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The catalytic performance of a set of technical, zeolite ZSM-5 extruded materials have been studied in a bench scale unit for the ex-situ Catalytic Fast Pyrolysis (CFP) of lignocellulosic biomass. The set of catalysts include micro- and mesoporous materials, with and without ZrO2-promotion, with different Si/Al ratios and with micro- and nanosized zeolite crystals. Mesoporosity, acidity and crystal size play a key role on the overall catalytic performances in terms of activity and selectivity (i. e., in their ability to obtain the highest bio-oil fraction with the lowest oxygen content), and also importantly, stability. Detailed post-mortem bulk and micro-spectroscopic studies of the solid catalysts complement the catalytic testing. The obtained results point towards coke deposits as the main cause for catalyst deactivation. Details of the nature, formation and evolution of these coke deposits revealed essential insights, which serve to evaluate the design of catalysts for the ex-situ CFP of biomass. In particular the mesoporous catalysts are overall better preserved with increasing time-on-stream and deactivate later than their microporous counterparts, which suffer from pore blockage. Likewise, it was seen that ZrO2-promotion contributed positively in the prevention against deactivation by hard coke spreading, thanks to its enhanced Lewis acidity. The zeolite's crystal size is another important characteristic to combine the different components within catalyst bodies, ensuring the proper interaction between zeolite, promoter and binder. This is illustrated by the nanocrystalline ZrO2/n-ZSM-5-ATP material, which shows the best catalytic performance.

The modes of deactivation -and the extent to which their properties can be restored- of two catalyst bodies used in cascade for bio-oil synthesis have been studied. These catalysts include a solid acid granulate (namely ZrO2/desilicated zeolite ZSM-5/attapulgite clay) employed in ex-situ catalytic fast pyrolysis of biomass, and a base extrudate (K-exchanged zeolite USY/attapulgite clay) for the subsequent bio-oil upgrading. Post-mortem analyses of both catalyst bodies with Raman spectroscopy and confocal fluorescence microscopy revealed the presence of highly poly-aromatic coke distributed in an egg-shell manner. Deactivation due to coke adsorption onto acid sites affected the zeolite ZSM-5-based catalyst, while for the base catalyst it is structural integrity loss, resulting from KOH-mediated zeolite framework collapse, the main deactivating factor. A hydrothermal regeneration process reversed the detrimental effects of coke in the acid catalyst, largely recovering catalyst acidity (∼80%) and textural properties (∼90%), but worsened the structural damage suffered by the base catalyst.

Developing efficient solid catalysts is necessary when for example moving from batch chemistry to continuous flow systems. In this work, scale-up effects of zeolite-based catalyst materials have been tested in aldol condensation as a model reaction for bio-oil upgrading via deoxygenation. For this purpose, shaped catalyst bodies were obtained via extrusion of ultrastable Y zeolite (USY) using either attapulgite (Att.) or bentonite (Bent.) as clay binder, followed by post-alkali metal ion grafting of K+ after (rather than before) extrusion. This approach proved essential to preserve the catalysts’ crystallinity. The Att.-bound catalyst body was more active than its Bent.-counterpart, correlating well with the observed changes in physicochemical properties. The K-(USY/Att.) catalyst showed new basic oxygen and strong Lewis acidic sites resulting from clay incorporation, in addition to the Lewis acid (K+) and basic sites (K−OH) created upon grafting. For K-(USY/Bent.), the grafting proved less efficient, likely due to pore blockage caused by the binder. Bent. addition resulted in acid sites of moderate Brønsted and strong Lewis acidity, but hardly any of the basicity desired for the aldol condensation reaction. The poor potassium grafting yet led to some cation exchange with the binder (likely with the Na+ naturally present in the Bent. material). The results obtained demonstrate the critical importance of the choice of the binder material and the synthesis protocol adopted for upscaling solid base materials in the form of catalyst bodies.

