Zeolites in a good shape: Catalyst forming by extrusion modifies their performances

Abstract

Chemical interactions occurring between zeolites and alumina binders during the critical steps of catalyst forming are the focus of this study. Three widely used and commercially significant variants of FAU zeolite, covering a wide range of Si/Al ratios, micro-and mesoporosity and acidic properties (Y [LZY-64, Si/Al = 2.3] and USY [CBV 720 and CBV 760 with Si/Al = 16 and Si/Al = 28, respectively]) were shaped by extrusion with pseudoboehmite to produce bound extrudates. These extrudates were characterized by conventional techniques (XRD, 27 Al NMR and IR spectroscopy, N2 physisorption...) and compared to their parent powders activated under the same conditions. The catalytic performances of the zeolite powders, their derived alumina extrudates and physical zeolite/ γ-Al2O3 mixtures were also evaluated employing two different reactions: i) n-octane hydroisomerization, to probe all catalytic sites and ii) 1,3,5 tri-isopropyl benzene dealkylation to probe only the external/mesoporous surfaces. The bound zeolites systematically displayed catalytic performance superior to their parent powders or physical mixtures, especially in the dealkylation of 1,3,5 tri-isopropyl benzene. Infrared spectroscopy measurements of the number, nature and strength of the acid sites were consistent with these catalytic results demonstrating that new catalytic sites are created and located on the external or mesoporous surface of the zeolites, i.e. at the zeolite-binder interface. The work reported here clearly illustrates that binding and subsequent thermal treatment of zeolite powders to produce commercially representative forms can significantly alter the quality and quantity of active sites creating active centers not usually present in pure powders which are typically studied and reported in much of the open literature. Such a study is also a blueprint for other catalytic phases, other forming processes (spray-drying, oil-dropping, pelletizing…) and could also be applied to the shaping of adsorbents.