Shaping the future of catalyst production
With resource scarcity a growing threat across industries, we’re witnessing a new era in catalyst manufacturing. Driven by the need to use materials more wisely, the holy grail is a higher reaction rate with less catalytic material. So, what is the most effective way to improve catalytic efficiency?
Increasing the surface area of catalytic materials by reducing particle sizes is a great way to increase reaction rates. But it’s also important to consider another factor: the shape of those tiny particles. Measuring and controlling both particle size and shape provides benefits at every stage of the catalyst’s lifecycle – from manufacturing to application to lifetime efficiency.
Achieving the flow state
Smaller particles, although suitable for increasing the reactive surface area, can be problematic in terms of handling, packing, and powder flowability. Automated image analysis, using instruments like the Morphologi 4 or on-line Hydro Insight system, can detect anomalies in particle shape and help predict potential particle flow problems. This allows adjustments to be made to achieve uniformity in particle shape, ensuring consistent particle flow during processing and more uniform packing during forming.
Particle size anomalies are another issue that must be addressed. During processing, particles can agglomerate, break up or suffer attrition – so it’s important to track the particle size distribution at various points along the production line. This can be accomplished with an at-line analytical tool like the Mastersizer. With this system, samples can be taken during a processing cycle and analyzed rapidly with minimal intervention.
Alternatively, an on-line tool such as the Insitec particle size analyzer can be used to get real-time insight into the materials flowing through production lines. On-line tools are ideal for efficient quality control, and form a key part of more comprehensive automation systems. Both analysis methods can help when scaling up lab methods for production – as even processes that worked well during research may suffer unexpected problems at scale.
Support material porosity: the “hole” truth
The more porous the support material, the more liquid or gas can flow through it and interact with the catalyst. Porosity is achieved at different length scales – from holes in formed ceramic supports, to gaps between packed particles in powder beds, to meso-pores actually within particles and crystal lattices. As the size and shape distribution of the support material particles both affect the packing density, they help determine the final porosity of the formed catalyst support. Meanwhile, X-ray scattering techniques such as small-angle X-ray scattering and reflectometry, both possible with the Empyrean XRD, can be used to study and control porosity within particles and crystal lattices.
Smarter particle analysis for more consistent results
From research to production, it’s essential to get accurate and efficient measurements of size and shape distributions, both for the catalyst and the support material particles. This information helps you to make better-informed, data-driven decisions during production – enabling more efficient catalysts, more effective reactions, and more responsible use of precious catalytic materials. That’s how measurement helps you meet the challenge of resource scarcity – and create a better future for the wider industry.
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