Advanced zeolites play a crucial role in industrial catalysis and separation applications, particularly in petrochemicals, refining, and the emerging sustainable chemistry sector. Their microporous structure makes these microcrystalline aluminosilicates highly suitable for selective molecular interactions, but inherently limits access to, and diffusion of, larger molecules.
This article will explore how it is possible to overcome these access limitations through a technology that has been developed with a patented post-synthetic mesoporisation process. This process creates a network of additional mesopores (10 to 50 times larger in diameter than existing pores), without compromising the zeolites’ intrinsic properties, such as microporosity, crystallinity, and acidity. These modified zeolites offer improved accessibility and efficiency.
Conventional refining and beyond
Zeopore’s mesoporous zeolites are already used in hydrocracking, dewaxing, and fluid catalytic cracking (FCC). Independent refinery tests have demonstrated a +4 wt% increase in high-value fuels and chemical feedstocks, and significant economic benefits (approximately US$0.50/bbl, or around US$15 million per cycle per refinery). In addition, the materials contribute to reduced consumption of auxiliaries, fewer low-value fractions, and lower process temperatures, enhancing both efficiency and sustainability.
Beyond conventional refining, it is possible to target green applications such as the production of sustainable fuels (SAF) and renewable diesel. Due to their larger pore network, Zeopore-modified zeolites improve access for bulky renewable molecules from waste oils and biomass, while preserving key catalytic properties. This enables higher yields of middle distillates with greater efficiency and selectivity. Refineries also benefit from lower hydrogen and energy consumption, reducing both costs and carbon footprint. At the same time, the lower output of saturated lights directly contributes to lower carbon dioxide (CO2) emissions.
Because the materials are drop-in components, they integrate seamlessly with existing refinery infrastructure. It is also possible to focus on other green applications, including catalytic recycling of plastic waste and conversion of CO2 into valuable products. This evolution supports international climate and energy goals, creating a bridge between economic value and ecological responsibility. It is not necessary to choose between one or the other.
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