Katalco
Delivering world world class ammonia plant performance performance
KATALCOJM PERFORMANCE Delivering world-class ammonia plant performance While commercial ammonia production can be traced back more than 100 years, the ammonia process as we know it today was initially developed in the 1960s. Since that time, Johnson Matthey Catalysts (having acquired the Synetix division from ICI) has invested enormous resources in research and development to ensure that t he technology has adapted to meet your ne eds. KATALCOJM™ ammonia plant catalysts are more active, more selective and more robust to give you the highest plant rates, longer run time and exceptional value for money. The selection of catalysts and technology for your ammonia plant is just the start of the process. At Johnson Matthey Catalysts we seek to develop close working relationships with all users of our catalysts to gain a good understanding of your operations. This allows our engine ers to provide the best advice on the operation of the catalysts within the ammonia process. KATALCOJM PERFORMANCE is a suite of value adding services to enhance the operation of KATALCOJM catalysts, designed to address plant operational issues including efficiency, reliability, throughout, environment and safety. Our knowledge is further underpinned by operating experience in ammonia plants, allowing us to better understand your needs as a plant operator. Within the ammonia industry, Johnson Matthey Catalysts is seen as the world-leader and has the greatest depth and breadth of knowledge. This position has been developed through our own technology, partnerships with leading contractors such as Uhde, catalyst development and the large number of plants that use our technology and catalysts. KATALCOJM PERFORMANCE is at the heart of the world’s largest ammonia plant, the Uhde Dual Pressure Process, for rates up to 4,250 mtpd. The flowsheet is specifically designed to take advantage of the KATALCOJM catalyst range. Our focus is delivering the best plant per formance in the world. We have on-going development programmes producing new and better catalysts and improving the process technology for the ammonia industry.
KATALCOJM PERFORMANCE enables the best performance to be achieved from these products. The overall impact of Johnson Matthey new catalysts and technology can improve ammonia plant costs by millions of dollars every year. Through KATALCOJM PERFORMANCE, Johnson Matthey Catalysts can offer the following services: •
energy audits
•
asset management studies
•
full plant revamp studies
•
equipment inspection
•
catalyst loading techniques
•
specialist measurement
•
computation fluid dynamics simulations
•
catalyst handling and disposal.
The ammonia catalyst range Purification
Secondary reforming
The KATALCOJM range of absorbents and hydrogenation catalysts ensures an optimized system for meeting individual plant requirements. KATALCOJM 32-5 was specifically developed to meet a new need on plants with high sulphur levels, and based on commercial performance offers the highest sulphur absorbency. Low temperature sulphur removal and ultra-purification can be carried out with proven PURASPECJM™ technology.
KATALCOJM PERFORMANCE combines sophisticated Computational Fluid Dynamic techniques and process models to ensure the best performance from its state of the art range of secondary reforming catalysts. We also offer a catalyst that acts as an active heat shield. This reforms the process gas whilst ensuring that the main catalyst bed is not disturbed during normal operation or transients such as shutdowns.
Pre-reforming Johnson Matthey Catalysts has been associated wi th pre-reforming catalysts since the 1960s and together with Davy Process Technology, (also part of the Johnson Matthey group), now offers the CRG LH series which has been demonstrated to be the most active and robust commercially available product. Primary reforming In this critical operating unit of the ammonia production train, the KATALCOJM PERFORMANCE combination of catalysts and services ensures optimal operation at all times. The choice of catalysts is unique with the ability to reform efficiently the full range of feedstocks used in modern steam reformers. Gas heated reforming Gas heated reforming (GHR) was originally developed by Johnson Matthey in the 1980s, specifically for use in the ammonia industry with over 50 years operational experience in four units worldwide.
KATALCOJM PERFORMANCE services include reformer optimization studies, LOTIS™ diagnostic techniques and UNIDENSE™ specialist loading. This has been proven to provide quicker and more uniform loading giving less temperature variation in operation.
Johnson Matthey Catalysts also offers a proprietary burner design to help uprate the secondary reformer, and this is available under licence. High temperature shift The KATALCOJM 71-5 range of high temperature shift catalysts offers high activity due to the inclusion of a structural promoter that gives an improved distribution of pore sizes. This thereby reduces the diffusional limitation associated with many high temperature shift catalysts. Furthermore, a promoter is included that allows operation at low steam to gas ratios without allowing over-reduction of the iron oxide or production of Fischer Tropsch type by-products.
