Influence of catalyst pelletization on propane dehydrogenation over hierarchical MFI zeolite supported with platinum-yttrium nanoparticles

Platinum-yttrium (PtY) nanoparticles supported on a siliceous form of mesoporous MFI zeolite (MZ) were recently found to exhibit excellent catalytic performance in propane dehydrogenation (PDH). Herein, potential shaping of the PtY/MZ catalyst is investigated from the laboratory-synthesized powder form into industrially preferable pellets. The MZ zeolite powder was synthesized using multi-ammonium surfactants as a structure-directing agent and then pelletized in a hydraulic press by itself or with inorganic binders (i.e., pseudoboehmite, fumed silica, or hydrotalcite). As a part of the sequential pelletization process, pressing was followed by a high-temperature treatment (923 K). Addition of 20 wt% pseudoboehmite resulted in the highest mechanical strength without a significant loss of the initial zeolite mesoporosity. The pseudoboehmite-bound pellet also showed high catalytic activity and longevity in PDH application when simultaneously impregnated with 1 wt% Pt [Pt(NH3)4(NO3)2] and 1 wt% Y [Y(NO3)2·6H2O]. Notwithstanding the observed high propane conversion, the pseudoboehmite-bound catalyst produced an unsatisfactory result of low propylene selectivity (∼60%). Image analyses of HAADF-STEM EDS and solid-state 31P NMR spectroscopic data suggest that such findings could be attributed to Al migration from pseudoboehmite onto zeolite regime during the phase transformation of pseudoboehmite in the shaping process. Alternatively, the uses of non-acidic binders, such as fumed silica and hydrotalcite binders were also demonstrated. The silica-bound catalyst yielded high propane conversion with high propylene selectivity although mechanical strengths of the pellet were compromised to a moderate level.