Zeolites are crystalline aluminosilicates or silicates that must be combined with a binder to produce catalysts with the desired shape and mechanical strength for industrial applications. Common binders are refractory oxides such as alumina, silica, and clay. While the process of physically transforming zeolite crystals into shaped particles is important, there is overwhelming evidence that developing synergy between binders and zeolites is critical to the successful commercialization of zeolite catalysts. In this talk, several aspects of shaping zeolite catalysts will be described, including the impact of binders on the porosity, acidity, and stability of the catalyst bodies. Several practical considerations will also be discussed regarding the selection of various binder materials for different applications. It is anticipated that these insights will enable us to understand the requirements for developing robust zeolite catalysts that are likely to further solidify the usage of zeolites in current and future commercial processes.

Describing multiple aspects of formulating zeolite catalysts: impact of binders and practical considerations

ACS Spring 2022

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