Commercialized catalysts are often needed in multiton quantities for industrial deployment. Although scalable, manufacturing methods to produce catalysts at quantity often produce materials with an ensemble of physical and chemical characteristics. This work explores an aerosol reactor to synthesize homogeneous, uniform catalyst materials in order to develop correlations between key chemical and physical characteristics and their resulting catalytic performance. With these insights, we optimize reactor processing conditions to engineer particles with the desired physical and chemical characteristics to produce enhanced performance catalysts. Control over several process parameters, including reactor residence time, temperature, precursor type, and precursor composition, allows for the rational determination of key physical and chemical characteristics on the resulting catalyst materials and enables process optimization to engineer catalysts with enhanced performance. To demonstrate the methodology, the aerosol reactor was used to synthesize and optimize WO _x catalyst materials for the isomerization and metathesis of a 2‐butene feed into propylene.

中文翻译：

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用于控制非均相催化剂颗粒合成的气溶胶反应器

为了工业应用，通常需要大量的商业化催化剂。尽管可扩展，但是生产大量催化剂的制造方法通常会产生具有物理和化学特性的集合的材料。这项工作探索了一种气溶胶反应器，以合成均相，均一的催化剂材料，以便在关键的化学和物理特性与其产生的催化性能之间建立关联。凭借这些见识，我们优化了反应器的加工条件，以设计具有所需物理和化学特性的颗粒，从而生产出性能更高的催化剂。控制几个工艺参数，包括反应器停留时间，温度，前体类型和前体组成，可以合理确定所得催化剂材料上的关键物理和化学特性，并可以进行工艺优化以设计出性能更高的催化剂。为了演示该方法，使用了气溶胶反应器来合成和优化WO _x用于2-丁烯进料到丙烯的异构化和复分解的催化剂材料。