Porosity is a factor affecting catalyst efficiency in
pelletized
form. This implies that care should be taken with uncritically relating
activity measurements from transmission operando FTIR to final catalyst
performance. If the pelletizing pressure is excessive, a destruction
of the pore structure of, for example, support oxides might take place,
which in turn affects the pore size distribution and the porosity
of the catalyst, leading to the observation of lower activity values
due to decreased catalyst efficiency. This phenomenon can also apply
to conventional activity measurements, in the cases that pelletizing
and recrushing of samples are performed to obtain adequate particle
size fractions for the catalytic bed. A case study of an operando
investigation of a V2O5-WO3/TiO2-sepiolite catalyst is used as an example, and simple calculations
of the influence of catalyst activity and internal pore diffusion
properties are considered in this paper for the evaluation of catalyst
performance in, for example, operando reactors. Thus, it is demonstrated
that with a pelletizing pressure of <1–2 ton/cm2, the pore structure is only negligibly altered, and small deteriorations
of estimated catalyst efficiencies are observed for first-order kinetic
constants lower than 100 mL/gs. However, if the operando study deals
with highly active catalysts, it is necessary to consider efficiency
losses. A simple procedure for evaluating efficiencies based on pellet
dimensions and solid phase characteristics is proposed. The Thiele
modulus is directly proportional to the thickness of the pellet, and,
thus, inversely related to the catalyst efficiency. As a rule of thumb,
we found that for catalytic constants below 100 mL/gs, the maximum
thickness of the pellet pressed at 2 tons/cm2 has to be
as low as 80 μm to exhibit catalyst efficiencies above 90%.
For catalysts with k′ = 10 mL/gs, the value
is 260 μm. This strongly underlines the importance of taking
internal diffusion limitations into account when working with highly
active catalysts.