Catalyst technology development from macro-, micro- down to nano-scale

Catalyst and catalytic process technology has been an ever-growing field that involves chemical engineering, chemistry, and material science. A number of excellent review articles and books have been published on the subject. In this work, the author reviews the evolution and development of catalyst products with multi-scale methodology. The catalyst technologies are classified into three levels, macro-scale (reactor size), mini- and micro-scale (catalyst unit), and nano-scale (catalyst intrinsic structures). Innovation at different scales requires different sets of expertise, method, and knowledge. Specific examples of significant impact to practical application are used to illustrate technology development at each scale. The multi-scale analysis enables clear delineation of technology components and their relationship for a catalyst product and catalytic process. Manipulation of catalyst structures at nano-scale to increase intrinsic activity and/or selectivity is considered of large potential for future catalyst product development. Recent research results on Cu-CeO2 and Au-CeO2 composite catalysts for air pollution control and hydrogen production are used to show how novel catalytic properties can be discovered by unique combination of different but common materials at the nano-scale.