Selective conversion of spent cracking catalyst to faujasite-structured zeolites
Publikation: Beitrag in Fachzeitschrift › Forschungsartikel › Beigetragen › Begutachtung
Beitragende
Abstract
Current recycling strategies for spent catalyst in Fluid Catalytic Cracking (FCC) focus on valuable rare-earth elements (REE) and sometimes include a reuse of spent materials by down-cycling, which hinders a circular economy. Herein, a new procedure for the selective conversion of spent FCC catalysts to FAU-type zeolite without secondary crystalline phases such as sodalite, zeolite P or zeolite A is reported. The steps include a leaching process of REE, followed by thermal activation with sodium hydroxide and acid treatment to get an aluminum-rich feed. The synthesis of FAU-type zeolites with varying Si/Al ratios uses the aluminum-rich catalyst feed and commercial water glass. The experiments show that incorporation of silicate from water glass into the zeolite structure is limited to zeolite products with Si/Al ratio ≤ 2.0. It indicates a flocculation of silicates in higher concentration in competition to the crystallization process of FAU-type zeolites. This is reinforced by the resulting crystals, covered and surrounded with small particles with morphology of silica. Moreover, a clear differentiation between zeolite Y and zeolite X is possible from materials properties with the definite evidence of a mixed phase. The kinetics of feed dissolution and incorporation of impurities, alumina and silica are controlled by the pre-treatment temperature, duration and silicon source. This enables flexible adjustment of the aluminum re-use from spent FCC catalyst, the amount of foreign elements (Fe, Ni, V), phase purity, Si/Al ratio, specific surface area and thermal stability of the final zeolite product. Structural and textural data of the resulting zeolites reveals high crystallinity > 80 %, Si/Al ratios of 1.6–2.0, and specific surface areas up to 780 m2/g.
Details
| Originalsprache | Englisch |
|---|---|
| Aufsatznummer | 110234 |
| Fachzeitschrift | Materials Today Communications |
| Jahrgang | 41 |
| Publikationsstatus | Veröffentlicht - Dez. 2024 |
| Peer-Review-Status | Ja |
Externe IDs
| Scopus | 85203803953 |
|---|---|
| ORCID | /0000-0002-8928-8340/work/190569883 |
| ORCID | /0000-0001-7323-7816/work/190573224 |