Catalysts 2015, 5, 145-269; doi:10.3390/catal5010145 OPEN ACCESS catalysts ISSN 2073-4344 www.mdpi.com/journal/catalysts Review Heterogeneous Catalyst Deactivation and Regeneration: A Review Morris D. Argyle and Calvin H. Bartholomew * Chemical Engineering Department, Brigham Young University, Provo, UT 84602, USA; E-Mail:
[email protected] * Author to whom correspondence should be addressed; E-Mail:
[email protected]; Tel: +1-801-422-4162, Fax: +1-801-422-0151. Academic Editor: Keith Hohn Received: 30 December 2013 / Accepted: 12 September 2014 / Published: 26 February 2015 Abstract: Deactivation of heterogeneous catalysts is a ubiquitous problem that causes loss of catalytic rate with time. This review on deactivation and regeneration of heterogeneous catalysts classifies deactivation by type (chemical, thermal, and mechanical) and by mechanism (poisoning, fouling, thermal degradation, vapor formation, vapor-solid and solid-solid reactions, and attrition/crushing). The key features and considerations for each of these deactivation types is reviewed in detail with reference to the latest literature reports in these areas. Two case studies on the deactivation mechanisms of catalysts used for cobalt Fischer-Tropsch and selective catalytic reduction are considered to provide additional depth in the topics of sintering, coking, poisoning, and fouling. Regeneration considerations and options are also briefly discussed for each deactivation mechanism. Keywords: heterogeneous catalysis; deactivation; regeneration 1. Introduction Catalyst deactivation, the loss over time of catalytic activity and/or selectivity, is a problem of great and continuing concern in the practice of industrial catalytic processes. Costs to industry for catalyst replacement and process shutdown total billions of dollars per year. Time scales for catalyst deactivation vary considerably; for example, in the case of cracking catalysts, catalyst mortality may be on the order of seconds, while in ammonia synthesis the iron catalyst may last for 5–10 years.