PTQ Q4 2025 Issue

contrast to energy savings of a single step of conversion, benefits in product yields or reduced product consumption directly impact the entire supply chain. Zeolite catalysts One of the most dominant influences on the efficiency of conversion for versatile conversions are porous solids, specifically zeolites. Zeolite catalysts have demonstrated a hegemonic role for several decades already, being used on a massive scale to decrease (cracking) or increase (alkyl - ation) the size of molecules, or by rearranging molecules (such as isomerisation), in processes such as fluidised bed catalytic cracking (FCC), hydrocracking, dewaxing, and aro - matics conversions. Zeolites have developed a dominant position based on their high surface area, stability, and acid strength, which in turn is due to their regular/crystalline pores being in the size range of individual molecules (ca. 0.5 nm, Figure 2 ). Accordingly, configurational constraints enable unprecedented selectivities towards desired products. Moreover, being aluminosilicates, zeolites are made from abundant materials, and their synthe- sis is relatively safe, environmentally friendly, and scalable. The design of zeolites has progressed impressively since their discovery as catalysts in the 1960s. It accordingly seems hard to believe that there is room to improve these materials. Yet, with enhanced understanding, new ways have emerged to push the envelope. Potential of superior porous zeolite catalyst Besides giving rise to the many attractive properties, the nar- row intrinsic zeolite properties also impose significant access (molecule cannot enter) and transport (molecule stuck in traffic) limitations. These limitations mean that the perfor - mance of standard zeolites can often be considered sup-op- timal and can therefore be subject to sizable improvement. Mesoporous zeolites complement the intrinsic zeolitic micropores with a secondary network of larger pores in the size range of 2-50 nm. The ‘mesopores’ enhance access to the zeolite micropores and alleviate molecular traffic jams, resulting in sizable catalytic benefits, as demonstrated in virtually any reaction involving a hydrocarbon.

Rening

Base chemicals

Fine chemicals

Generic

Fossil-based

CO-based Biomass-based

Hence, versatile innovations offer a high technolo- gy-ready level, a wide and secure market, and face fewer supply and demand complications, and may therefore be faster to implement and commercialise. Yet, despite this major advantage, versatile technologies have been described as less attractive to financial investors and less eligible for governmental subsidies, simply because they can also be used to process fossil-derived streams. Efficiency of production and usage Efficiency and related innovations are intuitively related to the amount of energy or time that is used to deliver a cer- tain product or service. And, indeed, there is ample room in the refining and chemical industry to lower emissions by, for example, a more efficient use (and recovery) of heat.1 Yet, lesser known is the efficiency of the use of a prod - uct. For example, the use of a more porous type of plas- tic.² In this case, fewer emissions and less feedstock are consumed, simply because less product would be needed to exert a certain function. Similarly, by enhancing the cat- alytic efficiency of a chemical conversion, fewer emissions are emitted per unit operation, and at the same time, more valuable product is yielded. As illustrated in the following discussion, the energy savings from product usage and chemical conversion can be sizable, especially when multiple steps are concerned, which is typical in the refining and chemical industry. In Figure 1 Scheme to illustrate the relative abundance of ver- satile technologies in the refining and chemical industry

Acid sites in narrow micropores

Standard zeolite crystal

Zeopore

0.6

Low cost ingredients Productive Scalable

0.4

100 nm

1 nm

Traditional approach

0.2

Costly ingredients Long cycle times Scaling dicult

0.0

Feedstock molecule

1980

2000

2020

Not utilised

Utilised

Time

Figure 2 (left) Visualisation of the narrow pore inside zeolite crystals; (right) Traditional vs Zeopore’s approach to increase accessibility in zeolites

PTQ Q4 2025