Chemical Process Optimization

Catalyst Characterization

Maximize activity, selectivity, and lifetime through precise surface area, pore structure, and deactivation monitoring for heterogeneous catalysts.

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$45B
Catalyst Market 2026
85%
Processes Using Catalysts
2500+
m²/g Surface Area Achieved
30%
Efficiency Improvement

Surface Area & Active Site Analysis

Critical parameters for catalyst activity and performance optimization

Supported Catalysts

Pt/Pd on Alumina/Carbon

  • BET surface area: 100-400 m²/g
  • Metal dispersion: 30-80%
  • Pore volume: 0.3-1.5 cm³/g
  • Mean pore size: 5-15 nm
2026 Insight: AI-optimized metal loading achieves 95% dispersion with 40% less precious metal.

Key Measurements

  • BET surface area for active site quantification
  • Micropore analysis via t-plot or α-s methods
  • Metal surface area by H₂ or CO chemisorption
  • Pore size distribution by BJH or DFT

Zeolites & MOFs

Molecular Sieves & Frameworks

  • Surface area: 300-2500 m²/g
  • Micropore volume: 0.15-0.6 cm³/g
  • Channel diameter: 0.3-2.0 nm
  • Acidity: NH₃-TPD quantified
Framework Stability: Moisture resistance now extends MOF lifetime beyond 5 years in industrial use.

Critical Parameters

  • Langmuir surface area for high-area materials
  • Micropore size distribution by NLDFT
  • Framework stability via cycling tests
  • Acid site density and strength profiling

Pore Size Distribution Optimization

Microporous (<2 nm)

Applications Shape selectivity
Examples Zeolites, MOFs
Method N₂/Ar at 77/87 K
Analysis NLDFT, HK
Typical SA 500-3000 m²/g

Critical for molecular sieving and size-selective reactions

Mesoporous (2-50 nm)

Applications Mass transport
Examples MCM-41, SBA-15
Method N₂ at 77 K
Analysis BJH, NLDFT
Typical SA 200-1000 m²/g

Optimizes diffusion for large molecule reactions

Macroporous (>50 nm)

Applications Access to sites
Examples Pellets, monoliths
Method Mercury intrusion
Analysis Washburn equation
Typical SA 10-100 m²/g

Essential for rapid access in pelletized catalysts

Catalyst Deactivation Monitoring

Sintering & Pore Collapse

Track structural changes during high-temperature operation and regeneration cycles.

  • BET surface area loss: 10-60% typical
  • Metal particle growth: 2-20 nm increase
  • Pore mouth blocking detection
  • Temperature-programmed analysis
Target: <20% SA loss after 5000 hours

Coking & Poisoning

Quantify carbon deposition and active site blockage affecting catalyst performance.

  • Micropore volume reduction tracking
  • Coke deposition: TGA quantification
  • Pore blocking mechanism identification
  • Regeneration effectiveness assessment
Recovery: >85% activity after regeneration

Hydrothermal Stability

Evaluate framework integrity under steam and moisture exposure conditions.

  • Steam aging protocols (750-900°C)
  • Crystallinity retention measurement
  • Dealumination quantification
  • Structural collapse detection
Benchmark: >70% SA after steam aging

Support Degradation

Monitor support material changes affecting metal dispersion and activity.

  • Phase transformation tracking
  • Support surface area evolution
  • Metal-support interaction changes
  • Mechanical strength assessment
Lifetime: 3-5 years industrial operation

Recommended Testing Protocols

Catalyst Type Primary Method Key Parameters Frequency
Supported metals N₂ adsorption + chemisorption SA, dispersion, metal area Each batch
Zeolites N₂/Ar adsorption Micropore volume, SA Each synthesis
MOFs N₂ at 77 K SA, PSD, stability Post-activation
Pellets/extrudates Mercury intrusion Macropore distribution QC sampling
Used catalysts Comparative BET + TGA SA loss, coke content Deactivation studies
Regenerated Full characterization Recovery vs fresh Each regeneration

Industry Case Studies

Refinery FCC Catalyst Optimization

Challenge: Improve gasoline yield while reducing coke formation

Solution: Hierarchical zeolite design with optimized mesopore channels

  • 15% increase in gasoline selectivity
  • 30% reduction in coke formation
  • Mesopore volume: 0.15 cm³/g optimized
Impact: $12M annual revenue increase

Automotive Emissions Control

Challenge: Meet Euro 7 standards with reduced precious metal loading

Solution: High-dispersion Pt/Pd on stabilized alumina support

  • Metal dispersion increased to 85%
  • 40% reduction in Pt/Pd usage
  • Thermal stability up to 1050°C
Achievement: $280/unit cost reduction

Green Hydrogen Production

Challenge: Develop durable electrocatalyst for PEM electrolysis

Solution: Nanostructured IrO₂ with controlled pore architecture

  • Surface area: 180 m²/g achieved
  • 10,000 hour stability demonstrated
  • 60% reduction in Ir loading
Breakthrough: $2/kg H₂ production cost

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