The catalyst evaluation system is a core tool for the research and industrial application of catalytic materials. Its performance runs through the entire life cycle of catalysts, from laboratory screening to industrial scaling and failure analysis. The core performance can be summarized into four dimensions: high-precision quantification, operating condition simulation, efficient screening, and intelligent decision-making. The specific details are as follows:
1、 Quantification of Basic Performance: Accurately Describing the "Energy Profile" of Catalysts
Determination of conversion rate and reaction rate
Quantify the catalytic efficiency of the catalyst under specific conditions (such as SCR denitrification efficiency>95%) by testing the NOx conversion curve at an air velocity of 20000 h ⁻¹ using a fixed bed reactor.
For example, in the development of fuel cell catalysts, the conversion frequency (TOF) of oxygen reduction reaction (ORR) can be measured to guide the design of highly active catalysts.
Selective optimization
Identify side reaction pathways (such as the oxidation of NH3 to generate N ₂ O) and quantify the yield of the target product. For example, in CO ₂ electroreduction, it is required that the Faraday efficiency of the C ₂+product be ≥ 80% to reduce the generation of by-products.
Stability and lifespan prediction
Test the activity decay rate for continuous operation for ≥ 500 hours (if the fuel cell catalyst requires a decay rate of<5% after 100 hours), and predict the industrial lifespan.
Simulate long-term operational effects through accelerated aging testing (such as 800 ℃ high temperature and high humidity environment) to reduce industrial amplification risks.
2、 Working condition simulation: building a bridge between laboratory and industry
Complex environment construction
Simulate industrial operation fluctuations (such as air-fuel ratio transients) to evaluate the catalyst's anti-interference ability. For example, a three-way catalyst needs to respond to changes in λ within 0.1 seconds to ensure the stability of automobile exhaust treatment.
Construct a testing environment containing toxic components (such as SO ₂ 200ppm and H ₂ O10% in SCR systems) to verify the catalyst's resistance to poisoning.
Adaptation to extreme conditions
Support industrial grade testing under high temperature (400-600 ℃), high pressure (5MPa) and other conditions to ensure the consistency of catalyst performance under real working conditions.
For example, in the coal gasification process, evaluating the catalytic efficiency of catalysts for coal gasification and synthesis gas conversion can promote the green development of the coal chemical industry.
Analysis of deactivation mechanism
By using TPO (temperature programmed oxidation) to detect carbon deposition and TPD (temperature programmed desorption) to analyze the loss of acidic sites, the root cause of deactivation can be identified.
Establish a quantitative model of the number of active sites and TOF using linkage characterization methods (such as NH ∝ - TPD acid strength measurement+reaction testing) to provide a basis for catalyst regeneration.
3、 Efficient screening and industrial validation
Multi channel parallel testing
A 16 channel parallel system (such as MicroactivityEffi) tests 50 sets of formulas daily, which is 15 times more efficient than traditional single channel systems and significantly shortens the development cycle.
For example, in petroleum refining, catalysts for hydrogenation cracking, hydrogenation refining and other reactions are screened simultaneously to optimize refining efficiency.
AI driven virtual optimization
Train AI models using evaluation data (such as neural network prediction of CoMo catalyst hydrogenation desulfurization activity), virtually optimize the formula, and reduce the number of experiments.
For example, analyzing the relationship between catalyst structure and performance through machine learning can guide the design of new catalysts.
Exploration of process parameters
Explore the optimal reaction parameters (such as temperature, pressure, and raw material ratio) to provide data support for industrial scaling up.
For example, in the synthesis of ammonia reaction, an evaluation device is used to determine the temperature range (400-500 ℃) and pressure (20-30MPa) with the highest catalyst activity.
4、 Intelligence and automation: improving experimental efficiency and reliability
Full process automation control
All system controls are automated using PLC software, monitoring the reaction process in real-time, processing data automatically, and providing a complete set of experimental plans.
For example, the Oushi Sheng EMC series catalyst evaluation device achieves full process automation from sample injection, reaction condition setting to data acquisition and processing, reducing human errors.
High precision monitoring and feedback
Equipped with cutting-edge intelligent control system, real-time monitoring of key parameters such as temperature and pressure, with a control accuracy of ± 0.1 ℃, ensuring the stability of experimental conditions.
For example, accurate positioning of preset pressure can be achieved through nonlinear fitting techniques to improve the accuracy of experimental data.
Safety and Environmental Design
Equipped with multiple safety measures such as over temperature power-off protection system, over pressure relief alarm, emergency stop setting, etc., to ensure the safety of the experiment.
For example, a tolerance type liquid level sensor for gas-liquid separators can detect liquid volume with an accuracy of ± 0.1mL, preventing liquid overflow and environmental pollution.