The general features of zeolites that led to their widespread use in oil refining and petrochemistry are highlighted as well as the details of their impact on selected processes. The analysis of the catalyst market and the position of zeolites therein is a good indication of their strategic importance. Zeolites have brought many disruptive changes to these fields (e.g. FCC). They impacted also these industries in an equally important way, although more subtle, by incremental improvement of processes. The new and vast challenges facing oil refining and petrochemistry as well as the managed transition to sustainable environmental benign transport fuel industries and chemical industries will require creative science and technologies. Zeolites offer the basis of many of these technological solutions provided efficient and balanced cooperations between industry and academia are further developed.

Nanosized faujasite (FAU) crystals have great potential as catalysts or adsorbents to more efficiently process present and forthcoming synthetic and renewable feedstocks in oil refining, petrochemistry and fine chemistry. Here, we report the rational design of template-free nanosized FAU zeolites with exceptional properties, including extremely small crystallites (10-15 nm) with a narrow particle size distribution, high crystalline yields (above 80%), micropore volumes (0.30 cm(3) g(-1)) comparable to their conventional counterparts (micrometre-sized crystals), Si/Al ratios adjustable between 1.1 and 2.1 (zeolites X or Y) and excellent thermal stability leading to superior catalytic performance in the dealkylation of a bulky molecule, 1,3,5-triisopropylbenzene, probing sites mostly located on the external surface of the nanosized crystals. Another important feature is their excellent colloidal stability, which facilitates a uniform dispersion on supports for applications in catalysis, sorption and thin-to-thick coatings.

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Five silica samples (four precipitated silicas provided by commercial suppliers and one with the MCM-41 structure) have been studied by infrared spectroscopy and by a homemade thermogravimetry-infrared spectrum (TG-IR) setup. The silanol amount, accessibility to water, and different alcohols, and the affinity to water of these various silicas were compared and quantified. TG-IR measurements allowed the precise determination of the integrated molar absorption coefficient of the (nu+delta)OH band, epsilon(nu+delta)OH=(0.16+/-0.01) cm micromol(-1). It is independent of the sample origin and the concentration of silanol groups on silicas. For the precipitated dried samples evacuated at room temperature, the silanol concentration COH varies between 3.6 and 7.0 mmol g(-1). It is 5.3 mmol g(-1) in the case of the MCM-41 sample. Exchange experiments with D2O, followed by back-exchanges with different alcohols (methanol, propan-2-ol, 2-methyl-propan-2-ol, and 3-ethyl-pentan-3-ol) have been followed by infrared spectroscopy. All of the silanols of the MCM-41 sample are accessible to water and alcohol molecules. By contrast, about 20% of the silanols in precipitated samples are not exchanged by D2O (internal silanols). Accessibility decreases with alcohol size; the main effect is relative to methanol. Taking into account the sample specific surface areas and the silanol accessibility to D2O, the surface silanol density of precipitated silicas is close to 8 OH per nm2, at maximum coverage. At variance, the silanol surface density of the MCM silica is much lower, 4 OH per nm2. The TG-IR setup has also been used to determine the amount of water adsorbed on silicas through the intensity of the deltaH2O band. It varies linearly with the concentration of adsorbed water, whatever the silica sample. The integrated molar absorption coefficient of two bands, epsilondeltaH2O=(1.53+/-0.03) cm micromol(-1) and epsilon(nu+delta)H2O=(0.22+/-0.01) cm micromol(-1), have been determined. The number of H2O molecules adsorbed per nm2 has been compared on the five samples under an equilibrium pressure of 13 hPa at room temperature. Taking into account the number of silanols accessible to D2O for each sample, the silica-water affinity has been defined by the H2O/(SiOHsurf) ratio. It is close to 0.8-0.9 for the precipitated samples but lower (0.7) in the case of the MCM one. This result is explained by the more important amount of isolated silanol groups presented by this sample.

The interaction of phenol, anisole, and guaiacol, representatives of oxygenate functions present in pyrolysis bio-oils, with oxides such as silica, alumina (pure or doped with K or F), and silica-alumina is investigated by infrared spectroscopy. While phenolic type compounds mainly interact via H-bonding with silica, chemisorption is their main mode of adsorption on alumina. Besides, guaiacol interacts very strongly by forming doubly anchored phenates instead of monoanchored ones with phenol and anisole. At temperatures typical of hydrodeoxygenation (HDO) operating conditions (∼673 K), the phenate type species cover 2/3 of the alumina surface. This study clearly indicates that substantial carbon deposition could take place on aluminasupported HDO catalysts. Hence, this suggests that silica-based supports should be considered as potential candidates to design HDO catalyst with better stability.

The isomerization of o-xylene, a prototypical example of shape-selective catalysis by zeolites, was investigated on hierarchical porous ZSM-5. Extensive intracrystalline mesoporosity in ZSM-5 was introduced by controlled silicon leaching with NaOH. In addition to the development of secondary porosity, the treatment also induced substantial aluminum redistribution, increasing the density of Lewis acid sites located at the external surface of the crystals. However, the strength of the remaining Brønsted sites was not changed. The mesoporous zeolite displayed a higher o-xylene conversion than its parent, owing to the reduced diffusion limitations. However, the selectivity to p-xylene decreased, and fast deactivation due to coking occurred. This is mainly due to the deleterious effect of acidity at the substantially increased external surface and near the pore mouths. A consecutive mild HCl washing of the hierarchical zeolite proved effective to increase the p-xylene selectivity and reduce the deactivation rate. The HCl-washed hierarchical ZSM-5 displayed an approximately twofold increase in p-xylene yield compared to the purely microporous zeolite. The reaction was followed by operando infrared spectroscopy to simultaneously monitor the catalytic performance and the buildup of carbonaceous deposits on the surface. Our results show that the interplay between activity, selectivity, and stability in modified zeolites can be optimized by relatively simple post-synthesis treatments, such as base leaching (introduction of mesoporosity) and acid washing (surface acidity modification).

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Zeolites are widely used in industrial processes, mostly as catalysts or adsorbents. Increasing their micropore volume could further improve their already exceptional catalytic and separation performances. We report a tunable extraction of zeolite framework cations (Si, Al) on a faujasite-type zeolite, the archetype of molecular sieves with cages and the most widely used as a catalyst and sorbent; this results in ca. 10% higher micropore volume with limited impact on its thermal stability. This increased micropore volume results from the opening of some of the small (sodalite) cages, otherwise inaccessible to most molecules. As more active sites become accessible, the catalytic performances for these modified zeolites are substantially improved. The method, based on etching with NHF, is also applicable to other cage-containing microporous molecular sieves, where some of the most industrially relevant zeolites are found.