Inorganic molecular sieves: Preparation, modification and industrial application in catalytic processes

The increasing environmental concern and promotion of “green processes” are forcing the substitution of traditional acid and base homogeneous catalysts by solid ones. Among these heterogeneous catalysts, zeolites and zeotypes can be considered as real “green” catalysts, due to their benign nature from an environmental point of view. The importance of these inorganic molecular sieves within the field of heterogeneous catalysis relies not only on their microporous structure and the related shape selectivity, but also on the flexibility of their chemical composition. Modification of the zeolite framework composition results in materials with acidic, basic or redox properties, whereas multifunctional catalysts can be obtained by introducing metals by ion exchange or impregnation procedures, that can catalyze hydrogenation–dehydrogenation reactions, and the number of commercial applications of zeolite based catalysts is continuously expanding. In this review we discuss determinant issues for the development of zeolite based catalysts, going from zeolite catalyst preparation up to their industrial application. Concerning the synthesis of microporous materials we present some of the new trends moving into larger pore structures or into organic free synthesis media procedures, thanks to the incorporation of novel organic templates or alternative framework elements, and to the use of high-throughput synthesis methods. Post-synthesis zeolite modification and final catalyst conformation for industrial use are briefly discussed. In a last section we give a thorough overview on the application of zeolites in industrial processes. Some of them are well established mature technologies, such as fluid catalytic cracking, hydrocracking or aromatics alkylation. Although the number of zeolite structures commercially used as heterogeneous catalysts in these fields is limited, the development of new catalysts is a continuous challenge due to the need for processing heavier feeds or for increasing the quality of the products. The application of zeolite based catalysts in the production of chemicals and fine chemicals is an emerging field, and will greatly depend on the discovery of new or known structures by alternative, lower cost, synthesis routes, and the fine tuning of their textural properties. Finally, biomass conversion and selective catalytic reduction for conversion of NOx are two active research fields, highlighting the interest in these potential industrial applications.