Reforming catalyst activity and performance is directly related to catalyst size and shape.

Advanced Catalyst Shapes Reforming catalyst activity and performance is directly related to catalyst size and shape.  Smaller sizes of any catalyst shape contribute higher surface area per unit volume, improving "geometric surface area" contribution to activity (apart from "intrinsic activity") at the expense of reduced catalyst void fraction and higher gas pressure drop.  Intrinsic catalyst activity comes from the catalyst constituents and manufacturing techniques.  Overall apparent catalyst activity is strongly influenced by advanced catalyst shapes combined with optimal catalyst constituents which promote high intrinsic catalyst activity.  This improves Nickel surface area for Reforming and optimizes catalyst void fraction for heat transfer, while reducing gas pressure drop.  This has been especially important in extending Primary Reformer performance over the last 20 years. The various Reforming catalyst suppliers have taken slightly different approaches to advanced catalyst shapes development, yet each has produced unique designs from their respective research and testing to promote higher overall catalyst activity, while maintaining satisfactory strength to fulfill long life and lower gas pressure drop. Certain common beneficial characteristics can be noted which pertain to all advanced catalyst shapes optimized for tubular Primary Reformers. Geometric surface area is improved by optimizing passages through the catalyst structure.  Void fraction and strength are simultaneously influenced by these changes.  Catalyst diameter and height are adjusted to accommodate desirable pressure drop and void fraction characteristics which also promote favorable heat transfer and Reforming reaction performance. A "second generation" of improved performance catalyst shapes have began to be introduced to the Chemical Industry by suppliers in recent years, promoting further Reforming catalyst performance enhancement.  With the proliferation of computing technology in industry, design and optimization tools are permitting refinement of Reforming catalysts for the benefit of operating plants throughout the World.  These new software tools will lead to faster turnaround and further development of reliable new catalyst products for ever changing uses in industry.