Karl M. Kraus
CAI Catalysts, LLC
881 Sumneytown Pike
Gwynedd Square, PA 19446-5303
Phone:
(610) 547-7399
E-mail: kkraus@caicatalysts.com
Web Site: www.caicatalysts.com
Specialties:
- Catalysts
- Manufacturing
- Product Development
- Process Control
Services:
CAI Catalysts, LLC works with developers and manufacturers of supported catalysts to provide design, development, and installation of catalyst manufacturing facilities, processing equipment and testing systems. CAI also develops procedures for the analysis of precious metals used in a wide range of catalyst formulations.
CAI's services include:
- Catalyst Product Development
- Process Development & Optimization
- Proprietary Catalyst Products
- Emission Control Catalysts
- Specialty Applications (Fischer-Tropsch, Fuel Cells, Chemical Processes, Catalytic Combustors)
- Small-quantity Catalyst Manufacturing (kilogram scale)
- Process Control & Product Quality Improvement
- Manufacturing Process Evaluation
- Process Improvement
- Quality Systems
- Manufacturing Facility Design And Implementation
- Customized Manufacturing Equipment
- Catalyst Analysis Strategy and Procedure Development
- Catalytic Activity Testing Systems (CATS)
CAI offers comprehensive solutions for today's catalyst manufacturing challenges including:
- development of new catalyst formulations to meet your needs
- expertise in supported catalysts for a broad range of applications
- controlled coating of catalyst substrates
- specialists in precious metal control & analysis
- skilled staff with extensive experience in design, construction, commissioning, & operation of catalyst manufacturing facilities throughout the world
EXAMPLES OF PREVIOUS PROJECTS
Catalyst Manufacturing Facility - Korea
CAI provided catalyst technology, manufacturing process design, and equipment installation and commissioning for a 1 MM catalyst per year facility. The facility produces both oxidation and SCR catalysts for the stationary source emission control market.
Catalyst Manufacturing Facility - Brazil
CAI provided catalyst technology, manufacturing process design, and equipment installation and commissioning for a 15,500 m3 per year automotive emission control catalyst facility.
Production-Scale Supplier Development
Evaluated the pilot-scale production process for a metal screen supported catalyst for a small engine emission control system. Identified and quantified scale-up issues. Evaluated toll manufacturers for the large scale production of these catalysts and assisted client with establishing an outsourcing strategy.
Supply Strategy Evaluation - US
Performed a catalyst make-buy analysis for a manufacturer of automobile catalytic converters. The project included preliminary design of a manufacturing process as well as full cost analysis of several alternative strategies.
Pilot Scale Process Development - UK
CAI worked with the client to translate laboratory-scale procedures into pilot-scale production processes for a series of metallic foil supported catalysts used in a proprietary fuel conversion process. The scope included the design of processes, equipment, and process control parameters for 3 separate catalyst formulations and physical structures.
Laboratory Scale Process Development - US
CAI worked with a development stage company to scale up a laboratory procedure for a proprietary steam methane reforming catalyst from gram quantities. CAI is currently producing this material in multi-kilogram quantities to support the ongoing development of a fuel cell power system.
Catalyst Analysis System - US
This project involved the development of the analytical strategy and techniques required to quantify the composition of automotive emission control catalysts manufactured for several large international automobile manufacturers. The project scope included developing and documenting the techniques, specifying instrumentation, training the technical staff, commissioning the analytical laboratory, and gaining the client's customers' approvals. The system was compliant with QS-9000 / ISO quality system requirements.
