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Catalyst impregnation is one of the most crucial steps for preparingindustrial catalysts. The inter-particle variability of the impregnated liquidinside the particles significantly affects the activity and selectivity of thecatalyst. Current scale-up practices lead to poor fluid distribution andinhomogeneity in the liquid content. This work aims to understand the dynamicbehavior of the particles under the spray nozzle and to develop a scale-upmodel for dry impregnation processes. We considered five dimensionless numbersin the scaling analysis. We performed Discrete Element Method simulations andexperiments of dry impregnation inside porous particles for different vesselsizes. The water content of the particles was compared for other timeslocations, and the relative standard deviation (RSD) was calculated from theaxial water content. Simulation and experimental results show excellentagreement, confirming that the scale-up rules apply to all vessel sizes.

Scale-up of Dry Impregnation Processes for Porous Spherical Catalyst Particles in a Rotating Drum: Experiments and Simulations