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

  • Rana Al-Rubaye

Student thesis: Phd


The objective of this work was the development of structured zeolite catalysts by growing of ZSM-5 and Y zeolites layers on the pre-treated FeCrAlloy wires, which could now offer technical advantage in catalytic application. The advantages of implementation of zeolitic coatings in industrial applications are that they have; lower pressure drop, high heat and mass transfer rates compared to standard pelleted or extruded catalysts. The key focus of this research was the generation of thin films of zeolite ZSM-5 and Y zeolite catalysts on the surface of a FeCrAlloy metal substrate. Using in-situ hydrothermal synthesis, the influence of the synthesis parameters such as substrate oxidation and crystallisation time on the zeolite crystallisation process in both the bulk phase (powder) and on the structured zeolite was studied and optimised. Then powder and structured Na-ZSM-5 and Na-Y were treated by calcination and ion exchange in post-synthesis treatment. Further post-synthesis modification was required in the zeolite Y case to improve the catalytic properties. The post synthetic modification of zeolite Y was carried out using acidified ammonium nitrate which was optimised to produce dealuminated zeolite Y with good crystallinity and a Si/Al = 8. Characterisation was performed after each stage of this work to optimise catalyst development using XRD, SEM, EDAX, BET, MAS-NMR, and TGA. Once the optimised zeolite Y and ZSM-5 structured catalysts prepared, cracking of n-heptane was carried out to assess the in catalytic performance compared with Y and ZSM-5 pellets in a fixed-bed reactor under the same operation conditions.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 apparent activation energy of around 60 kJ mol-1. This research 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.
Date of Award31 Dec 2013
Original languageEnglish
Awarding Institution
  • The University of Manchester
SupervisorArthur Garforth (Supervisor) & David Cresswell (Supervisor)


  • Zeolite Y
  • Zeolite ZSM-5, FeCrAlloy, structured catalyst , cracking

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