Module 1 : Introduction

Lecture 1: Introduction to catalysis

 

History : Catalyst technology has been used for many centuries. It ranged from inorganic catalyst to make soaps to enzyme catalysts for producing wines, cheese and other food and beverages. The industrial catalyst technology started with the large-scale production of sulfuric acid on platinum catalyst in 1875. In subsequent years, various major catalytic processes were invented. In 1903, ammonia oxidation on Pt gauge was developed by Ostwald for nitric acid production. Another major breakthrough was ammonia synthesis with promoted iron in 1908-1914 by Mittasch, Bosch and Haber.

Conversion of synthesis gas to liquid hydrocarbons by hydrogenation of CO, which was developed in 1920-1940, was a major development in the energy sector. In petroleum industry, the development of catalytic cracking process during 1935- 1940 changed the energy scenario. This process used a solid catalyst in the petroleum industry for the first time. Subsequent decades saw the development of various catalytic hydrocarbon processes such as catalytic naphtha reforming (1950) and hydrotreating for removal of sulphur, nitrogen, metals from petroleum feed stock (1960). With the discovery of Ziegler-Natta catalyst in 1955, the polymer industry grew significantly. The first large scale industrial homogeneous catalytic process came up in 1960 in the form of Walker process for making acetaldehyde from ethylene. The development of shape selective catalysts such as molecular sieves or zeolites for cracking (1964) resulted in the production of exclusively shape selective products. The other major development in cataly sis was in 1970-1980 for environmental pollution control. Noble metal catalysts were developed for emission control of CO, NOx and hydrocarbons from automobiles. Vanadia-titania and zeolite catalysts were developed for selective reduction of NO x . Catalysis is a continuously growing area and discovery of new catalysts and their applications has led to major development in the chemical industry.

The economic significance of the catalyst industry is enormous. The catalytic processes contribute greater than 35% of global GDP. The world catalyst industry amounts to US $ 12 billion. It is expected to grow annually by 6 % to US $ 16 billion US$ in 2012. Polymerization catalysts are expected to grow most rapidly due to significant expansion in polymer industry. Enzyme and organometallic catalysts will also grow. Reduction of sulphur levels in fuels and ongoing shifts towards heavy grade crude oil with high sulphur content is expected to contribute to the growth of catalytic hydrocarbon industry.

Catalysis involves understanding of the thermodynamics, kinetics, electronic interaction, crystal structure, reactor design and process development for a catalytic process. It is an interdisciplinary area involving contribution from chemical engineers, chemists and material scientists for successful implementation of the entire process starting from preparation of catalysts to final utilization in a chemical reactor.