Sintering is an important cause for loss of catalytic activity, especially on supported metal catalysts. It decreases the surface area of the catalyst and changes the surface structure. For a porous catalytic surface, the pores may collapse due to sintering, resulting in loss of surface area. Sintering is in general an irreversible process.
Small catalyst particles have the highest possible relative surface area and high reaction temperature, both factors that generally increase the reactivity of a catalyst. However, these factors are also the circumstances under which sintering occurs. Specific materials may also increase the rate of sintering. On the other hand, by alloying catalysts with other materials, sintering can be reduced. Rare-earth metals in particular have been shown to reduce sintering of metal catalysts when alloyed.
For many supported metal catalysts, sintering starts to become a significant effect at temperatures over . Catalysts that operate at higher temperatures, such as a car catalyst, use structural improvements to reduce or prevent sintering. These improvements are in general in the form of a support made from an inert and thermally stable material such as silica, carbon or alumina.