Process Intensification at the Nanoscale: Embedding SiC in Zeolites for Energy-Efficient Catalysis

Microwave-absorbent materials are typically blended with low-absorption solids to improve local heating efficiency in catalytic systems. However, the mixing method has a crucial effect on the additive’s heating efficiency. We report here how by embedding silicon carbide (SiC) nanoparticles in ferrierite (FER) zeolite crystals during their synthesis (FER@SiC), a 2.2-fold increase in the catalytic activity for mesitylene and benzyl alcohol alkylation was achieved compared to a physical mixture of FER and SiC nanoparticles (FER/SiC). While the properties of the zeolite in the FER@SiC hybrid and SiC-free FER zeolites are almost identical, we observed a significant increase in catalytic activity under microwave heating when SiC is present within FER crystals. This enhancement is not mirrored by the physical mixture, highlighting the importance of the SiC addition method and the intimate contact between the additive and catalytic phases for effective microwave heating. Actually, FER@SiC achieves the same conversion with 40% less energy, offering insights into designing more efficient zeolite-based catalysts for sustainable chemistry.