CAI Catalysts, LLC services

CAI experts will evaluate your current manufacturing and process control procedures and provide recommendations for areas of improvement to meet your specific quality and cost goals.

Many times our customers have a catalyst formulation that has already been developed in the laboratory, or has successfully passed pilot studies. CAI can provide the expertise needed to qualify these systems and quickly get them into full commercial scale manufacture. Our experience with developing catalyst coating processes for a variety of substrates (ceramic honeycomb, metallic honeycomb, foamed supports, wire mesh, and more) coupled with various coating formulations (alumina, mixed oxides, titania) and catalyst formulations (both precious metal and base metal) provides our clients with the breadth and depth of knowledge to develop a full range of manufacturing solutions for their catalyst needs.

Comprehensive services are supplied that include production procedures, manufacturing system specifications, raw material sources, equipment, plant layout, quality control and quality assurance documentation and procedures, and more. In addition to developing and implementing manufacturing systems for catalyst production, CAI also can provide clients with the technology and equipment for fabricating metallic honeycomb substrates in-house in a full range of sizes.

CAI can provide a variety of proprietary coatings that provide catalytic activity for a range of chemical processes. These include both precious metal (platinum, palladium, rhodium, ruthenium) and base metal catalysts technologies to provide optimum performance and durability for each application. Specific areas of expertise include: Emission control (mobile, small engine, stationary source). Steam reforming. Syngas conversion. Gas-to-liquid (Fischer-Tropsch). Fuel cells.

The CAI staff have extensive backgrounds in the evaluation of the performance as well as the chemical and physical analysis and characterization of both fresh and used catalysts. We help our clients develop analytical strategies for determining the presence and quantities of both catalyst components and foreign contaminants on catalyst surfaces and testing approaches to evaluating the comparative performance of catalysts under simulated in-use conditions. Often the combination of both analytical and performance testing data are required to create a clear understanding of the causes for observed variations in catalyst function.