KATALCOJM 71-6 range has been developed specifically for highly stressed units with known waste heat boiler leaks and for radial flow reactors. This catalyst range maintains its strength and pellet size from fresh to reduced, maximizing in-situ strength, activity, and pellet integrity. Johnson Matthey Catalysts offers SHIFTSHIELD for installation on top of the catalyst bed. These are designed to capture boiler solids and prevent the impingement of liquid droplets onto the main catalyst. Johnson Matthey Catalysts also offers the STREAMLINE ™ system for reducing pressure drop through the high temperature shift bed.
Low temperature shift The KATALCOJM 83-series of low temperature shift catalysts offers high activity whilst maintaining high strength to ensure physical robustness. It is available in a range of sizes to allow for optimization of pressure drop and catalyst activity. Furthermore, the addition of promoters increases poisons resistance such that a guard bed is not required. These same promoters also minimize methanol by-product formation within the low temperature shift bed. Johnson Matthey Catalysts also offers the STREAMLINE system for reducing pressure drop though the low temperature shift bed. Methanation The KATALCOJM 11-series of methanation catalysts offers a high activity and a very robust form that allows for washing after an upset in the CO 2 removal system. The catalyst is also tolerant of temperature excursions. Lives of up to 20 years have been achieved. The catalyst is available in an optimized pre-reduced form to allow for fast start-ups and operation at inlet temperatures as low as 250°C (482°F). Ammonia synthesis The KATALCOJM range of ammonia synthesis catalysts offers excellent lives with high activity. Furthermore, the catalysts are available in a wide range of sizes that are suitable for all converter types. The KATALCOJM 74-series offers superior activity for low pressure plants, i.e. those in the range 80–120 bar (1160–1740 psi) due to the inclusion of activity promoters. All catalysts in this range are available in the pre-reduced form to allow for fast plant start-ups.
Purification KATALCOJM 41-6T KATALCOJM 61-1T KATALCOJM 59-3 KATALCOJM 32-4 KATALCOJM 32-5 PURASPECJM 2084
KATALCOJM catalyst
41-6T
61-1T
59-3
32-4
32-5
PURASPECJM2084
Duty
hydrogenation hydrogenation
halide removal
sulphur removal
sulphur removal
sulphur polishing
Composition
cobalt oxide/ nickel oxide/ molybdenum molybdenum
sodium aluminate
zinc oxide cement
zinc oxide cement
zinc oxide/ copper oxide
trilobe extrusions
spherical granules
spherical granules
spherical granules
spherical granules
2.5
2.5
2.0 - 4.75
2.8 - 4.75
2.8 - 4.75
2.8 - 4.75
(kg/m3)
590
560
860
1140
1350
870
(lb/ft 3)
37
35
54
71
84
54
Form
trilobe extrusions
Physical properties (typical) Diameter (mm) Typical loaded density
Johnson Matthey Catalysts can also provide a range of other purification catalysts including mercury removal and low temperature operation for HDS or ZnO. For coal based flowsheet applications, PURASPECJM materials are available
to perform ultrapurification duties downstream of acid gas removal systems such as RECTISOL™ and SELEXOL™. Please contact your representative for further information.
Pre-reforming catalyst CRG LH
CRG LHMC Catalyst formulation (typical)
CRG LH is a precipitated catalyst based on nickel as the active component and the typical composition of the catalyst as manufactured below. The catalyst can be supplied pre-reduced and stabilized, or in the oxidized form. Typical analysis (loss basis)
Physical properties (typical)
CRG LHR
CRG LHR
CRG LHCR
pellets
cloverleaf
Nickel as NiO
47
Form
Silicon as SiO2
4.3
Chromium as Cr2O3
1.5
Nominal diameter (mm)
3.4
8.0
Calcium as CaO
7.8
Nominal Length (mm)
3.5
5.4
Alumina as Al2O3 and promoters
balance
kg/m3
1370
850
lb/ft 3
86
53
Johnson Matthey Catalysts has the largest heritage in pre-reforming technology with hundreds of CRG references since the 1960s.
