Catalyst surface at a fractal of cost—a quest for optimal catalyst loading

Intuition tells us that any decrease in the catalytically active surface area should result in an equivalent decrease in the reaction yield and efficiency. Our findings counter this by showing that the active surface and hence the catalyst loading can be reduced drastically in the diffusion-limited heterogeneous reaction systems, while the conversion rate remains essentially unchanged by using fractals for spatial distribution of the catalyst load. The results of this study provide an unusual circumstance for optimal design of chemically active surfaces and can be used to drastically reduce cost of heterogeneous chemical and biological reactors, sensors, and electrodes of fuel cells. The proposed approach can be exploited to its fullest extent in chemical microsystems by utilizing the latest advances in our abilities to manipulate matter on the micro/nano scale.