The catalytic performance of a set of technical, zeolite ZSM-5 extruded materials have been studied in a bench scale unit for the ex-situ Catalytic Fast Pyrolysis (CFP) of lignocellulosic biomass. The set of catalysts include micro- and mesoporous materials, with and without ZrO2-promotion, with different Si/Al ratios and with micro- and nanosized zeolite crystals. Mesoporosity, acidity and crystal size play a key role on the overall catalytic performances in terms of activity and selectivity (i. e., in their ability to obtain the highest bio-oil fraction with the lowest oxygen content), and also importantly, stability. Detailed post-mortem bulk and micro-spectroscopic studies of the solid catalysts complement the catalytic testing. The obtained results point towards coke deposits as the main cause for catalyst deactivation. Details of the nature, formation and evolution of these coke deposits revealed essential insights, which serve to evaluate the design of catalysts for the ex-situ CFP of biomass. In particular the mesoporous catalysts are overall better preserved with increasing time-on-stream and deactivate later than their microporous counterparts, which suffer from pore blockage. Likewise, it was seen that ZrO2-promotion contributed positively in the prevention against deactivation by hard coke spreading, thanks to its enhanced Lewis acidity. The zeolite's crystal size is another important characteristic to combine the different components within catalyst bodies, ensuring the proper interaction between zeolite, promoter and binder. This is illustrated by the nanocrystalline ZrO2/n-ZSM-5-ATP material, which shows the best catalytic performance.

Ex situ catalytic biomass pyrolysis was investigated at both laboratory and bench scale by using a zeolite ZSM-5-based catalyst for selectively upgrading the bio-oil vapors. The catalyst consisted of nanocrystalline ZSM-5, modified by incorporation of ZrO2 and agglomerated with attapulgite (ZrO2 /n-ZSM-5-ATP). Characterization of this material by means of different techniques, including CO2 and NH3 temperature-programmed desorption (TPD), NMR spectroscopy, UV/Vis microspectroscopy, and fluorescence microscopy, showed that it possessed the right combination of accessibility and acid-base properties for promoting the conversion of the bulky molecules formed by lignocellulose pyrolysis and their subsequent deoxygenation to upgraded liquid organic fractions (bio-oil). The results obtained at the laboratory scale by varying the catalyst-to-biomass ratio (C/B) indicated that the ZrO2 /n-ZSM-5-ATP catalyst was more efficient for bio-oil deoxygenation than the parent zeolite n-ZSM-5, producing upgraded bio-oils with better combinations of mass and energy yields with respect to the oxygen content. The excellent performance of the ZrO2 /n-ZSM-5-ATP system was confirmed by working with a continuous bench-scale plant. The scale-up of the process, even with different raw biomasses as the feedstock, reaction conditions, and operation modes, was in line with the laboratory-scale results, leading to deoxygenation degrees of approximately 60 % with energy yields of approximately 70 % with respect to those of the thermal bio-oil.

The properties of the zeolite ZSM-5 have been optimised for the production and deoxygenation of the bio-oil∗ (bio-oil on water-free basis) fraction by lignocellulose catalytic pyrolysis. Two ZSM-5 supports possessing high mesopore/external surface area, and therefore enhanced accessibility, have been employed to promote the conversion of the bulky compounds formed in the primary cracking of lignocellulose. These supports are a nanocrystalline material (n-ZSM-5) and a hierarchical sample (h-ZSM-5) of different Si/Al ratios and acid site concentrations. Acidic features of both zeolites have been modified and adjusted by incorporation of ZrO2, which has a significant effect on the concentration and distribution of both Brønsted and Lewis acid sites. These materials have been tested in the catalytic pyrolysis of acid-washed wheat straw (WS-ac) using a two-step (thermal/catalytic) reaction system at different catalyst/biomass ratios. The results obtained have been assessed in terms of oxygen content, energy yield and composition of the produced bio-oil∗, taking also into account the selectivity towards the different deoxygenation pathways. The ZrO2/n-ZSM-5 sample showed remarkable performance in the biomass catalytic pyrolysis, as a result of the appropriate combination of accessibility and acidic properties. In particular, modification of the zeolitic support acidity by incorporation of highly dispersed ZrO2 effectively decreased the extent of secondary reactions, such as severe cracking and coke formation, as well as promoted the conversion of the oligomers formed initially by lignocellulose pyrolysis, thus sharply decreasing the proportion of the components not detected by GC-MS in the upgraded bio-oil∗.