Page 138 - Principles of Catalyst Development
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126 CHAPTER 6
and formulation, but is difficult for precipitation and deposition. These are
usually handled by batch or semibatch processes, with intermediate storage
to ensure continuous downstream processing. Continuous adsorption or
impregnation is practiced with belts or baskets moving through tanks or
with spraying.
6.7.3. Energy Conservation and Environmental Control
Washing, drying, and calcination in the laboratory do not pose serious
energy or pollution problems. With large-scale processing, heating steps
must be adapted to minimize energy consumption. This is possible with
good engineering design and control. Water and volatile effluents from
washing and heating must be cleaned before discarding or reuse. In severe
cases, expensive processing may be necessary. If at all possible, manufac-
turers try to minimize these problems through modification of the precipita-
tion steps.
6.7.4. Multiproduct Flexibility
Some products, such as catalysts for cracking, hydrotreating, and
reforming, are consumed in such large quantities that plants may be dedi-
cated to their production. Most catalysts, however, do no justify special
facilities, especially in pilot testing. Manufacturers prefer to use existing
equipment for producing different catalysts. An available facility may not
be the most optimum, but its use could result in substantial savings, even
if modifications of the recipe are required.
6.7.5. Confidentiality, Secrecy, and Know-How Protection
Catalyst manufacturers face special problems with confidentiality,
secrecy, and know-how protection. Because of the nature of their business,
they enter into confidentiality agreements with many customers. Care must
be taken to ensure that proprietary information does not pass outside existing
and past agreements. Secrecy is very strict, sometimes even within a single
organization, where different groups may be collaborating with competing
customers.
Solutions to problems in scale-up become part of the manufacturer's
assets. Such solutions are keys to commercial successes and constitute
competitive advantages. For this reason, technology within a plant is care-
fully guarded and protected.