Process-oriented approach towards catalyst design and optimisation

Translation of catalysts developed in academia to industrial end-users remains a challenge due to a lack of knowledge about the impact of catalyst attributes on the whole process and vice versa. A systematic methodology is proposed that assesses these in terms of Key Performance Indicators (KPIs). As a case study, the dehydration of butanol to butenes and dibutyl ether is considered over H-ZSM5 and H-Beta catalysts. It is demonstrated that catalysts should be designed for complete conversion and high butene selectivity, as removal of unreacted 1-butanol requires a complex separation due to the thermo-physical properties of the product mixture. [Display omitted] •An integrated methodology is proposed to aid catalyst selection and design.•Advanced approaches are used for kinetic modelling and process design.•The impact of uncertainties in the kinetic parameter is quantified for H-ZSM5 and H-Beta catalysts.•1-butanol dehydration process is used as a case study to compare two catalysts.•Results showed that complete conversion is needed for an optimum catalyst/process.