Catalyst Producers

Catalyst companies running an existing catalyst plant are constantly facing issues such as how to improve throughput and product consistency from available assets, how to minimize costs, how to produce new products in existing assets and how to minimize environmental impact? 

These are all practical questions as demand for catalyst may increase, environmental regulations get tightened, or competition may increase and there is a need for a better performing products at lower manufacturing cost. A plant may be de-bottlenecked by making some hardware changes or by making some catalyst recipe changes. Manufacturing costs may also be reduced by switching to another raw material. It is our role to help our clients find the best way to optimize their production process. 

When you are building a new plant or de-bottlenecking an existing plant, we can assist with the design, construction, commissioning and start-up of the plant. We can also assist with product trial runs when products from the lab are produced on a large scale for the first time and fine adjustments need to be made to get acceptable production rates and quality. 

Manufacturing experts at Catalyst Intelligence have experience with debottlenecking studies, project execution, product scale-up, transfer from one production line to another line and identification of the best available technology for minimizing environmental impact. These projects often span a period of several months, including trials of new equipment at equipment suppliers or at the plant site. Given the scale of such projects and the amount of Capex involved, it is beneficial to form a multi-disciplinary team with specialists from the client and specialists from Catalyst Intelligence. Combining in-house expertise with complementary (temporary) external expertise means that manufacturing projects get completed on time, at lower costs and lower risk.

Next to assisting with catalyst manufacturing, we have also assisted existing catalyst companies with a review of their product portfolio to minimise the production and storage of slow moving inventory, effectively eliminating obsolete products. This project resulted in a much lower inventory (working capital) at the catalyst producer, and lower production costs for remaining grades. In addition, we have also participated in a long-term R&D strategy project, where we identified emerging technologies of interest to a catalyst producer allowing a strategic decision on which technologies to invest in. 

See also our blog with articles that might interest you.