The ever increasing demand to develop highly fuel efficient engines coincides with the need to minimize air pollution originating from the exhaust gases of internal combustion engines. Dramatically improved fuel efficiency can be achieved at air-to-fuel ratios much higher than stoichiometric. In the presence of oxygen in large excess, however, traditional three-way catalysts are unable to reduce NOx. Among the number of lean-NOx reduction technologies, selective catalytic reduction (SCR) of NOx by NH3 over Cu- and Fe-ion exchanged zeolite catalysts has been extensively studied over the past 30+ years. Despite the significant advances in developing a viable practical zeolite-based catalyst for lean NOx reduction, the insufficient hydrothermal stabilities of the zeolite structures considered cast doubts about their real-world applicability. During the past decade renewed interest in zeolite-based lean NOx reduction was spurred by the discovery of the very high activity of Cu–SSZ-13 (and the isostructural Cu–SAPO-34) in the NH3-SCR of NOx. These new, small-pore zeolite-based catalysts not only exhibited very high NOx conversion and N2 selectivity, but also exhibited exceptionally high hydrothermal stability at high temperatures. In this review we summarize the key discoveries of the past ∼5 years that led to the introduction of these catalysts into practical applications. This review first briefly discusses the structure and preparation of the CHA structure-based zeolite catalysts, and then summarizes the key learnings of the rather extensive (but not complete) characterisation work. Then we summarize the key findings of reaction kinetic studies, and provide some mechanistic details emerging from these investigations. At the end of the review we highlight some of the issues that still need to be addressed in automotive exhaust control catalysis.

Recent advances in automotive catalysis for NOx emission control by small-pore microporous materials

Great interest has arisen in the past years in the development of hierarchical zeolites, having at least two levels of porosities. Hierarchical zeolites show an enhanced accessibility, leading to improved catalytic activity in reactions suffering from steric and/or diffusional limitations. Moreover, the secondary porosity offers an ideal space for the deposition of additional active phases and for functionalization with organic moieties. However, the secondary surface represents a discontinuity of the crystalline framework, with a low connectivity and a high concentration of silanols. Consequently, hierarchical zeolites exhibit a less “zeolitic behaviour” than conventional ones in terms of acidity, hydrophobic/hydrophilic character, confinement effects, shape-selectivity and hydrothermal stability. Nevertheless, this secondary surface is far from being amorphous, which provides hierarchical zeolites with a set of novel features. A wide variety of innovative strategies have been developed for generating a secondary porosity in zeolites. In the present review, the different synthetic routes leading to hierarchical zeolites have been classified into five categories: removal of framework atoms, surfactant-assisted procedures, hard-templating, zeolitization of preformed solids and organosilane-based methods. Significant advances have been achieved recently in several of these alternatives. These include desilication, due to its versatility, dual templating with polyquaternary ammonium surfactants and framework reorganization by treatment with surfactant-containing basic solutions. In the last two cases, the materials so prepared show both mesoscopic ordering and zeolitic lattice planes. Likewise, interesting results have been obtained with the incorporation of different types of organosilanes into the zeolite crystallization gels, taking advantage of their high affinity for silicate and aluminosilicate species. Crystallization of organofunctionalized species favours the formation of organic–inorganic composites that, upon calcination, are transformed into hierarchical zeolites. However, in spite of this impressive progress in novel strategies for the preparation of hierarchical zeolites, significant challenges are still ahead. The overall one is the development of methods that are versatile in terms of zeolite structures and compositions, capable of tuning the secondary porosity properties, and being scaled up in a cost-effective way. Recent works have demonstrated that it is possible to scale-up easily the synthesis of hierarchical zeolites by desilication. Economic aspects may become a significant bottleneck for the commercial application of hierarchical zeolites since most of the synthesis strategies so far developed imply the use of more expensive procedures and reagents compared to conventional zeolites. Nevertheless, the use of hierarchical zeolites as efficient catalysts for the production of high value-added compounds could greatly compensate these increased manufacturing costs.

Synthesis strategies in the search for hierarchical zeolites

Increasing demand for sustainable chemicals and fuels has pushed academia and industry to search for alternative feedstocks replacing crude oil in traditional refineries. As a result, an immense academic attention has focused on the valorisation of biomass (components) and derived intermediates to generate valuable platform chemicals and fuels. Zeolite catalysis plays a distinct role in many of these biomass conversion routes. This contribution emphasizes the progress and potential in zeolite catalysed biomass conversions and relates these to concepts established in existing petrochemical processes. The application of zeolites, equipped with a variety of active sites, in Bronsted acid, Lewis acid, or multifunctional catalysed reactions is discussed and generalised to provide a comprehensive overview. In addition, the feedstock shift from crude oil to biomass involves new challenges in developing fields, like mesoporosity and pore interconnectivity of zeolites and stability of zeolites in liquid phase. Finally, the future challenges and perspectives of zeolites in the processing of biomass conversion are discussed.

