Preparation and catalytic performance of FAU-type zeolite films supported on FeCrAl grids

The preparation of FAU-type zeolite films on FeCrAl grids by hydrothermal synthesis was studied with an emphasis on effects of ageing of the synthesis mixture, seeding of the support and addition of polyvinyl alcohol (PVA) in the seed solution. The catalytic activity of FAU-type zeolite films was evaluated for cracking of a model endothermic fuel (n-octane). The results show that coating of the support with Y-type zeolite seeds could increase the loading of zeolite crystals on the support and thus facilitate to grow a continuous and dense FAU-type zeolite film around the wire, especially using an aged synthesis mixture. Under the same synthesis conditions, the loading of zeolite crystals was enhanced using a PVA-containing seed solution for seeding. The initial conversion of n-octane at 500°C was higher over FAU-type zeolite films (7.2%–13.2%) than that over the bare support (4.4%). The activity of zeolite films depends on not only the loading of zeolite crystals but also the morphology of the film.