HiSiaddi is an innovative foreign trade service provider driven by dual engines of technology transformation and foreign trade services. It has established a "1+2+3+4=1" service system and can supply original factory products of high-activity ruthenium-based hydrogenation catalysts from multiple well-known brands. As a foreign trader with R&D attributes, HiSiaddi has repeatedly collaborated with factories on technology transfer and accurately captured market demands, frequently proposing formulation optimization schemes and application improvement suggestions for high-activity ruthenium-based hydrogenation catalysts. Below is a consultation case where HiSiaddi optimized catalyst formulations.
Please contact HiSiaddi customer service if you need more formulation optimization consultation services.
The client is NORD BIO AB, a Swedish high-end bio-based material enterprise specializing in eco-friendly degradable materials and high-end food additive intermediates, supplying leading Nordic food and daily chemical manufacturers. The company complies with EU food contact material standards, REACH and GLP specifications, representing a typical overseas medium-to-high-end client.
Annual procurement volume of high-activity ruthenium-based hydrogenation catalyst: 260 kg, applied to continuous hydrogenation processes of vegetable oil derivatives. The client previously imported foreign catalysts and switched to domestic high-activity ruthenium catalysts to optimize supply chains. After material commissioning, continuous production line failures occurred including rapid activity decay, reduced selectivity, fine powder entrainment in materials and severe system foaming, jointly lowering product purity and production efficiency. Internal technical teams repeatedly adjusted reaction temperature, pressure and feed ratio without fundamental solutions, prompting the client to commission HiSiaddi for fault diagnosis, formulation optimization and process adaptation rectification.
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Rapid catalyst activity decay, insufficient service life Under client operating conditions (85°C, 1.6 MPa), domestic catalysts suffered obvious activity loss after 120 hours of continuous operation, with hydrogenation conversion dropping from initial 99.4% to below 93%, far inferior to imported catalysts stable for 500 hours. Testing revealed active sites covered by reaction by-products accompanied by mild agglomeration of ruthenium microcrystals, reducing effective active surface area.
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Deteriorated hydrogenation selectivity, excessive by-products The target reaction is directional hydrogenation of unsaturated C=C bonds, yet over-hydrogenation occurred during mass production, pushing by-product content up to 2.7% and exceeding the client’s internal control limit of ≤1%. This reduced main product yield and rendered downstream food-grade intermediates unqualified for quality inspections. The root cause was excessive acidic sites on the catalyst surface triggering side reactions.
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Shedding catalyst powder entrained in finished products Insufficient wear resistance of the carrier generated fine dust under continuous stirring and material scouring, which entered finished products with discharge streams, elevating product turbidity and solid particle content, increasing downstream filtration workload and defective product rates.
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Severe foaming disrupting continuous production Mismatch between catalyst pore structure/surface properties and high-viscosity oil media generated massive foam during hydrogenation, occupying reactor effective volume. The client was forced to reduce feeding volume and slow feed rates, cutting production line capacity by 20% and introducing material overflow safety hazards.
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Batch performance deviation requiring repeated process adjustment Activity and porosity varied across catalyst batches, forcing the client to recalibrate temperature, pressure and feed speed parameters after each batch change, disrupting automated continuous production rhythms and increasing manual operation costs.
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HiSiaddi assembled a team of catalytic material engineers, application process specialists and QC experts to sample test and replicate on-site working conditions, delivering rectification solutions covering catalyst formulation modification, carrier reinforcement and surface regulation in three phases: lab test, pilot test and mass production.
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Surface Modification & Structural Optimization to Slow Activity Decay Trace rare earth additives were introduced to coat and modify Ru active components based on the original formulation, inhibiting microcrystal agglomeration under elevated temperatures. Carrier pore structure was optimized to form hierarchical pores, reducing accumulation and blockage of active sites by macromolecular by-products inside pores. After rectification, the catalyst maintained conversion above 99% after 520 hours of continuous operation, matching the service life of imported catalysts.
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Regulate Surface Acid-Base Sites to Boost Hydrogenation Selectivity Alkalization treatment neutralized excess acidic sites on the catalyst surface, precisely limiting catalytic orientation of active sites to only hydrogenate carbon-carbon double bonds. Post-modification by-product content stabilized below 0.8%, fully meeting food-grade raw material indicators and raising main product yield simultaneously.
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Carrier Reinforcement to Eliminate Powder Shedding Activated carbon carriers underwent high-temperature curing and cross-linking reinforcement to improve mechanical strength and wear resistance. The loading process was optimized to embed Ru components deep within internal carrier pores, minimizing free surface powder. Post-commissioning testing showed no obvious dust entrainment in discharged materials, restored finished product turbidity and drastically reduced filtration workload.
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Optimize Surface Wettability to Eliminate System Foaming Catalyst surface polarity was adjusted to improve compatibility with oil media and weaken foam generation at gas-liquid interfaces. Supplementary operational guidance was provided to fine-tune stirring speed and hydrogen injection mode. Post-rectification foam inside reactors was nearly eliminated, feeding volume returned to design standards and production line capacity recovered to full load.
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Solidify Full-Process Process Parameters to Narrow Batch Deviations All critical parameters including raw material ratio, loading temperature, reduction duration and post-treatment procedures were locked at the production end. A cross-batch physical property benchmarking mechanism was established to tightly control fluctuations of activity, porosity and particle size. Standardized process parameter sheets customized to product characteristics were delivered to the client, eliminating repeated equipment calibration and enabling stable automated production line operation.
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Technical Document Delivery & Remote On-Site Guidance Chinese-English bilingual Application Operation Manuals were compiled detailing batching methods, reaction parameters, daily maintenance and abnormal handling protocols. Technical teams tracked three consecutive trial production batches, resolving on-site issues in real time to sustain long-term rectification effects.
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All technical faults fully resolved Rectified catalysts delivered compliant performance across conversion rate, selectivity and service life, benchmarking imported products. Defective product rates dropped below 0.5%, passing all food-grade quality inspections.
Improved production efficiency and economic benefits Foaming and powder entrainment were completely eliminated, restoring full production line capacity. Labor costs for operation and filtration processes decreased, lifting overall production efficiency by 21%.
Significant procurement cost advantages Compared with original imported catalysts, the optimized domestic product reduced procurement costs by 34%. Combined with reduced material loss and higher capacity, the client’s overall production costs were substantially optimized.
Deepened long-term exclusive cooperation The client fully recognized HiSiaddi’s fault diagnosis and implementation capacity, awarding the full annual 260 kg order of high-activity ruthenium-based hydrogenation catalysts to our company. A regular technical communication mechanism was established, with priority cooperation planned for subsequent testing and formulation optimization of new hydrogenation catalysts.
High-activity ruthenium-based hydrogenation catalysts deployed in high-end bio-based and food additive manufacturing require not only qualified basic activity, but structural stability, selectivity, mechanical strength and system compatibility as core determinants of mass production performance. Conventional products frequently trigger on-site production failures due to flawed formulation design and incomplete post-treatment processes.
Drawing on catalyst formulation optimization expertise and end-user application experience, HiSiaddi delivers raw material modification upgrades paired with on-site process guidance to resolve all production technical challenges in one stop. We help overseas medium-to-high-end clients stabilize product quality, cut costs and boost efficiency, while supporting domestic high-end ruthenium-based hydrogenation catalysts to further penetrate Europe’s premium fine chemical market.
Please contact HiSiaddi customer service if you need more formulation optimization consultation services.
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