From fossil to renewable energy: a key role for catalysis

But what exactly is a catalyst and why is that research needed? A catalyst is a substance that forms the base of a chemical reaction without the catalyst itself being used. Key properties of a catalyst are activity, selectivity and stability. 

The activity determines to what extent the chemical reaction accelerates, with a high selectivity, there are as few waste products as possible and the stability determines the lifespan of the catalyst.

A catalyst does not have these properties automatically. The development of a catalyst can take years. Typical catalysts used by Shell consist of active components and a so-called carrier material. The active substance is usually a metal such as nickel, cobalt, iron, silver or platinum. The carrier material is often porous with a large internal surface, a bit like a fine sponge. On that internal surface, the active ingredient of the catalyst is then dispersed. That is where the chemical reaction takes place. 

ETCA makes catalysts in a so-called catalyst kitchen. First, we mix the various powder components and then we add a liquid to knead a kind of dough. This dough is pressed into spaghetti-like strings by a so-called extruder. These long strings are baked and then broken in little pieces. The researchers first make the catalysts at gram scale and test whether they meet the requirements. After a positive result, the extruder can produce the catalyst at kilogram scale, suitable for testing in a test installation. Once the development in ETCA is completed, the catalysts can be made on a large scale. Even if the catalysts are used in real plants, ETCA continues to play a major role in technical support.

Traditional catalysis research has resulted in a considerable number of innovations by Shell over the years, with the catalyst being key to success. One example is the gas-to-liquids (GTL) technology. This process converts natural gas into liquid products such as diesel, kerosene and lubricants. Without a catalyst, this technology is not technically feasible. 

Below are two examples of why catalysts can now play an important role in the energy transition:

• To store a surplus of renewable electricity, such as from wind turbines and solar panels, electricity can be converted into hydrogen. A catalyst helps to produce more hydrogen with the same amount of energy.
• Catalysts can convert CO₂ into fuels, making them carbon neutral when used. 

Shell researchers are working hard to further develop the new catalysts needed for the energy transition.