Shaping of Zeolite Pellets: Formulation and Procedures to Improve Material Properties as Catalytic Support

Abstract

This study focuses on the shaping of zeolites for their application as catalyst supports for nickel-based catalysts in hydrocracking reactions. Zeolites are porous materials with high surface areas and unique structures that offer excellent catalytic properties. The shaping process involves forming zeolite particles into desired shapes to enable their application in industrial reactors and enhance their performance and stability in catalytic reactions. The effects of shaping parameters, including binder and plasticizer selection, shaping conditions, and post-treatment techniques, are investigated to achieve improved mechanical strength, porosity, and catalytic performance. A rheological study has been carried out which has shown to reduce the work of formulation. It was found that the use of a plasticizer, such as methylcellulose, is necessary to achieve good extrusion. An inorganic binder, specifically boehmite, accompanied by a peptizer like acetic acid, is used to achieve good mechanical strength. Additionally, the effects of the alkaline desilication technique and the dealumination caused by the use of acetic acid on the zeolite structure are investigated. These treatments aim to modify the zeolite framework by reducing the silica and alumina content, respectively, in order to improve diffusion properties by increasing the pore size. The resulting shaped zeolites exhibit improved mechanical strength and increased pore size