 ppm. The gasoline spills in the circulating backwater of the refinery were successfully recognized by the classification model. This method enables the rapid prediction of oil spill type in refinery circulating water, and a similar method by installing online instrument and software potentially can be used for monitoring the circulating water in real time.

Synthesis of Micromesoporous Zeolite-Alumina Catalysts for Olefin Production from Heavy Crude Oil

Maximizing the production of high-value olefins from heavy crude oil is a crucial topic in the downstream refining industry. However, converting heavier fractions is a major challenge due to the small pore size of the zeolites. Therefore, this work aimed to develop extrudate zeolite catalysts posing adequate micromesoporous pore network and moderate acidity by combining microporous zeolite with the boehmite phase of alumina. These extruded zeolite-alumina catalysts are expected to allow sufficient diffusion of heavy fractions, thus leading to high cracking of heavy oil into valuable olefins. Different zeolite-alumina catalysts of varying alumina content ranging from 25 to 75% (AlZ-25, AlZ-50, and AlZ-75) were prepared in the laboratory to study the optimum zeolite-alumina ratios for maximum olefin production from heavy oil. The catalysts were characterized for their chemical and physical properties using nitrogen adsorption (N2 adsorption), X-ray diffraction (XRD), inductively coupled plasma (ICP) spectrometry, Fourier transform infrared (FT-IR) spectroscopy, and NH3 temperature programmed desorption (TPD). A gradual increase in the average pore diameter (APD) of the catalysts was observed due to the alumina ratio with a distinct range of acidity that is in the range of 125 to 375°C, and also the geometry of pores is not the same for all of the supports. Catalytic performance tests were conducted in a fixed-bed reactor at 450°C, 10 bar, and liquid hourly space velocity (LHSV) of 1 h−1. The results revealed that the prepared catalysts were thermally stable and effective in heavy oil conversion to olefins. Moreover, the selectivity of propylene was higher than that of ethylene (P/E) due to the modified textural and acidic properties of the catalysts. The results showed that the catalysts prepared with moderate acidity and adequate mesopores exhibited a considerable effect on the conversion of heavy crude oil into olefins. Hence, the acidity and mesoporosity of the catalysts play a vital role in determining the catalyst performance.

Research Progress on Modifications of Zeolite Y for Improved Catalytic Properties

Zeolite Y, as a solid acid catalyst with excellent performance, is a landmark in petroleum refining and chemical industry production–especially in catalytic cracking reactions. Improving the SAR of Y zeolite, enriching its pore structure, and modifying it with heteroatoms can realize the multifunctional catalysis of Y zeolite, improve the application value of it, and then meet the demands of petroleum refining. In this review, the synthesis of Y zeolites with high SAR, multistage pores, and heteroatom modification is summarized.

Zeolites in Adsorption Processes: State of the Art and Future Prospects

Zeolites have been widely used as catalysts, ion exchangers, and adsorbents since their industrial breakthrough in the 1950s and continue to be state-of the-art adsorbents in many separation processes. Furthermore, their properties make them materials of choice for developing and emerging separation applications. The aim of this review is to put into context the relevance of zeolites and their use and prospects in adsorption technology. It has been divided into three different sections, i.e., zeolites, adsorption on nanoporous materials, and chemical separations by zeolites. In the first section, zeolites are explained in terms of their structure, composition, preparation, and properties, and a brief review of their applications is given. In the second section, the fundamentals of adsorption science are presented, with special attention to its industrial application and our case of interest, which is adsorption on zeolites. Finally, the state-of-the-art relevant separations related to chemical and energy production, in which zeolites have a practical or potential applicability, are presented. The replacement of some of the current separation methods by optimized adsorption processes using zeolites could mean an improvement in terms of sustainability and energy savings. Different separation mechanisms and the underlying adsorption properties that make zeolites interesting for these applications are discussed.

Crucial Role of Silica-Alumina Binder Mixtures for Hydrocarbon Cracking with ZSM-5 Additives

Alumina-containing binders are widely used for the binding of catalyst particles by spray drying and calcination. As a part of the active matrix, they contribute to the catalytic performance of the resulting catalyst grain during hydrocarbon cracking. In this study, correlations are investigated using different compositions of Al- and Si-based binders (AlCl₃ and colloidal silica) together with kaolin as a filler and ZSM-5 zeolite as an active compound. It was demonstrated that the conversion of a 50:50 hexane mixture, the selectivity toward unsaturated hydrocarbons, and the shape-selective conversion of the hexane feed are highly dependent on the amount and distribution of alumina in binder formulations. While silica species are distributed near the outer shell of catalyst grains, the alumina species are distributed evenly as an adhesive between the catalyst compounds ZSM-5 and kaolin. An optimum amount of alumina in binder formulations results in an increasing conversion of hydrocarbon feedstock due to optimum in active-site accessibility but only a slight decrease in shape-selective properties compared to pure ZSM-5, resulting in an optimum yield of light olefins, especially propylene.