Catalyst and Adsorbent Development

From Raw Material Selection to Full Scale Production
Metal foam substrate coated with a specialty catalyst

Environex works with clients to develop novel catalysts and adsorbents, from material selection through scale-up for commercial production lines. Environex selects the right materials, measures catalyst performance, and tests durability.

In addition to catalyst and adsorbent development work, Environex’s scientists are able to select and adapt commercially available catalysts to a client’s desired application. Laboratory facilities are available to test catalysts and adsorbents for aging, contaminant resistance, performance, and durability to guide product development and benchmark against existing designs.

Environex has experience working with

Raw Materials

  • Precious Metals (PGM)
  • Ceria & Zirconia
  • Titania
  • Alumina
  • Zeolite
  • Silica
  • Inorganic and Organic Binders
  • CARULITEĀ® 400 Catalyst

Substrates

  • Ceramic Honeycomb
  • Metal Honeycomb
  • Metal Foam
  • Pellets
  • Spherical Beads & Trilobes
  • Polyethylene Foam
  • Metal Plate
  • Paper

Applications

  • Three-Way Catalysts (TWC)
  • Diesel Oxidation Catalysts (DOC)
  • CO and VOC Oxidation Catalysts
  • Selective Catalytic Reduction (SCR)
  • Water Adsorption
  • Ozone Destruction Catalyst
  • Sulfur-Resistant DOC
  • Oxygen Storage
  • Catalysts for High or Low Temperature Environments

Catalyst and adsorbent development, with or without active catalytic materials, is associated with an array of challenges:

Washcoat Batching

Environex understands the unique requirements of coating on different substrate materials, the importance of substrate preparation, as well as how critical it is to get washcoat particle size distribution, rheology, pH, viscosity, and additive ingredient selection right. Whether your application requires low back-pressure, a high porosity washcoat, a high adsorption rate, high adsorption capacity, or poison resistance, Environex can help optimize your washcoat in a way that is as coatable as it is effective.

Washcoat Coatability

Coatability is critical to developing a catalyst which can be reliably and cost-effectively coated with minimal waste of materials. To create an effective coating, particle size distribution of the washcoat material must be properly controlled. Rheology and pH are critical to fluidity and adhesion to the substrate surface.

Substrate Selection

It is critical to understand substrate characteristics in order to provide a quality washcoat. Substrate adhesion can be a challenge, particularly when dealing with non-ceramic substrates such as metal and polyurethane; some of these materials require specialized pre-treatment to ensure adhesion. Coefficients of expansion characteristic of each substrate material are also critical to understand, as some washcoat formulations will be more prone to flake off under repeated expansion and contraction cycles. The effect of substrate porosity on washcoat uptake is another factor critical to performance and the ultimate materials cost.

Catalyst Durability

Different applications must withstand different environments and will thus have different durability requirements. These requirements are considered when developing the coating technique for your application to ensure suitable substrate, particle size, and binder choices. Environex has worked with a wide variety of applications and can tailor durability testing conditions to your unique needs. We have standard procedures for adhesion testing and hydrothermal aging to ensure the reliability of your washcoat throughout its full useful life.