(403a) Science and Arts of Carrier Forming:Case Study: Development of Carrier with Target Properties

A catalyst carrier (support) is an important component of heterogeneous catalysis. It is a low-activity or inert material which serves to stabilize the particles of the catalytic active phase on its surface. Industrial catalysts require not only good catalytic performance, but also a certain shape and mechanical strength to avoid pressure drop through the reactor which may cause high energy consumption, and in the worst-case, a reactor shutdown situation. Therefore, it is critical to select catalyst carriers which are based on optimized combinations of mechanical, structural and chemical properties that provide the right catalyst support for different reactions and process challenges. In this work, a roadmap of parameters in carrier forming and post treatment will be discussed. This case study will demonstrate how to develop a new carrier with target properties, such as density, dust level, pore size distribution, surface acidity, etc. to meet unmet needs.