Typical loaded density
Primary reforming Johnson Matthey Catalysts manufacture three main catalysts for use in primary reformers using a natural gas feedstock: KATALCOJM 23-series, 57-series and 25-series catalysts. These are made in a range of sizes, allowing optimum reformer loading for each individual plant.
Selecting the right catalyst for your application is essential for good reformer performance. Johnson Matthey Catalysts will make recommendations on the correct catalyst loading based on your plant operating conditions. However, some generic guide lines are given opposite.
KATALCOJM 23-series This catalyst is nickel oxide on an alpha alumina support.
When recommended, KATALCOJM 25-series catalyst should be installed in the top 40–50% of the primary reformer tube to ensure that the carbon forming potential is minimized.
KATALCOJM 57-series This catalyst is nickel oxide on a calcium aluminate support. KATALCOJM 25-series This is a lightly alkalized version of the KATALCOJM 57-series catalyst. Physical properties (typical)
KATALCOJM catalyst
23/25/57-4MQ
23/25/57-4Q
23/25/57-4GQ
57-4XQ
4 hole cylinder with 4
4 hole cylinder with 4 flutes and domed ends
4 hole cylinder with 4 flutes and domed ends
4 hole cylinder with 4 flutes and domed ends
10.5
13
16
19.7
Length (mm)
13
17
20
20
Hole size (mm)
2.7
3.5
4.4
5.5
(kg/m3)
1140
1090
1050
-
(lb/ft 3)
71
68
66
-
(kg/m3)
950
870
790
-
(lb/ft 3)
59
54
49
-
(kg/m3)
900
850
760
700
(lb/ft 3)
56
53
47
44
Form Diameter (mm)
Typical loaded density 23-4
25-4
57-4
Johnson Matthey Catalysts is the world-leader in steam reforming catalysis. Our dominant market share is a result of unbeatable catalysts backed up by KATALCOJM PERFORMANCE unique design, optimization and service capabilities. We are also the leading supplier of reforming catalysts for heavier feedstocks up to naphtha, with more than 50 years of operational experience.
Feedstock type
KATALCOJM PERFORMANCE recommendation
High methane content gas, design plant rates
57 or 23-series
Feedstock with significant levels of higher hydrocarbons
Combination of 25-series with 57/23-series
Low steam to carbon ratio, high methane content gas
Combination of 25-series with 57/23-series
Improvement required
KATALCOJM catalyst recommendation
Low pressure drop (high plant rates)
XQ, GQ and Q size combination
Low tube wall temperatures
MQ and Q size combination
Low methane slip
MQ and Q size combination
Reformer services Through KATALCOJM PERFORMANCE we want you to get the most from our catalysts. We optimize each application using our world-leading modelling capability and support the operation of your reformers with a wide range of services, including: •
UNIDENSE reformer loading technique
•
LOTIS laser optical tube inspection system
•
reformer surveys and operational audits
•
catalyst tube temperature measurement
•
managing the life cycle of reformer catalyst tubes
•
reformer process and mechanical design consultancy and engineering services
•
computational fluid dynamic (CFD) modelling
•
plant design
•
revamp studies and revamp implementation
•
re-tube studies
•
reformer consultancy
•
pressure drop measurement
•
combustion systems advice
Secondary reforming KATALCOJM PERFORMANCE offers a combination of leadingedge catalysts, burner technology, simulation capability and high temperature engineering know-how to give the best total solution for secondary reformers.
