Proposal Title Commercialization of PyroCat(tm) Catalyst in Leading Reforming and Destructive Oxidation Catalyst Markets
Category Materials Science and Advanced Manufacturing
Abstract Pyrochem Catalyst Company (PCC) makes PyroCat™, a novel catalyst. Catalysts play a key role in our everyday lives. Without catalysts, we couldn’t upgrade fuel, make chemical products like ammonia, methanol, plastics, nor clean our automotive exhaust streams. Over $16 billion of catalyst is sold annually in PyroCat™ target markets. PyroCat™ is a patented crystalline mixed metal oxide catalyst where the catalytically active metal is atomically dispersed in a pyrochlore crystal lattice. This is important to achieving similar or higher catalyst performance with 10-100X lower precious metal content compared to conventional catalysts. This significantly reduces the cost of the catalyst while extending longevity. PyroCat™ has been tested by PCC’s customers to show that these materials are capable of handling the build-up of catalyst poisons, like sulfur, at concentrations far higher than those present in commercial and military fuels. In addition, the PyroCat™ provides inherent thermal stability, making it a high-value material for high temperature applications (>900C). PyroCat™ is applicable in a number of markets: 1) steam methane reforming for hydrogen production for oil refining and chemical products manufacturing; 2) autothermal reforming for use in fuel cells, for example; 3) destructive oxidation for automotive catalytic converters; and 4) oxygen transport membranes (OTM) developed by leading gas products companies. Given its suitability in high temperature environments or where contaminants like sulfur or poly aromatics are present, PyroCat™ is expected to capture market share. This proposal expands our commercialization activity to build-on the initial success of PyroCat™ in customer trials. PCC will work closely with prospective customers to tailor PyroCat™ to meet their specific needs. PCC will supply catalyst to these customer prospects using the innovative spray pyrolysis manufacturing process developed with NSF and Kentucky Phase I funding, with the goal of generating revenue and positive cash flow for the company within 18 months.
Amount Awarded $390,000
Keywords Flame spray pyrolysis, Pyrochlores, Natural gas reforming, Hydrogen generation, Diesel reforming, Solid Oxide Fuel Cells, Fuel Cells, Syngas generation, Autothermal reforming, destructive oxidation
Point of Contact Tim Appleberry
[email protected]
Pyrochem Catalyst Company
Location Louisville
Jefferson County