Catalyst substrate spheres (CSS)

BASF catalyst substrate spheres (CSS) are smooth spheres of activated alumina produced by BASF's unique manufacturing processes.

BASF CSS have seven special properties, which comprehensively are not normally found in other catalyst substrate spheres: (1) uniform size, (2) low abrasion loss, (3) smooth surface, (4) high crush strength, (5) low water breakage, (6) controlled surface area, and (7) controlled pore volume. CSS are designed especially for catalyst and petrochemical companies who manufacture finished catalysts.

1. Uniform size: BASF CSS are uniformly sized spheres. The uniform size yields a low pressure drop. Higher pressure drop results in less throughput and higher operating costs. More importantly, the uniform size minimizes channeling yielding a uniform reaction throughout the entire system.

2. Low abrasion loss: The low abrasion loss of CSS ensures that metals impregnated on the catalyst stay on the catalyst.

3. Smooth surface: BASF CSS's smooth allows optimum flow through a reactor bed. Optimum flow ensures that uniform temperatures are achieved yielding better selectivity and conversions.

4. High crush strength: CSS's high crush strength is especially important during the impregnation and subsequent calcination step in catalyst formulation. Since most impregnation solutions are acidic and activated aluminas are very soluble at a pH less than four, the spheres are susceptable to attack by the solution. Upon subsequent calcination, fines can be generated. BASF's CSS all have exceptionally high crush strength to minimize this problem.

5. Low water breakage: Catalyst substrate spheres evolve high heats of wetting when immersed in impregnating solutions. As the solution fills pores and displaces air, bubbles are emitted. The escaping gas pressure can be so high that some of the spheres break. Each lot of CSS is carefully analyzed to ensure low water breakage.

6. Controlled surface area: Two distinct types of CSS are available:
  • High surface area: BET surface area is as high as possible to maximize surface activity.
  • Intermediate surface area: Surface area is reduced via calcination to 165 m2/g to shift pore volume distribution, converting micropores to mespores.
Customers desiring lower surface areas should consider BASF's SAS premium support spheres.

7. Controlled pore volume: Total pore volume is controlled to nominal 0.5 cc/g in above products. With relatively high macropore and total pore volumes, Engelhard CSS are ideal for use as a catalyst substrate. Impregnation with metals and similar active agents, via spray or solution processes, results in a finshed catalyst with superior physical properties.

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