Intelligent Catalyst Shaping: Effect of Binders on the Physicochemical and Catalytic Properties of Zeolite-Based Catalysts

Today, zeolitic catalysts play an important role in catalytic processes such as cracking, alkylation, etc. However, shaping these catalysts for industrial applications remains a challenge. Despite extensive research in this area in recent years, the number of studies is limited, and detailed information is scarce. Consequently, this study aims to increase awareness of the challenges associated with catalyst shaping and to contribute to the body of knowledge in this field. Following an introduction to the fundamental concepts and shaping techniques, our focus in this review has been on the binder agent, whereby we have categorized the effects of binders that can influence catalyst performance. We demonstrate that while binders may not necessarily possess catalytic properties, the chemical interaction between the binder and the catalyst, as well as the extrusion process, can significantly impact the physicochemical characteristics of the final catalyst, including its acid characteristics, pore characteristics, distribution of loaded metals, and so on. Moreover, depending on the desired properties of the catalyst, different sequences can be employed to utilize the binder. Finally, we identify research gaps in this domain and present recommendations for future studies.