Catalysis Technology System

Catalysis Technology System is a partner in cutting-edge catalyst design, materials development, and reaction process consulting. We provide consulting from micro-scale to pilot-scale, supporting catalytic industry applications across the full technology readiness range, TRL 1 through TRL 6.

• Catalyst Formulation & Scale-Up: Custom catalyst formulation and scale-up, from novel synthesis to commercial production.
• Reactor System Services: Reactor system design, testing, and operation contracts, from concept through commissioning.
• Advanced Characterization: Catalyst characterization and testing with TPD, TPR, TGA, and BET analysis.
• Kinetics & Modeling: Lumping kinetics, molecular-level kinetics, and hybrid artificial neural networks for industrial scale.

Catalyst formulation and scale-up services, from laboratory development to industrial production.

• Custom & Novel Synthesis: Custom catalyst, novel catalyst, and support material synthesis tailored to your reaction chemistry.
• Formulation Optimization: Systematic optimization of catalyst composition and preparation to meet performance targets.
• Scale-Up: Scale-up from gram-scale laboratory batches to commercial contract for production.

Complete reactor solutions from concept to commissioning, with contract design, testing, and operation services across the full technology readiness spectrum.

• TRL 1-2: Microreactor Systems: Catalyst screening, kinetics studies, and proof-of-concept testing at micro-scale.
• TRL 3-4: Bench-Scale Systems: Validation of catalyst performance, process optimization, and data collection for scale-up decisions.
• TRL 5-6: Pilot-Scale Plants: Full process demonstration and long-duration testing, available on request.

High-Pressure Reactor Systems

Operating pressure of 1-200 bar with temperatures of 100-400°C under pressure and ~400-800°C at atmospheric conditions. Applications include reforming, CO₂ hydrogenation and utilization, H₂ and syngas, deoxygenation, hydrogenation, hydrocracking, alkylation, and isomerization, with integrated online analysis.

Micro-Reactor & Chemisorption Systems

Rapid catalyst screening for ammonia cracking, RWGS, MTG, MTO, and dry reforming.

Advanced reaction kinetics modeling and simulation capabilities to support catalyst and process development.

• Lumping Kinetics: Simplified multi-component reaction network modeling, well suited for FCC and refinery reaction systems.
• Molecular-Level Kinetics: Detailed mechanistic models that track individual species, surface intermediates, and elementary reaction steps.
• Hybrid ANN Models: Artificial neural network models integrated with first-principles approaches to handle nonlinear kinetic behavior and sparse experimental data.

Characterization consulting with comprehensive analysis and performance evaluation of catalytic materials, carried out by our team of specialist scientists.

• Surface Chemistry & Chemisorption: NH₃-TPD for acid site quantification and strength distribution. CO₂-TPD for basic site characterization and CO₂ capture performance. H₂-TPR for metal reducibility and dispersion. O₂-TPO for oxidation behavior and coke analysis.
• Thermal Chemistry Analysis (TGA): Thermogravimetric analysis under controlled atmospheres. N₂-TGA for thermal stability, polymer decomposition, and biomass analysis. Air-TGA for coke formation quantification, catalyst deactivation, and combustion kinetics. CO₂-TGA for capture capacity, breakthrough curves, and cyclic stability.
• BET & Textural Properties: N₂-BET for surface area (BET), pore size distribution (BJH), micropore volume, and total pore volume. CO₂-BET for capture capacity, material screening, N₂/CO₂ selectivity, and cyclic adsorption-desorption stability.

Integrated online gas and liquid analysis coupled to our reactor systems, supporting kinetic parameter extraction, conversion and selectivity monitoring, and process optimization.

• RGA (Refinery Gas Analyzer): 3-detector configuration (TCD, FID, FPD) with detection from H₂, CO, CO₂, and CH₄ up to C₁₀⁺ hydrocarbons.
• PIONA Analysis: Paraffins, iso-paraffins, olefins, naphthenes, and aromatics, including benzene, toluene, and xylene quantification and aromatic distribution profiles.

Training and educational programs for individuals, teams, and large organizational groups.

• Catalyst Formulation Fundamentals: Foundations of catalyst formulation, from material selection to preparation methods.
• Reactor Design and Operation: Practical training on reactor system design, operation, and safety.
• Advanced Characterization: Hands-on instruction in TPD, TPR, TGA, and BET techniques and interpretation.
• Process Optimization Methods: Systematic approaches to improving conversion, selectivity, and stability.

Partner with Catalysis Technology System for your next catalyst and reactor engineering project. We work on both short-term and long-term contracts, delivering tailored solutions from concept through commissioning.