ZSM-22 (TON) Zeolite: Addressing Key Refining Challenges with Advanced Catalytic Solutions

Refiners today face growing challenges: meeting ultra-low sulfur standards, producing cleaner fuels, and improving energy efficiency while minimizing catalyst costs. One persistent issue is the production of low pour point diesel—essential for winter-grade fuels—without sacrificing yield or stability. Traditional catalysts such as ZSM-5 or Beta zeolites offer certain advantages, but they often fall short in selectivity and stability.

This is where ZSM-22 (TON) zeolite enters the scene. With its one-dimensional 10-membered ring pore structure, ZSM-22 exhibits unique catalytic behavior, particularly in hydroisomerization and dewaxing processes. Recent studies have demonstrated that ZSM-22 not only improves cold flow properties of diesel, but also maintains high activity and resistance to coke formation, addressing some of the most pressing refining pain points.

Pain Point 1: Diesel with Poor Cold Flow Properties

Diesel engines in colder climates require fuel with low pour points and excellent cold flow properties. Traditional solutions—such as blending with lighter fractions or using pour point depressants—often reduce fuel quality or increase operating costs.

• How ZSM-22 Helps:
  ZSM-22’s linear TON channels promote the selective isomerization of long-chain paraffins into branched isomers, which lowers pour point without excessive cracking.

Research support:

• Corma, A. Catalysis Reviews, 1995 – Discussed how medium-pore zeolites like ZSM-22 achieve efficient paraffin isomerization with reduced yield loss.

• Guisnet, M. & Magnoux, P. Applied Catalysis A, 2001 – Showed ZSM-22’s superior performance in diesel dewaxing compared to ZSM-5.

Pain Point 2: Selectivity vs. Cracking Loss

One major challenge with traditional catalysts (e.g., ZSM-5) is over-cracking, where valuable diesel-range hydrocarbons are converted into lighter gases, reducing yield.

• How ZSM-22 Helps:
  Thanks to its one-dimensional pores, ZSM-22 restricts secondary reactions, leading to higher selectivity for isomerization over cracking.

• ZSM-5: higher cracking, lower diesel yield

• SAPO-11: stable, but lower acidity → reduced activity

• ZSM-22: balanced acidity + shape selectivity → best compromise

Research support:

• Weitkamp, J. Microporous and Mesoporous Materials, 2000 – Demonstrated TON’s balance of acidity and shape selectivity.

• Song, C. Fuel Processing Technology, 2003 – Confirmed ZSM-22’s ability to increase isomerization selectivity while minimizing gas yield.

Pain Point 3: Catalyst Deactivation and Coke Formation

Catalyst life is a major concern in refineries. High operating temperatures and heavy feeds accelerate coke deposition, leading to frequent regeneration cycles.

• How ZSM-22 Helps:

• Narrow TON pores limit the formation of bulky coke precursors.

• Balanced acidity reduces undesired cracking pathways.

• Studies have shown ZSM-22 exhibits slower deactivation rates compared to ZSM-5.

Research support:

• Guisnet, M. Topics in Catalysis, 2009 – Analyzed coking resistance of TON zeolites.

• Martínez, C. & Corma, A. Coordination Chemistry Reviews, 2011 – Reported TON framework zeolites demonstrate extended cycle lives.

Pain Point 4: Flexibility in Industrial Applications

Refineries require catalysts adaptable to multiple processes, from diesel hydroisomerization to wax upgrading. Many existing zeolites are optimized for only one application.

• How ZSM-22 Helps:

• Effective in diesel dewaxing (low pour point fuels).

• Applicable in light hydrocarbon isomerization (improving octane numbers).

• Used in lubricant base oil production to achieve high-quality Group II/III base stocks.

Research support:

• Perego, C. & Ingallina, P. Catalysis Today, 2002 – TON-type zeolites highlighted as versatile hydroisomerization catalysts.

Why Refiners Should Watch ZSM-22

Unlike more established zeolites, ZSM-22 is still underutilized in commercial refining, which makes it a promising “next-generation solution.” Its unique balance of acidity, pore size, and shape selectivity enables refiners to solve challenges that traditional catalysts cannot fully address.

At Yutai Zeolite, we are preparing to introduce ZSM-22 into our product line in the coming months. Our offering will feature:

• Controlled Si/Al ratio for consistent acidity.

• Custom particle size ranges to match reactor requirements.

• Full analytical data (XRD, BET, acidity profile) to ensure traceability.

This will allow refiners to adopt ZSM-22 with confidence, knowing both performance and quality are backed by transparent testing.

FAQ

Q1: How is ZSM-22 different from ZSM-5?
A: ZSM-5 has a three-dimensional pore system, leading to more cracking and gas formation. ZSM-22’s one-dimensional TON channels promote selective isomerization with higher diesel yield.

Q2: Can ZSM-22 replace SAPO-11 in all applications?
A: Not entirely. SAPO-11 is less acidic and suited for feeds sensitive to over-cracking. ZSM-22 offers higher activity, making it better for waxy feeds.

Q3: What operating conditions are optimal for ZSM-22?
A: Typically, hydroisomerization processes at 300–380°C and moderate hydrogen pressures. Precise conditions depend on feedstock properties.

Q4: How does ZSM-22 impact refinery economics?
A: By lowering pour point without excessive cracking, it reduces reliance on blending or additives, increasing yield and lowering OPEX.

Q5: Is ZSM-22 already commercially used?
A: While not as common as ZSM-5 or SAPO-11, ZSM-22 has been studied extensively in academia and pilot plants, with growing industrial adoption.

Q6: When will your ZSM-22 be available?
A: Yutai Zeolite is planning to launch ZSM-22 catalysts soon. All products will include SGS-certified reports for independent verification.