Modeling the aspect ratio of commercial catalysts.

Mathematical modeling plays a diverse and crucial role in the chemical industry and academia. This manuscript describes how the physical and mechanical engineering disciplines help the commercialization of catalysts from evaluation to scale‐up and manufacturing. Forming and shaping the catalyst is the first basic step in the catalyst manufacturing industry. Part A shows some of the classic process methods that are employed for this purpose. Catalyst extrudates require proper engineering and process control of their aspect ratio. Catalyst extrudates with a high aspect ratio tend to yield a low reactor fill due to a loose packing. Catalyst extrudates with a low aspect ratio tend to yield high pressure drop. Part B introduces the tensile strength of the catalyst in order to predict the aspect ratio of catalyst extrudates in commercial plants. A force‐balance between the tensile strength of the catalyst and the impact forces due to collision experienced during manufacture leads to the dimensionless group Be. The group Be allows to introduce and quantify the severity of equipment and the severity of entire commercial plants. [ABSTRACT FROM AUTHOR]