KATALCOJM 23-8MQ KATALCOJM 54-8MQ KATALCOJM 23-8Q
Composition:
KATALCOJM 54-8Q KATALCOJM 23-8EQ
KATALCOJM 23-8Q nickel oxide dispersed on an alpha alumina ceramic support KATALCOJM 54-8Q nickel oxide dispersed on a calcium aluminate ceramic support
Physical properties (typical)
KATALCOJM catalyst
23/54-8MQ
23/54-8Q
23-8EQ
Size
mini
standard
elephant
Form
4 hole cylinder with 4 flutes and domed ends
4 hole cylinder with 4 flutes and domed ends
4 hole cylinder with 4 flutes and domed ends
10.5
13
33
Length (mm)
13
17
20
Hole size (mm)
2.7
3.5
9
(kg/m3)
1090
1040
1100
(lb/ft 3)
68
65
69
(kg/m3)
850
800
-
(lb/ft 3)
53
50
-
Diameter (mm)
Typical loaded density 23-8
54-8
High temperature shift catalysts Catalyst characteristics
KATALCOJM 71-5 KATALCOJM 71-6
KATALCOJM 71-6M Physical properties (typical)
KATALCOJM catalyst
Size
71-5
71-6
71-6M
various
standard
mini
iron/chrome/copper
iron/chrome/copper
iron/chrome/copper
pellets
pellets
pellets
Diameter (mm)
-
8.5
5.4
Height (mm
-
4.9
3.6
(kg/m3)
1220
1230
1250
(lb/ft 3)
76
77
78
Composition Form Nominal sizes
Typical loaded density
KATALCOJM 71-5 is used in most applications since it offers high activity and low pressure drop. The smaller size KATALCOJM 71-5M is used where maximum activity is required. Johnson Matthey Catalysts will provide recommendations for optimum loadings for individual applications on request. A protective layer of SHIFTSHIELD is usually advised. The Johnson Matthey Catalysts STREAMLINE system is available where a pressure drop reduction is required. For difficult applications our premium product KATALCOJM 71-6 is now available.
The KATALCOJM 71-6 range takes a major step forward in the ability of HTS catalysts to withstand boiler leaks and in radial flow reactors to maximize performance. This is achieved through an additional processing step to carry out structural changes in a controlled way resulting in: •
no shrinkage when put in operation
•
maximized and managed in-service strength
•
maximized on-line activity.
Low temperature shift catalysts KATALCOJM 83-3/ 83-3X
KATALCOJM 83-3M/ 83-3MX Physical properties (typical)
KATALCOJM catalyst
83-3
83-3M
copper oxide/ zinc oxide
copper oxide/ zinc oxide
pellets
pellets
pellets
pellets
Diameter (mm)
5.2
3.1
5.2
3.1
Height (mm)
3.0
3.1
3.0
3.1
(kg/m3)
1360
1360
1360
1360
(lb/ft 3)
85
85
85
85
Combination Form
83-3X
copper oxide/zinc oxide with promoters
83-3MX
copper oxide/zinc oxide with promoters
Nominal sizes
Typical loaded density
KATALCOJM 83-3X is a promoted version of our standard catalyst, specifically formulated to give low levels of by-product methanol and provides enhanced poison retention, eliminating the need for speciality guard catalysts. The smaller size of KATALCOJM 83-3M/83-3MX is used where maximum activity and/or poisons pick-up is required. Johnson Matthey Catalysts will provide recommendations for optimal loadings for individual applications on request. For further information contact Johnson Matthey Catalysts.
Methanation catalysts KATALCOJM 11-4 KATALCOJM 11-4R KATALCOJM 11-4M KATALCOJM 11-4MR Physical properties (typical)
KATALCOJM catalyst
11-4
11-4M
11-4R
11-4MR
Size
standard
mini
standard
mini
Form
pellet
pellet
pellet
pellet
Diameter (mm)
5.4
3.1
5.4
3.1
Length (mm)
3.6
3.4
3.6
3.4
35
35 30
30
Typical nickel content % Ni as NiO % Ni Typical loaded density (kg/m3)
1180
1180
1100
1100
(lb/ft 3)
74
74
69
69
The pre-reduced catalysts KATALCOJM 11-4R and 11-4MR have been reduced and stabilized with an oxide layer which makes the catalyst stable in air and prevents further re-oxidation. These catalysts require no activation stage and initiate methanation at maximum activity as soon as reaction conditions are established. The KATALCOJM 11-series offers unrivalled dependability and stability for maximum protection of the synthesis catalyst.
KATALCOJM 11-4 catalysts have the highest nickel loading and activity of any methanation catalyst commercially available.
