Experimental data based combinatorial kinetic simulations for predictions of synergistic catalyst mixtures

Physical mixtures of catalysts can sometimes show synergistic activity which exceeds the sum of the activities of the same amount of catalysts employed separately. However, identifying such synergistic mixtures is non-trivial. Not all mixtures display synergy, and the number of combinations that are possible (even for binary mixtures of equal portions) scales very rapidly, and thus they would be costly to screen experimentally. In this work, we show that it is possible to predict synergistic mixtures using combinatorial kinetic simulations based on experimental data collected on individual catalysts. The data was first collected for conditions-of-interest under low conversions (also called near differential conditions, such that each condition approximates a small volume in a non-differential conditions reactor) to build a library of kinetic models (one model for each catalyst). This data was then used for combinatorial kinetic simulations of non-differential reactor scale conversions, and successfully predicted the qualitative behavior of two synergistic physical mixtures. The capability was utilized in the present work in the context of converting CO, C₃H₆, and NO species in simulated car exhaust, but is a general approach. We provide equations to estimate the costs of the screening method as well as the combinatorial kinetics method and show that the costs of identifying synergistic physical mixtures become much lower with the combinatorial kinetics method even before ten catalysts of interest. The cost of using prediction by the combinatorial kinetics method continue to become lower (relative to screening) when more catalysts are added – and even more so if mixtures beyond two components, or consideration of multiple catalyst ratios, is of interest.