where P 1 is the initial weight of the fresh sample after sieving, P 2 the weight of the tested sample after sieving and P 3 the weight of fines.3.1.4.3.1 Grains or Powders Conventional catalyst attrition testing has been used for years to provide refiners with a relative measure of catalyst attrition resistance (commonly referred to as ''hardness''). Some tests use a high-velocity stream of gas to cause attrition of the catalyst. The major attrition test uses an air jet device. This apparatus measures the creation of 0-20-µm particles formed by particle-to-particle collisions in a high-velocity air jet. This measurement best represents the tendency of the catalyst to undergo attrition due to high jet velocities inside a fluid bed reactor.For quantification of the results of attrition tests, Grace Davison has specified the DI (Davison Index), which is measured using a jet-cup technique. In some tests, a small-scale plant which simulates the commercial plant is used. The amount of attrition measured in all these tests is very dependent on the exact procedure used. Reproducibility among laboratories is likely to be possible only if precise details of the method are given.In essence, the attrition test results are not scalable as a good indicator of unit retention performance.
Attrition Resistance of Coated MonolithsWashcoated catalyst supports suffer from several disadvantages in use. In service, the supports are exposed to a flow of gases that often contain dusts or particulate matter, which can cause abrasion of the active layer.
Adhesiveness of CoatingsApart from high dust exposure, a high surface area coating can flake off from the underlying ceramic or metallic support when the support is exposed to temperature cycles because the wash coat and the underlying ceramic material often have different thermal expansion coefficients.Several techniques have been developed by individual producers for testing the adhesiveness of a catalytic wash coat on a metallic or ceramic support. A simple example is to scratch with a specially designed tip of a needle at constant force on a plain part of a wash coat. The result should be a microscopically clear cut and no flake-off. A slightly more complicated test is the DIN EN ISO 2409 Cross Cutting, which also shows the adhesiveness of coatings on the carrier surface. The adhesiveness is determined by cutting in the varnish surface at a distance of 2 mm (1 mm in case of a layer less than 60 µm thick) in parallel lines down to the carrier surface and repeating this process after rotating the specimen by 90 • so that the cuts cross.The results are classified into different characteristic values (GT 0-5) by comparison with standard images of increasingly damaged coatings stating the adhesive loss on the test surface as a percentage. However, because the morphology of most of the monolith catalysts is characterized by a very fine fin structure, the cross cutting test needs to be performed on an equally treated separate plain model piece.Other methods such as those that are used in th...