Russian Journal of Applied Chemistry, 2013, Vol. 86, No. 12, pp. 1805−1810.
Pleiades Publishing, Ltd., 2013.
Original Russian Text © K.K. Gorshunova, O.S. Travkina, M.L. Pavlov, B.I. Kutepov, R.Z. Kuvatova, N.A. Amineva, 2013, published in Zhurnal Prikladnoi
Khimii, 2013, Vol. 86, No. 12, pp. 1857−1862.
AND INDUSTRIAL INORGANIC CHEMISTRY
Synthesis of Binder-Free Granulated MOR-Type Zeolite
with Hierarchic Pore Structure
K. K. Gorshunova
, O. S. Travkina
, M. L. Pavlov
, B. I. Kutepov
, R. Z. Kuvatova
and N. A. Amineva
Institute of Petrochemistry and Catalysis, Russian Academy of Sciences, Ufa, Bashkortostan, Russia
Bashkir State University, Ufa, Bashkortostan, Russia
Received October 3, 2013
Abstract—A procedure was developed for preparing an aluminosilicate with a hierarchic pore structure and
granules in the form of united polycrystalline concretions of MOR-type zeolite in the Na form. The procedure
includes the step of mixing of MOR-type powdered zeolite with kaolin and white carbon black, granule forming,
granule calcination, and crystallization in an autoclave in a sodium silicate solution.
Catalysts based on MOR-type zeolite are suggested
for a number of petrochemical processes [1–5]. All the re-
ported procedures for their preparation involve synthesis
of MOR-type zeolite in the form of 1–5-μm crystals in the
required cation or decationized forms, followed by form-
ing into granules 1.6–2.0 mm in diameter and 3–6 mm
long in a mixture with a binder. Aluminum hydroxide
of pseudoboehmite structure, transforming into γ-Al
on heating, is used as an additional component. The
binder content of the catalyst varies from 20 to 30 wt %.
Introduction of the binder decreases the concentration of
catalytic sites by approximately the same value. Further-
more, for such catalysts it is not always possible to attain
the required level of mechanical strength for long-term
operation under industrial conditions.
Binder-free zeolites are known [6–8]; their granules
are united concretions of crystals. The degree of crystal-
linity in such aluminosilicates exceeds 90%. Hence, larger
amount of catalytically active sites can be formed in such
catalysts. Furthremore, such granules are considerably
stronger than those with a binder. However, when devel-
oping catalysts based on binder-free zeolites, the problem
of creating a secondary pore structure ensuring efﬁ cient
diffusion of the reactant molecules to the catalytically
active sites is more topical than for zeolites with binders.
Procedures have been developed for preparing binder-
free granulated MOR-type zeolite (BF-MOR) in the Na
form [7, 9]. Characteristics of the secondary pore struc-
ture of these materials are not reported. The secondary
pore volume in these materials can be expected to be
small, because powdered mordenite in these studies was
absent in the formulation of the granules subjected to
crystallization. At the same time, it is known  that no
less than 50 wt % powdered zeolite should be present in
the granules prior to crystallization to obtain binder-free
granulated zeolites of types LTA and FAU with the pore
structure consisting not only of micropores, but also of
coarser pores. At a lower zeolite content, common crystal
concretions containing virtually no meso- and macropores
are formed after crystallization.
This study was aimed to develop a procedure for pre-
paring BF-MOR zeolite with the pore structure consisting
not only of micropores, but also of coarser pores.
Previous data  on the preparation of binder-free
granulated LTA- and FAU-type zeolites allowed us to
choose the following sequence of steps of sample prepara-