Velocys has developed a series of preparation methods for the production of super-active catalysts for use in its microchannel reactors; specifically a Co-based catalyst for use in its Fischer-Tropsch reactors.
Our patented organic matrix combustion (OMX) catalyst preparation method makes it possible to produce catalysts with higher metal loadings, while still maintaining optimal crystallite sizes. Compared to conventional catalyst production methods, such as incipient wetness impregnation, OMX produces more active and stable catalysts.
The level of catalyst activity is related to the surface area of the catalyst. This, in turn, is related to metal crystallite size, so producing catalysts with the optimal crystallite size for a given application is a key goal for catalyst developers. The big challenge lies in achieving the right balance between catalyst activity and stability. If the crystallite size is too large, the catalyst activity – and therefore conversion rates – will be reduced. If too small, the catalyst becomes unstable.
The OMX method combines the metal salt and organic components to make a complex that effectively stabilises the metal. On calcination, combustion occurs that fixes the crystallites at the ideal size – not too big or too small. Crystallites are formed in the nanometre diameter range and exhibit terraced surfaces, both features that enhance catalyst activity and stability, making catalysts that are ideal for microchannel reactors.