Fluid Catalytic Cracking

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Catalyst Manufacturing Science and Engineering Consortium (CMSEC) Rutgers University New Jersey, U.S.A.

Rutgers Catalyst Manufacturing Science and Engineering Consortium (CMSEC) Rutgers Catalyst Consortium since 2003 While a large segment of the US industry, including the petroleum, chemical, pharmaceutical, automotive, and energy industries makes and/or uses catalysts, there has been no academic program focusing on the operations required to make catalytic materials. Thus, catalyst manufacturing processes are often designed relying on empiricism, leading to uncertain/suboptimal processes, decreased quality, and increased cost. By combining the substantial level of expertise in particle technology, optimization, multi-scale simulation, catalysis and molecular modeling available at Rutgers, we are developing and promoting science-based methods for designing and optimizing catalyst manufacturing methods and processes such as impregnation, drying, slurry mixing, extrusion, calcination, etc. This is integrated with a number of educational activities including research training of undergraduate students, graduate students and postdoctoral fellows in the area of Catalyst Manufacturing. A combination of experiments and computer models has been used to improve the understanding and performance of the unit operations used to make catalysts. This knowledge, and the resulting methods and practices, have been transferred to Industrial partners to help transform this important segment of the global economy into a science-driven enterprise. The specific goals of the consortium are: • To create a world-wide prime Center of Excellence in catalyst manufacturing research. • To enhance fundamental understanding of catalyst manufacturing operations. • To develop new technology for efficient catalyst manufacturing. • To provide a research, development, and education resource for industry. The consortium was founded on October 1, 2003. The Rutgers faculty that are currently participating in the consortium and their expertise areas are: Benjamin J. Glasser (drying, fluidized beds), Johannes G. Khinast (drying, catalysis), Fernando J. Muzzio (particle technology, mixing), Arthur Chester (industrial liaison, catalyst preparation), William Borghard (calcination, catalyst preparation), Silvina Tomassone (impregnation, interfaces), Alberto Cuitino (particle technology, compaction), and Rohit Ramachandran (particle technology, agglomeration). The annual fee for membership in the consortium is $35,000. These are unrestricted funds for research. The consortium members (companies and faculty) meet every 6 months (October and March) for project reviews. In the October meeting, the consortium decides on continuing with current projects or starting new projects. Where consensus is not possible, a vote is taken, with each company getting one vote. Copies of the slides from the talks at the consortium meeting are made available to the consortium members. In addition, each project provides a written report on progress every six months. A list of possible manufacturing operations of interest to the consortium is given below: Powder blending, Powder sampling, Calcination, Slurry Mixing, Pellet compaction, Roller Compaction, Powder segregation, Catalyst drying, NonNewtonian Liquid Mixing, Powder Flow/Handling, Multiphase Flow/CFD, Dispersion of solids, Impregnation, Mulling, Extrusion , Nano-templating, Fluidized bed coating, Granulation, Catalysis, Spray Drying, Atomization, Flash/Rotary Drying/Calcination, Plow-shear mixing, Liquid-Solid Separation (Filtration/Flocculation), Precipitation Catalysts. Projects that are currently funded by CMSEC are: • Impregnation of Catalysts • Drying of Supported Catalysts • Calcination • Powder Flow, Handling and Characterization • Sensing of Mulling Operations Projects that have been funded by CMSEC in the past include: • Powder Segregation • Mulling/Extrusion of Catalyst Supports • Slurry Mixing • Continuous Powder...
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