1. Multiscale Mechanistic Insights of Shaped Catalyst Body Formulations and Their Impact on Catalytic Properties
- Author
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Whiting, Gareth T., Chung, Sang Ho, Stosic, Dusan, Chowdhury, Abhishek Dutta, Van Der Wal, Lars I., Fu, Donglong, Zecevic, Jovana, Travert, Arnaud, Houben, Klaartje, Baldus, Marc, Weckhuysen, Bert M., NMR Spectroscopy, Inorganic Chemistry and Catalysis, Sub Inorganic Chemistry and Catalysis, Sub NMR Spectroscopy, Institut de recherches sur la catalyse et l'environnement de Lyon (IRCELYON), Université Claude Bernard Lyon 1 (UCBL), Université de Lyon-Université de Lyon-Institut de Chimie du CNRS (INC)-Centre National de la Recherche Scientifique (CNRS), Inorganic Chemistry and Catalysis, Department of Chemistry, Utrecht University [Utrecht], Laboratoire catalyse et spectrochimie (LCS), Centre National de la Recherche Scientifique (CNRS)-École Nationale Supérieure d'Ingénieurs de Caen (ENSICAEN), Normandie Université (NU)-Normandie Université (NU)-Institut de Chimie du CNRS (INC)-Université de Caen Normandie (UNICAEN), Normandie Université (NU), Institut de biologie et chimie des protéines [Lyon] (IBCP), Université de Lyon-Université de Lyon-Centre National de la Recherche Scientifique (CNRS), NMR Spectroscopy, Inorganic Chemistry and Catalysis, Sub Inorganic Chemistry and Catalysis, and Sub NMR Spectroscopy
- Subjects
Chemistry(all) ,catalysis ,010405 organic chemistry ,Commodity chemicals ,Chemistry ,extrudates ,zeolites ,General Chemistry ,[CHIM.CATA]Chemical Sciences/Catalysis ,catalyst body ,010402 general chemistry ,01 natural sciences ,0104 chemical sciences ,Catalysis ,Chemical engineering ,additives ,Zeolite ,binder ,Refining (metallurgy) - Abstract
International audience; Zeolite-based catalysts are globally employed in many industrial processes, such as in crude-oil refining and in the production of bulk chemicals. However, to be implemented in industrial reactors efficiently, zeolite powders are required to be shaped in catalyst bodies. Scale-up of zeolite catalysts into such forms comes with side effects to its overall physicochem-ical properties and to those of its constituting components. Although fundamental research into "technical" solid catalysts is scarce, binder effects have been reported to significantly impact their catalytic properties and lifetime. Given the large number of additional (in)organic components added in the formulation, it is somehow surprising to see that there is a distinct lack of research into the unintentional impact organic additives can have on the properties of the zeolite and the catalyst bodies in general. Here, we systematically prepared a series of alumina-bound zeolite ZSM-5-based catalyst bodies, with organic additives such as peptizing, plasticizing, and lubricating agents, to rationalize their impacts on the physicochemical properties of the shaped catalyst bodies. By utilizing a carefully selected arsenal of bulk and high-spatial resolution multiscale characterization techniques, as well as specifically sized bioinspired fluorescent nanoprobes to study pore accessibility, we clearly show that, although the organic additives achieve their primary function of a mechanically robust material, uncontrolled processes are taking place in parallel. We reveal that the extrusion process can lead to zeolite dealumination (from acid peptizing treatment, and localized steaming upon calcination); meso-and macropore structural rearrangement (via burning-out of organic plasticizing and lubricating agents upon calcination); and abating of known alumina binder effects (via scavenging of Al species via chelating lubricating agents), which significantly impact catalytic performance. Understanding the mechanisms behind such effects in industrial-grade catalyst formulations can lead to enhanced design of these important materials, which can improve process efficiency in a vast range of industrial catalytic reactions.
- Published
- 2019
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