Upscaling Effects on Alkali Metal‐Grafted Ultrastable Y Zeolite Extrudates for Modeled Catalytic Deoxygenation of Bio‐oils

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 bio-oil upgrading via deoxygenation. For purpose, shaped bodies were obtained extrusion ultrastable Y zeolite (USY) using either attapulgite (Att.) or bentonite (Bent.) clay binder, followed by post-alkali metal ion grafting K+ after (rather than before) extrusion. This approach proved essential preserve the catalysts’ crystallinity. The Att.-bound body was more active its Bent.-counterpart, correlating well with observed changes physicochemical properties. K-(USY/Att.) showed new basic oxygen and strong Lewis acidic sites resulting incorporation, addition acid (K+) (K−OH) created upon grafting. K-(USY/Bent.), less efficient, likely due pore blockage caused binder. Bent. resulted moderate Brønsted acidity, but hardly any basicity desired reaction. poor potassium yet led some cation exchange binder (likely Na+ naturally present material). results demonstrate critical importance choice material synthesis protocol adopted upscaling base form bodies.