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Potential and challenges of zeolite chemistry in the catalytic conversion of biomass

Design of hierarchical zeolite catalysts by desilication

State Key Laboratory of High Performance Ceramics and Superfine Microstructure, Shanghai Institute of Ceramics, Chinese Academy of Sciences, 1295 Dingxi Road, Shanghai 200050, People’s Republic of China; Department of Materials Science and Engineering, East China University of Science and Technology, 130 Meilong Road, Shanghai 200233, People’s Republic of China; and National Engineering Research Center for Nanotechnology, 28 East Jiangchuan Road, Shanghai 200241, People’s Republic of China

On the synergetic catalytic effect in heterogeneous nanocomposite catalysts.

With the necessity for the refining industry to treat heavier feedstocks, there is a clear demand for improved zeolite materials displaying better accessible surface areas and higher pore volumes in order to capitalize on their effectiveness. To this end, over the last decade, there has been an intensification of research on the exploration of new routes to synthesize zeolite materials combining micropores with mesopores. Different synthesis strategies are used for their preparation (i.e., by structure breaking or so-called ‘destructive’ pathways, or structure building or so-called ‘constructive’ synthesis pathways). This Review discusses the variety of current synthesis strategies, while emphasizing the strengths and weaknesses of the different routes regarding material characteristics; health, safety, and environment aspects; and synthesis costs.

Overview and Industrial Assessment of Synthesis Strategies towards Zeolites with Mesopores

Ring opening of decalin and methylcyclohexane over alumina-based monofunctional WO3/Al2O3 and Ir/Al2O3 catalysts

The present invention relates to a process for the dehydration of at least an alcohol to make at least an olefin, comprising: introducing in a reactor a stream (A) comprising at least an alcohol, optionally water, optionally an inert component, contacting said stream with a catalyst in said reactor at conditions effective to dehydrate at least a portion of the alcohol to make an olefin, recovering from said reactor an olefin containing stream (B), Wherein the catalyst is : • a crystalline silicate having a ratio Si/AI of at least about 100, or • a dealuminated crystalline silicate, or • a phosphorus modified zeolite, the WHSV of the alcohols is at least 2 h-1, the temperature ranges from 280°C to 500°C. It relates also to the same process as above but wherein the catalyst is a phosphorus modified zeolite and at any WHSV. The partial pressure of the alcohol in the dehydration reactor advantageously ranges from 1.2 to 4 bars absolute (0.12 MPa to 0.4 MPa), the temperature of the dehydration reactor ranges advantageously from 300°C to 400°C and the alcohol is selected among ethanol, propanol, butanol and phenylethanol.

Dehydration of alcohols on crystalline silicates

The present invention relates to a process for the conversion of ethanol to make essentially ethylene and propylene, comprising : a) introducing in a reactor (A) (also called the first low temperature reaction zone) a stream comprising ethanol, optionally water, optionally an inert component, b) contacting said stream with a catalyst (A1) in said reactor (A) at conditions effective to dehydrate at least a portion of the ethanol to essentially ethylene, c) recovering from said reactor an effluent comprising : essentially ethylene, minor amounts of various hydrocarbons, water, optionally unconverted ethanol and the optional inert component of step a), d) fractionating said effluent of step c) to remove water, unconverted ethanol, optionally the inert component, and optionally the whole or a part of the various hydrocarbons to get a stream (D) comprising essentially ethylene and optionally the inert component, e) introducing at least a part of said stream (D) mixed with a stream (D1 ) comprising olefins having 4 carbon atoms or more (C4+ olefins) in a OCP reactor (also called the second high temperature reaction zone) under the condition that the mixture (D)+(D1) comprises at least 10wt% of C4+ olefins, f) contacting said stream comprising at least a part of (D) and the stream (D1 ) in said OCP reactor with a catalyst which is selective towards light olefins in the effluent, to produce an effluent with an olefin content of lower molecular weight than that of the feedstock, g) fractionating said effluent of step f) to produce at least an ethylene stream, a propylene stream and a fraction consisting essentially of hydrocarbons having 4 carbon atoms or more, optionally recycling ethylene in whole or in part at the inlet of the OCP reactor of step f), or at the inlet of the reactor (A) or in part at the inlet of the OCP reactor of step f) and in part at the inlet of the reactor (A), optionally recycling the fraction consisting essentially of hydrocarbons having 4 carbon at

Process to make olefins from ethanol

A process for obtaining a catalyst composite comprising the following steps: a) selecting a molecular sieve having pores of 10-or more-membered rings b) contacting the molecular sieve with a metal silicate different from said molecular sieve comprising at least one alkaline earth metal and one or more of the following metals: Ga, Al, Ce, In, Cs, Sc, Sn, Li, Zn, Co, Mo, Mn, Ni, Fe, Cu, Cr, Ti and V, such that the composite comprises at least 0.1 wt% of silicate.

Process for obtaining a catalyst composite

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