Modeling the aspect ratio of commercial catalysts

Abstract

Mathematical modeling plays a diverse and crucial role in the chemical industry and academia. This manuscript describes how the physical and mechanical engineering disciplines help the commercialization of catalysts from evaluation to scale-up and manufacturing. Forming and shaping the catalyst is the first basic step in the catalyst manufacturing industry. Part A shows some of the classic process methods that are employed for this purpose. Catalyst extrudates require proper engineering and process control of their aspect ratio. Catalyst extrudates with a high aspect ratio tend to yield a low reactor fill due to a loose packing. Catalyst extrudates with a low aspect ratio tend to yield high pressure drop. Part B introduces the tensile strength of the catalyst in order to predict the aspect ratio of catalyst extrudates in commercial plants. A force-balance between the tensile strength of the catalyst and the impact forces due to collision experienced during manufacture leads to the dimensionless group $Be$. The group $Be$ allows to introduce and quantify the severity of equipment and the severity of entire commercial plants.