Chemical engineering of zeolites: alleviating transport limitations through hierarchical design and shaping

Zeolites are indispensable catalysts in a wide range of industrial applications due to their well-defined microporous structures and exceptional shape-selective properties. However, their practical use is often constrained by diffusion limitations, which can hinder reactant accessibility, influence product selectivity, and accelerate catalyst deactivation. This review critically examines strategies to alleviate these diffusion constraints, focusing on hierarchical structuring, nanozeolite synthesis, and advanced shaping techniques. We discuss fundamental diffusion theories, experimental characterization methods, and emerging methodologies that enhance mass transport in zeolites. By bridging fundamental principles with industrial applications, this review provides a comprehensive overview of how tailored zeolite architectures can optimize catalytic performance, paving the way for more efficient and sustainable processes.