A leading European research institution required manufacturing 10 kg of bespoke catalyst for a pilot test. The catalyst preparation procedure was based on a 10 g laboratory-scale process that required developing a scale-up approach.
Is the 10 kilo scale a problem?
Bespoke catalysts on a multi-kilogram scale are usually impossible to procure from major suppliers due to:
(i) 10 kilo scale is too small for commercial production, and
(ii) the catalyst preparation recipe is often not directly scalable.
Stoli offered a service to develop a scale-up procedure, validate that the catalyst meets specifications, and manufacture the required catalyst amount.
What did we do?
Firstly, we adapted the lab-scale catalyst preparation procedure for the large-scale manufacture. We obtained samples of catalysts using both procedures.
A detailed characterisation of the lab-scale recipe and a small amount catalyst produced with the kilo-scale recipe confirmed identical characteristics.
Once the scaled-up manufacturing procedure had been validated with characterisation, we rapidly prepared 10 kg of catalyst.
Stoli met the customer requirements and shipped the catalyst to the customer within weeks. The catalyst was successfully demonstrated in a biofuel production process.
The catalyst recipe and method developed by Stoli could be used directly for commercial-scale production.
Stoli cascaded imine formation and hydrogenation; intensified process to maximise rate, and catalyst utilisation.
We completed in situ synchrotron studies of a customer’s catalyst at the Diamond Light Source Facility.
Short residence time and high temperature – an impossible combination for batch – allowed increasing specific reaction rates 8-fold in flow with the same product quality.
We have developed a monolith-based fuel cell catalyst for sustainable remote energy generation.
After 100 long-term runs and building a bespoke reactor system to manage safety risks, we developed a stable catalyst with months at least 2 month lifetime.
With Stoli proprietary coating technology, we developed a novel catalyst coating for an intensified reactor for a more efficient and sustainable process.