Zeolite catalysis for a cleaner future: Engineering active sites and the FCC desulfurization revolution

Title : Zeolite catalysis for a cleaner future: Engineering active sites and the FCC desulfurization revolution

Abstract:

The global demand for ultra-clean fuels has intensified the search for catalytic systems capable of performing selective transformations under the severe operating conditions of modern fluid catalytic cracking (FCC) units. This work presents recent advances in the rational engineering of zeolites aimed at improving desulfurization efficiency directly within the FCC riser. By modulating acidity, porosity, and electronic environments through the incorporation of metals such as La, Zn, Nb, and Mg, it is possible to strategically redesign Brønsted and Lewis acid sites and optimize key reaction pathways.

Studies involving HBeta, HY, and HZSM-5 frameworks reveal that metal incorporation alters local acidity strength, changes diffusion regimes, and suppresses unwanted hydrogen-transfer routes that commonly promote aromatic formation and coke deposition. Advanced characterization techniques—XRD, FTIR-pyridine, NH₃-TPD, N₂ physisorption, SEM/TEM, and TGA—combined with kinetic and isoconversional modeling, demonstrate strong correlations between structural modifications and the selective cracking of thiophenic sulfur compounds.

Catalytic evaluation shows significant enhancement in sulfur removal while preserving octane-related pathways, offering an alternative to deep hydrotreating. Hierarchical and mesostructured zeolites further reduce diffusion limitations and increase catalyst longevity under FCC conditions.

These results position advanced zeolite engineering as a key strategy for producing ultra-clean fuels and accelerating the transition toward environmentally compliant refining technologies.

Keywords: zeolite engineering; acidity modulation; FCC catalysts; desulfurization; thiophene cracking; hierarchical zeolites; metal incorporation; coke suppression; ultra-clean fuels; catalytic cracking.

Biography:

Ronaldo Costa Santos is a Professor and Researcher at Universidade SENAI CIMATEC, Brazil, specializing in heterogeneous catalysis, zeolite modification, and catalytic processes for ultra-clean fuel production. He holds a Ph.D. in Chemical Engineering and completed postdoctoral research in petroleum refining and advanced materials at UFBA. His scientific contributions focus on acidity engineering, metal incorporation in zeolites, hierarchical structures, and catalytic cracking and desulfurization mechanisms relevant to modern FCC operations. He has authored research articles in major journals such as ChemCatChem, Catalysis Today, Molecular Catalysis, and Brazilian Journal of Chemical Engineering, and collaborates with industrial partners including FCC S.A. His work bridges fundamental catalysis and industrial application, contributing to innovations in cleaner fuels, biomass valorization, and refinery process intensification. He has received multiple scientific awards and serves as a reviewer for international journals in catalysis and chemical engineering.