Generation of Catalytic Films of Zeolite Y and ZSM-5 on FeCrAlloy Metal

This work details the generation of thin films of
structured zeolite catalysts (ZSM–5 and Y) onto the surface of a
metal substrate (FeCrAlloy) using in-situ hydrothermal synthesis. In
addition, the zeolite Y is post-synthetically modified by acidified
ammonium ion exchange to generate US-Y. Finally the catalytic
activity of the structured ZSM-5 catalyst films (Si/Al = 11, thickness
146 0m) and structured US–Y catalyst film (Si/Al = 8, thickness
230m) were compared with the pelleted powder form of ZSM–5 and
USY catalysts of similar Si/Al ratios.
The structured catalyst films have been characterised using a range
of techniques, including X-ray diffraction (XRD), Electron
microscopy (SEM), Energy Dispersive X–ray analysis (EDX) and
Thermogravimetric Analysis (TGA). The transition from oxide-onalloy
wires to hydrothermally synthesised uniformly zeolite coated
surfaces was followed using SEM and XRD. In addition, the
robustness of the prepared coating was confirmed by subjecting these
to thermal cycling (ambient to 550oC).
The cracking of n–heptane over the pellets and structured catalysts
for both ZSM–5 and Y zeolite showed very similar product
selectivities for similar amounts of catalyst with an apparent
activation energy of around 60 kJ mol-1. This paper demonstrates that
structured catalysts can be manufactured with excellent zeolite
adherence and when suitably activated/modified give comparable
cracking results to the pelleted powder forms. These structured
catalysts will improve temperature distribution in highly exothermic
and endothermic catalysed processes.

• Rana Th. A. Al-Rubaye
• Arthur A. Garforth

• FeCrAlloy
• Structured catalyst
• and Zeolite Y
• Zeolite ZSM-5.

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