Formulation of Shaped ZSM–5/Al2O3 Composites: Comparison of Pseudoboehmite and Nitrate-Derived Aluminum Binders

This study focuses on the shaping of ZSM–5-based granules using conventional pseudoboehmite as well as aluminum hydroxynitrate precursors obtained by partial thermal treatment of Al(NO3)3·9H2O. The starting materials and nitrate-derived precursors were characterized by X-ray diffraction, thermal analysis, infrared spectroscopy, scanning electron microscopy, and low-temperature nitrogen adsorption. Model pseudoboehmite systems were used to evaluate the effects of moisture, peptization equivalent, and HNO3 concentration in the initial liquid portion on pore volume, apparent density, shrinkage, and axial and radial crushing strength. Acid peptization showed a strongly non-linear effect: small HNO3 additions increased strength and densification, whereas excess acid promoted structural heterogeneity and granule disintegration during thermal treatment. Even at constant moisture and total acid dosage, strength depended markedly on the initial peptizer concentration. In unpeptized ZSM–5/pseudoboehmite composites, increasing zeolite content reduced pore volume but increased density and strength, indicating formation of a more compact framework. Aluminum hydroxynitrate precursors enabled effective shaping of ZSM–5-containing pastes, demonstrating their potential as alternative binder precursors, while the optimized pseudoboehmite systems provided the most favorable overall balance between porosity and mechanical stability.