In today’s refinery and petrochemical industries, catalyst performance is more than a technical parameter—it is a direct driver of profitability. Unplanned shutdowns, rapid catalyst deactivation, or poor product selectivity can add millions in hidden costs annually.

Over decades of research, zeolite-based catalysts have remained at the center of refinery optimization. Yet, even within zeolites, not all frameworks solve the same challenges. This article outlines the three most pressing pain points in refinery catalysis and highlights how different zeolite families—especially the upcoming ZSM-22 (TON framework)—are redefining performance standards.

Pain Point 1: Coke Formation and Short Catalyst Lifetime

Coke deposition remains the number one cause of premature catalyst regeneration. Refiners often struggle with blocked pores, loss of surface area, and declining throughput.

• ZSM-5 (MFI framework): Widely used in FCC due to its 3D pore system, but prone to coke when processing heavy feeds.

• Beta zeolite (BEA framework): Offers large pores for bulky molecules, but increased pore size also accelerates coke formation.

• ZSM-22 (TON framework): Its 1D 10-membered ring channels suppress the growth of polyaromatic species, leading to significantly lower coke deposition and longer cycle lengths.

Supported by: Guisnet, M., & Magnoux, P. (2001). Coking and Deactivation of Zeolites. Applied Catalysis A: General, 212, 83–96.

Pain Point 2: Poor Selectivity in Hydroisomerization

When upgrading paraffins, many catalysts over-crack molecules into light gases rather than producing valuable isomers. This directly affects diesel cold flow properties and lubricant base oil quality.

• ZSM-5: High activity but favors over-cracking.

• MCM-22 (MWW framework): Improves shape-selectivity but less effective with long-chain paraffins.

• ZSM-22 (TON framework): The narrow 1D pore system prevents bulky transition states, enabling highly selective isomerization into branched paraffins. This results in better diesel operability at low temperatures and improved octane ratings.

Reference: Weitkamp, J. (2000). Catalytic Hydroisomerization of Alkanes. Catalysis Today, 62, 115–122.

Pain Point 3: Limited Hydrothermal Stability

Many zeolites lose crystallinity under prolonged steam and heat exposure, forcing frequent catalyst replacement.

• Beta & Y-zeolites: High surface area but suffer rapid hydrothermal degradation.

• ZSM-5: More stable but not ideal for selective hydroisomerization.

• ZSM-22: Demonstrates excellent hydrothermal resistance and retains crystallinity under harsh refinery conditions. When metal-loaded (e.g., Pt/ZSM-22), it provides long-term performance for dewaxing and isomerization units.

Reference: Chen, N. Y., Degnan, T. F., & Smith, C. M. (1994). Molecular Transport and Reaction in Zeolites. Wiley-VCH.

Why ZSM-22 Is the Next Catalyst to Watch

• Shape-selectivity reduces unwanted cracking

• Lower coke formation extends cycle length

• Hydrothermal stability ensures durability

• Ideal for diesel upgrading, lubricants, and paraffin isomerization

Product Update:

We are preparing to launch ZSM-22 (TON framework zeolite) as part of our catalyst portfolio. Once available, we will provide complete datasheets including Si/Al ratios, BET surface areas, particle size distributions, XRD profiles, and independent QC reports. Clients can pre-register for early access to technical documentation.

Extended FAQ

Q1: Why should I consider ZSM-22 if I already use ZSM-5?
ZSM-5 offers strong cracking activity but is prone to coke. ZSM-22, with its 1D channels, balances activity with selectivity, reducing coke formation and extending catalyst lifetime.

Q2: What is the key application for ZSM-22 in refineries?
Primarily hydroisomerization of long-chain paraffins, dewaxing of lubricants, and diesel cold flow improvement.

Q3: How does ZSM-22 compare with Beta zeolite in isomerization?
Beta zeolite allows bulky molecules but tends to crack excessively. ZSM-22 enforces shape-selectivity, resulting in fewer light gases and more branched isomers.

Q4: Can ZSM-22 be customized for refinery units?
Yes, ZSM-22 can be supplied in different Si/Al ratios and particle size ranges, and can be metal-loaded (e.g., Pt) for bifunctional catalysis.

Q5: When will ZSM-22 be available from your company?
We have produced ZSM-22 and have started to provide samples to domestic and foreign customers. We will soon disclose the detailed information of the product on our official website.