In this study a H‐ZSM‐5 zeolite (Si/Al=11) was modified by a stepwise treatment with steam, sodium hydroxide and hydrochloric acid. During progressing dealumination by various treatment methods, the drawbacks of initial post‐synthetic steps, e. g. pore‐filling by steam dealumination, are compensated by subsequent steps, e. g. washing by acid, which leads to a scientifically based preparation of required ZSM‐5 zeolite. Solid‐state properties of as‐synthesized and modified zeolites are determined by structural (XRD, ICP‐OES, NMR), textural (physisorption, laser scattering) and acid sites analysis (TPAD). Consequently, extended dealumination without structural damage is demonstrated. Its origin by framework dealumination and pore cleaning is verified in ethanol to hydrocarbon process (ETH) by shape‐selective formation of coke and aromatics, characterized by “aromatics index” (AI).

In this study a commercial H-ZSM-5 zeolite (Si/Al = 11) was post-synthetically modified by a combined dealumination procedure to adjust its catalytic properties for the selective formation of aromatics from ethanol. The solid-state properties of original and modified zeolites are determined by structural, textural and acidity analysis. The formation of aromatics and durability of the zeolites were investigated depending on space velocity or contact time in the catalyst bed. In particular, the formation rate and desorption of aromatics from solid-state surface as well as their tendency to form coke precursors by consecutive build-up reactions determine the formation of coke. Therefore, the rate of buildup and finished aromatization by hydride transfer (predetermined by the kind, location and geometric arrangement of surface acid sites) and the statistical number of reaction events until final desorption at the specific contact time have to be harmonized to increase aromatics yield and to decrease catalyst decay by coke simultaneously.

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Hydrothermal synthesis of ZSM-5 is an often applied but incompletely understood procedure. In comparison to current research efforts that aim to produce complex micro-mesoporous catalysts for the conversion of biogenic and bulky hydrocarbons, this work focuses on the dependency between Si/Al ratio and zeolite morphology of microporous ZSM-5 to understand and to control the synthesis process. In two series of time dependent crystallization, kinetics were analyzed at Si/Al ratio 20 and 100 to optimize the crystallization time. Subsequently, zeolites with different Si/Al ratio were obtained and character-ized. The results show a transition from a slow dissolutionrecrystallization process to a fast solid-state-transformation with increasing Si/Al ratio. This is followed by a switching morphology from clusters of small agglomerates to bigger spherical particles. Respective acid site density and zeolite morphology determine local residence time, hydride transfer behavior and finally selectivity towards aromatics and higher hydrocarbons during methanol conversion. This background should provide control of even more complex syntheses of porous catalysts.

The replacement of fossil carbon sources with green bio-oils promotes the importance of several hundred oxygenated hydrocarbons, which substantially increases the analytical effort in catalysis research. A multilinear regression is performed to correlate retention indices (RIs) and response factors (RFs) with structural properties. The model includes a variety of possible products formed during the hydrodeoxygenation of bio-oils with good accuracy (RRF2 0.921 and RRI2 0.975). The GC parameters are related to the detailed hydrocarbon analysis (DHA) method, which is commonly used for non-oxygenated hydrocarbons. The RIs are determined from a paraffin standard (C5–C15), and the RFs are calculated with ethanol and 1,3,5-trimethylbenzene as internal standards. The method presented here can, therefore, be used together with the DHA method and be expanded further. In addition to the multilinear regression, an increment system has been developed for aromatic oxygenates, which further improves the prediction accuracy of the response factors with respect to the molecular constitution (R2 0.958). Both predictive models are designed exclusively on structural factors to ensure effortless application. All experimental RIs and RFs are determined under identical conditions. Moreover, a folded Plackett–Burman screening design demonstrates the general applicability of the datasets independent of method- or device-specific parameters.

Aluminum‐based composite particles are widely applied complex catalyst materials in oil refining. Due to their tunable shape, porosity, and acidity, they are commonly used for the production of cracking catalysts. Shaping of well‐defined particles remains a challenge for industrial catalyst preparation by spray drying, because catalyst properties must satisfy local demands of a refinery. The selectivity can be modified and the cracking activity enhanced with acid binders, e.g., AlCl3. Therefore, peptization of AlCl3‐containing suspensions with zeolite Y and kaolin was characterized by pH value, 27Al NMR spectroscopy, and zeta potential. A new control strategy for binding of kaolin and zeolite Y in spray drying was developed by adjusting the pH and binder Al/Cl ratio.

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Activity, selectivity, and deactivation behavior of catalyst materials determine their efficiency in hydrocarbon conversion processes. For hydrocarbon cracking, the industrial catalyst is an important parameter in reaction technology to produce valuable compounds, e.g. , light olefins (C 3 –C 5 ) and gasoline from crude oil fractions with high molecular weight (C 16+ ). One strategy to enhance the catalytic activity for precracking is increasing the matrix activity, which depends on the used binder and additives. In this work, three binders (water glass, aluminum chloride, and a mixture of colloidal silica with aluminum dihydrogen phosphate) were used in combination with active zeolite Y, kaolin as filler, and ZSM-5 as additive to produce composite materials. Specific surface area and surface acidity measurements were combined with catalytic testing of the formulated samples in order to find the relation between the catalyst morphology and its activity. In addition, constraint index was used as a control parameter for the determination of the shape-selective properties and their correlation with the catalytic activity. The results show that the binders determine the porosity of the matrix and so the accessibility to zeolite pores and active sites. Matrixes with low porosity and activity enhance coke production and deactivate faster than matrixes with mesopores. Furthermore, ZSM-5 modifies the individual morphological and catalytic effects of the binders. Everything considered, the small crystals of ZSM-5 together with mesopores increase the olefins yield, reduce coking, and therefore enhance the performance of the final grain.