(702e) A Perspective on Engineering Catalysts

Catalysts are used in a variety of processes to produce fuels, to make chemicals and materials, and to reduce pollution. These catalysts are developed within the context of a reactor that is then integrated into a process. The driving forces for developing and/or improving catalysts can include emerging opportunities, environmental regulations, sustainability, and competition.

The catalyst developer plays a unique role in tailoring catalysts to cost-effectively meet reactor and process requirements. This tailoring or application development often is critical for establishing technical feasibility. The viability of the active site depends on the impact of inhibiting agents and poisons (contained in feed and recycle streams) on reaction rate. In addition to normal physical handling, the catalyst structure must withstand the reactor environment over its lifetime. Reactor design may depend on pressure drop considerations alone in one application or on downstream ease of separation in another. Input from subject matter experts in chemical and other engineering disciplines also may be needed. An incomplete understanding of catalyst deactivation under field conditions can pose a risk to process warranties. The risk profile for a process can increase further if corners are cut to compress the development timeline or if the process is scaled up without adequate piloting. An economic evaluation ultimately determines the fate of the technical work.

This present talk will discuss select examples of application development from the author’s experience.