Engineering catalysts at the multiscale: past, present, and future of catalyst manufacturing and shaping processes

Catalyst shaping is pivotal in optimizing catalytic performance across industrial chemical processes. The engineering of catalysts at multiple scales, ranging from nano to macro, has considerably evolved over the years, driven by advancements in shaping technology. We explore the progression of catalyst shaping, beginning with traditional methods, such as pelletizing and granulation, and advancing to modern techniques, including extrusion, spray-drying, fluidized-bed processes, and additive manufacturing (AM). This work emphasizes shaping technology tailored to specific reactor types, such as fixed-bed (up to structured catalyst) and fluidized-bed reactors. We highlight critical parameters to optimize and control catalyst properties and their direct influence on enhancing catalyst durability, activity, and selectivity. Advances in computational modeling, including multiscale simulations and machine learning-driven design, have further revolutionized catalyst shaping by enabling precise control and accelerating innovation. This review offers a comprehensive perspective on the future of multiscale catalyst shaping and underscores its potential to drive enhanced catalytic performance and sustainable chemical processes by analyzing historical developments, current trends, and emerging technology.