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Catalyst Selection and Production Optimization

Introduction

Catalyst Selection and Production Optimization

Catalyst Selection & Production Optimisation Course Objectives

​By the end of this Catalyst Selection & Production Optimisation training course, participants will be able to:​

• Demonstrate foundational and advanced understanding of industrial catalytic processes, including their roles in refining, petrochemical, and polymerisation applications.
• Evaluate and select appropriate catalysts for various industrial reactions, including alkylation, hydrogenation, dehydrogenation, isomerisation, hydrocracking, and catalytic reforming. Decisions are guided by process chemistry, operating conditions, and desired product specifications.
• Apply modern catalyst characterisation and evaluation techniques, including activity profiling, selectivity analysis, regeneration protocols, and catalyst life-cycle optimisation.
• Design and optimise catalytic systems within reactor environments, considering key factors such as feedstock variability, process integration, and reaction kinetics.
• Implement and troubleshoot Ziegler-Natta polymerisation processes, focusing on stereochemistry control, active site behaviour, and catalyst morphology in both heterogeneous and homogeneous systems.
• Deploy metallocene and post-metallocene single-site catalysts with precision for advanced polyolefin production, addressing polymer structure-property relationships and co-catalyst interactions.
• Analyse catalyst reaction mechanisms, including initiation, propagation, chain transfer, and deactivation, with insights into structure-reactivity correlations and kinetic modelling.
• Interpret the influence of ligands, counterions, co-catalysts, and electronic effects in designing high-performance catalysts for polymerisation and refining applications.
• Examine current innovations and competitive advances in catalyst technology, such as constrained geometry catalysts, late-transition-metal systems, and new-generation polyethene catalysts (e.g., NovaCat T).
• Anticipate future industry needs and R&D directions, including functionalised polymer synthesis, polar monomer incorporation, catalyst sustainability, and digital tools for catalyst simulation and optimisation.

Who Should Attend?

• Chemical Engineers and Process Engineers
• Senior Operators and Plant Technicians
• Technical Managers and Superintendents
• R&D Engineers, Scientists, and Laboratory Chemists
• Professionals engaged in troubleshooting, production enhancement, or catalyst procurement.

Course Outline

Module 1: Catalysis and Process Chemistry Overview

• Pre-Test assessment of existing knowledge
• Introduction to Industrial Chemistry and Refinery Operations
• Role of Catalysis in Process Design and Optimisation
• Process Plant Configuration: Reactor vs. Separation Section
• Catalyst Classification and Performance Metrics

Module 2: Core Industrial Catalytic Processes

• Alkylation: Process chemistry, feedstock, catalyst mechanisms, operational variables
• Hydrogenation: Catalyst types, reaction conditions, evaluation techniques
• Dehydrogenation: Mechanisms, catalyst ageing, optimisation techniques
• Isomerisation: Catalyst structure-activity relationships, selectivity improvement
• Hydrocracking & De-alkylation: Reaction pathways, catalyst systems, performance analysis
• Fluidised Catalytic Cracking (FCC): Reactor design, catalyst regeneration, yield optimisation
• Hydrodesulfurization (HDS): Sulfur removal technologies, catalyst life-cycle
• Catalytic Reforming: Aromatisation processes, catalyst performance criteria

Module 3: Polymerisation Catalysis – Ziegler-Natta Systems

• Overview of Ziegler-Natta Catalyst Technologies
• Heterogeneous vs. Homogeneous Catalysts
• Mechanisms of Polymerisation and Stereochemical Control
• Process Conditions for Polyolefin Production

Module 4: Metallocene and Post-Metallocene Catalysts

• Historical Development and Industrial Role
• Titanocene, Zirconocene, and Lanthanide Catalyst Families
• Catalyst Activation, Chain Propagation, Transfer & Deactivation
• Role of Co-catalysts, Ligands, and Counterions
• Mechanistic and Structural Comparison: Single-site vs. Multi-site Catalysts

Module 5: Advanced Single-Site Catalysis and Functional Polymer Design

• Constrained Geometry and Late Metal Catalysts
• Amide-Based Ti/Zr Catalysts, Di-imine Ni/Pd Catalysts
• Pyridine Bis-Imine Fe/Co Catalysts and SHOP Systems
• Functionalized Polyolefins and Polar Monomer Copolymerization
• Future Trends in Single-Site Catalysis

Module 6: Competitive Technology and Innovation in Catalysis

• Ziegler-Natta vs. Metallocene: Comparative Process Analysis
• NovaCat T and Next-Generation Polyethene Catalysts
• Multiple Process Technology Integration
• Industry Strategies for Catalyst Innovation

Module 7: Capstone and Assessment

• Review of Core Topics and Key Learnings
• Final Group Discussion and Q&A
• Post-Test Evaluation
• Certificate Presentation