ZeoNext: call for industrial interest

Introduction

Zeolites are widely applied as catalysts in industrial processes because of their high activity, stability and unique shape-selective properties. However, their predominantly microporous structure can result in diffusion limitations, particularly when larger molecules are involved. Restricted transport of reactants and products can reduce accessibility to active sites and contribute to catalyst deactivation through pore blocking and coke formation.

To overcome these limitations, Zeopore has developed advanced mesoporization technologies that introduce controlled hierarchical porosity into zeolite catalysts. This approach improves molecular diffusion and accessibility while maintaining the intrinsic advantages of the zeolitic framework. In parallel, VITO has developed 3D micro-extrusion technology for structured catalyst manufacturing, allowing precise control over catalyst geometry, flow distribution, pressure drop, geometric surface area and mechanical stability.

Combining these two approaches offers the potential to improve catalyst accessibility across multiple length scales, from transport within the zeolite particles to mass transfer and flow through the structured catalyst body.

Ambition

Within this project, the partners aim to further develop and test a new generation of hierarchical and structured zeolite catalysts combining mesoporization with advanced 3D shaping.

A proof of concept has already demonstrated improved performance in the methanol-to-olefins (MTO) reaction, particularly when mesoporized zeolites are combined with advanced 3D printing for catalyst shaping. The ambition is now to investigate the broader applicability and industrial potential of this technology platform.

Within this project, the partners aim to address several key challenges:

• Optimization of hierarchical zeolite structures to improve molecular diffusion and accessibility of active sites;
• Development and optimization of 3D-printed catalyst architectures for improved mass transfer, flow distribution and reduced pressure drop;
• Integration of catalyst material design and macroscopic structuring to maximize catalyst performance across different length scales;
• Evaluation of catalytic activity, selectivity, stability and lifetime under industrially relevant conditions;
• Validation of the technology in selected industrially relevant catalytic processes;
• Assessment of the scalability and cost-effectiveness of the catalyst manufacturing approach.

While MTO provides a demonstrated starting point, the technology could potentially be applied to other diffusion-limited catalytic processes, including hydrocarbon oligomerization for sustainable aviation fuel (SAF) production, hydrocracking, dewaxing, biomass upgrading, etc.

Call

At this stage, the project is still in an exploratory phase. Before shaping the concept into a collaborative innovation project, Catalisti, Zeopore and VITO would like to gauge the level of industrial interest within the ecosystem.

We are therefore looking for companies that:

• Operate catalytic processes involving bulky or diffusion-limited molecules, where improved transport to and from catalytic active sites could provide advantages;
• Are active in MTO, hydrocarbon upgrading, oligomerization, SAF production, hydrocracking, dewaxing, biomass upgrading or related catalytic processes where the proposed technology could be relevant;
• Have expertise in catalyst shaping, reactor technology, scale-up or process integration and could contribute to translating the catalyst concepts towards industrial implementation;
• Are interested in testing the technology for their own catalytic reactions or feedstocks and could contribute to relevant industrial use cases and performance requirements.

This list is non-exhaustive. We welcome interest from companies operating anywhere along the value chain that see potential relevance for their products, processes or future innovation ambitions.

How do I reply?

Companies interested in learning more about this project idea, exploring potential synergies, or contributing expertise are invited to contact Catalisti.

At this stage, expressing interest does not imply any commitment to participating in a future project consortium. The objective is to identify common interests, assess industrial relevance, and determine whether sufficient momentum exists to further develop the concept into a collaborative innovation project.

Please contact Martijn Roosen (mroosencatalisti.be (mroosen[at]catalisti[dot]be)) and Stef Koelewijn (skoelewijncatalisti.be (skoelewijn[at]catalisti[dot]be)) and briefly indicate:

• Your company’s area of expertise;
• Your interest in the topic;
• Potential applications, challenges or opportunities you would like to explore within the framework of this initiative.