CATALYST CHARACTERIZATION SOLUTION FOR PETROCHEMICAL REFINING: HIDEN CATLAB-PCS SYSTEM

In petrochemical plant operations and R&D laboratories, a persistent question arises: How can we maintain optimal conversion efficiency and control energy costs? The answer lies in understanding the catalyst. It is not enough to simply confirm whether a catalyst is active. Engineers and researchers need to know exactly which reaction mechanisms are taking place, why activity declines, and what operating conditions are optimal.

Hiden CATLAB-PCS is an integrated Microreactor and Mass Spectrometer system designed to answer these questions. The equipment provides empirical data on the physicochemical properties of catalysts, supporting decision-making in production and research.

Why is Catalyst Characterization Important in Petrochemical Refining?

Catalysts directly influence product quality (e.g., Octane number in reforming), conversion efficiency, and energy consumption. During operation, catalysts typically face issues such as:

• Coking: Carbon deposition on the surface covers active sites.

• Poisoning: The presence of sulfur (S), nitrogen (N), or heavy metals (Ni, V) causes loss of activity.

• Sintering: Metal particles agglomerate, reducing the active surface area.

• Structural degradation: Zeolite structure or pore system undergoes changes.

Determining properties such as surface area, metal dispersion, acid site density, and adsorption capacity helps engineers optimize temperature, pressure, feed/catalyst ratio, and hydrogen flow. This, in turn, extends catalyst life and reduces operating costs.

Hiden CATLAB-PCS: An Integrated Solution for Catalyst Research

The CATLAB-PCS system from Hiden Analytical combines two main modules: a Microreactor and a QGA 2.0 Gas Analysis System. The operating principle is based on gas flowing through the catalyst bed in the reactor furnace. As the temperature changes according to a programmed profile, adsorption, desorption, reduction, oxidation, or catalytic reactions occur. The evolved gases are directed to the mass spectrometer for real-time composition and concentration analysis.

Integrated Analytical Techniques

Instead of using multiple standalone instruments, CATLAB-PCS allows simultaneous execution of key characterization methods:

• • TPD (Temperature Programmed Desorption): Studies the adsorption capacity and bond strength of adsorbates on the catalyst surface.

  • TPR (Temperature Programmed Reduction): Evaluates the reducibility of metal oxides.

  • TPO (Temperature Programmed Oxidation): Investigates oxidation or combustion processes of substances on the catalyst surface.

  • TPRx (Temperature Programmed Reaction): Monitors chemical reactions as temperature increases (e.g., CO oxidation light-off test).

  • Pulse Chemisorption: Measures metal dispersion, active surface area, and acid site density.

Technical Strengths for R&D Environments

The system is designed to handle analytical challenges in advanced research environments:

• • Wide temperature range: Operates from ambient temperature up to 1000°C, with a ramp rate of 1 – 20°C/min.

  • High sensitivity: The QGA 2.0 mass spectrometer detects from 100% down to below 100 ppb, with a response time under 300 ms.

  • Flexible gas flow control: Standard 4-channel MFC (expandable to 8 channels), supporting pulse and continuous flow modes.

  • Error minimization: Sampling probe placed close to the Hot zone combined with heated sample lines reduces memory effects and prevents vapor condensation.

  • Corrosion-resistant options: MFC valves made of Kalrez or PTFE materials for applications involving corrosive feeds or products.

Control and Analysis Software

The CATLAB PCS software runs on Windows, integrating automatic control of peripherals (MFCs, furnace temperature, switching valves, pulse injectors). MS data, temperature, and flow rates are collected within the same software package. Data analysis routines automatically determine metal surface area, dispersion, pulse adsorption isotherms, and reaction kinetics. MASsoft Professional software supports mass spectrometer control and detailed data processing.

Practical Applications

The CATLAB-PCS system is applied in various fields:

• Screening and evaluation of new catalysts.

• Kinetic and reaction mechanism studies.

• Assessment of catalyst deactivation causes during operation.

• Optimization of reaction conditions for reforming, hydrocracking, hydrodesulfurization (HDS), and isomerization processes.

Understanding catalyst characteristics not only improves production efficiency but also shortens R&D time. With CATLAB-PCS, researchers can move from observing surface phenomena to understanding the kinetic nature of the reaction.

For detailed consultation on the Hiden CATLAB-PCS solution, please contact:

• Website: www.reecotech.com.vn

• Email: info@reecotech.com.vn

• Sales Hotline: 0938 696 131