Ammonia synthesis catalysts KATALCOJM S6-10/
KATALCOJM 74-1
35-4
KATALCOJM S6-10R/
KATALCOJM 74-1R
35-8 Composition
KATALCOJM S6-10/35-4: multi-promoted (Al2O3:K2O:CaO) magnetite
KATALCOJM 74-1: multi-promoted magnetite
KATALCOJM S6-10R/35-8: pre-reduced and stabilized multi-promoted (Al2O3:K2O:CaO) magnetite
KATALCOJM 74-1R: pre-reduced and stabilized multi-promoted magnetite
Physical properties
Size grade
Typical loaded density - kg/m 3 (lb/ft 3)
Size range (mm)
KATALCOJM S6-10/35-4
KATALCOJM S6-10R/35-8
KATALCOJM 74-1
KATALCOJM 74-1R
A
1.5 - 3.0
C
3.0 - 6.0
2800
2200
2750
2150
E
6.0 - 10.0
(175)
(137)
(172)
(134)
G
14.0 - 20.0
Johnson Matthey Catalysts supplies both un-reduced and pre-reduced ammonia synthesis catalysts, based on more than 80 years operating experience with ICI and all other operating technologies. Both types are based on multi-promoted magnetite compositions and are available in a range of sizes to give dependable, long and active lifetimes. Other sizes can be made to order. The KATALCOJM 35-series catalysts can be used in all types of ammonia converters. The catalysts operate at temperatures in the range 350–530°C (667–986°F) and at pressures of 100–600 bar (1450–8700 psi).
The KATALCOJM 74-series offers superior activity for low pressure plants, i.e. those in the range 80–120 bar (1160–1740 psi). It has been proven in operation since the mid 1980s and chosen for the Uhde Dual Pressure Process for ammonia plants producing more than 3,000 tpd.
Research and development: Centre for excellence New catalysts continue to deliver significant plant improvements. Every catalyst activity improvement enables a corresponding potential increase in plant rate, and can also deliver a longer life before current end of run conditions are achieved. Lower pressure drop options enable plant rate and efficiency improvements. For steam reforming catalysts, improved heat transfer reduces the temperature of reformer tubes, extending the time between costly renewal. Better poison pick-ups extend absorbent lives and improve the performance of downstream catalysts.
Johnson Matthey–Uhde collaboration agreement for ammonia production technology
Johnson Matthey Catalysts has teams focusing on the catalysts for each plant reactor and targeting performance improvements driven by customers. Each area has a dedicated team of experienced scientists. Research and development activities in Johnson Matthey catalysis research, technology and engineering centre at Billingham, United Kingdom, benefit directly from the close interaction of chemists, physicists and engineers with plant operations experience. There is close co-operation between the teams involved in fundamental research, catalyst development, catalyst manufacture, and synthesis gas production. Catalyst development is supported by the most modern techniques in applied surface science. Catalysts and processes are developed in laboratory reactors, semi-technical units, and side-stream reactors specifically designed to simulate accurately the important features of operation in the full scale plants. The catalysts are then finally proven on the commercial scale before incorporating on the Johnson Matthey Catalysts KATALCOJM sales range.
Since 1999, Johnson Matthey Catalysts and Uhde have formed an alliance to combine and accelerate the development of our portfolio of synthesis gas (syngas) and ammonia technologies. This has resulted in the ability to provide: •
world leading technology
•
high performance catalysts
•
new conceptual design
•
commissioning and ongoing operational support.
Uhde is based in Dortmund, Germany and is one of the world’s leading engineering companies in the design and construction of chemical, refining and other industrial plants. Since its establishment in 1921, Uhde has played a leading role in the development of ammonia technology and has been continuously involved in the design and construction of ammonia plants.
Partners in ammonia technology Tracerco Johnson Matthey’s business for on-line diagnostics and tracer techniques.
Johnson Matthey Noble Metals Precious metal catalysts including the removal of hydrogen from carbon dioxide for urea plants.
Uhde Our ammonia partnership for new ammonia plant capacity.
Quest Trutec Unique technology for inspection of reformer tubes and other plant equipment
ABB Expertize, consultancy and resources for engineering solutions, revamps and asset improvement.
Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. Johnson Matthey plc (JM) gives no warranty as the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. JM accepts no liability for loss or damage (other t han that arising from death or personal injury caused by JM’s negligence or by a defective Product, if proved), resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. © Johnson Matthey 2008
For further information on Johnson Matthey Catalysts, contact your local sales office or visit our website at www.jmcatalysts.com KATALCO, PURASPEC, DYPOR and STREAMLINE are trademarks of the Johnson Matthey Group of companies. UNIDENSE is a trademark of Unidense Technology GmbH. PO Box 1 Belasis Avenue Billingham Cleveland TS23 1LB UK Tel +44 (0)1642 553601 Fax +44 (0)1642 522542
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