How are Catacel catalyst materials different?


24/10/2012

 

The most important difference is not so much in the catalyst chemistry as in the support technology. Our catalysts are supported differently than traditional catalysts. Instead of using ceramic pellet supports, our catalysts are coated onto supports fabricated from thin metal foils. Our unique technology delivers improved performance, longer life and greater design flexibility.
 

Improved performance


For example, Catacel steam methane reforming catalysts have about twice the reaction surface area of conventional catalysts for a given volume, allowing greater throughputs in existing reformers, or enabling smaller, lighter, lower cost and more energy efficient reformer designs. Our metal foil structures transfer heat more efficiently, resulting in reduced fuel consumption by the burner and reduced severity in the conditions within the burner. Our engineered catalyst supports allow superior gas flow with low-pressure drops. All of this leads to lower fuel consumption and reduced flue emissions.

Longer life
 

Ordinary ceramic catalysts demonstrate failure modes such as crushing over time. This degradation causes increasing pressure drops, the formation of “hot spots” and overall decreased performance. Our metal supports do not exhibit these failure modes and consequently are expected to last up to twice as long as ceramic-supported catalysts.
 

Greater design flexibility
 

Catacel can fabricate catalytic materials in a wide range of geometries, ranging from simple flat parts to complex corrugated, coiled, finned or other uniquely formed parts. Our designs create opportunities for process optimization that would be difficult with ordinary catalysts. Foil supports can be designed to promote mixing or gas flow, and supports can be specifically engineered to deliver specific heat transfer or pressure drop characteristics. Catalysts can also be applied selectively in patterns to control reaction rates or flashback characteristics.
 

Catacel’s high-performance catalysts are developed for process intensification and efficiencies not possible from traditional ceramic pellet catalysts. Our products are custom developed to meet your needs, either to fit in an existing OEM design or to create optimized space-saving designs. Contact us to discuss how you can benefit from using our catalysts.

© Johnson Matthey 2018