Sud Chemie Catalysts

Future Perspectives

Content

Page

Introduction

4

Feed Purification – ActiSorb Catalyst Series

12

Acidic Catalysts (K-Catalysts) (K-Catal ysts)

26

Zeolites

30

Catalysts for the Petrochemical Industry

34

Catalysts for the Production of Chemicals

48

Catalysts for the Oil Refinery Industry

80

Air Purificatio Pur ificationn

102

Reduction of Iron Ore, Production of Towngas, Inert & Support Material

110

Custom Catalysts – À la Carte Catalysts

114

Fuel Cell Technologies echnolog ies

118

Research and Development

122

Service and Performance Guarantees

126

Catalyst Index and Contact Details

130

Introduction Creating masterpieces for high performance Our catalysts are created according to our “performance technology” philosophy. Crafting state-of-the-art catalyst solutions is like creating a piece of art. Whether it is produced for refining, chemical, petrochemical or environmental solutions, our catalysts vary in shape, colour and formulations to suit your needs – but they are always avant-garde to offer you the highest performance.

Introduction

The History of Süd-Chemie The Beginning Süd-Chemie’s initial operations were launched in 1857 by one of the world‘s leading chemists of the time, Justus von Liebig. The Munich-based company began producing mineral fertiliser s in 1906. It subsequently branched out into the chemistry of surface reactions, producing highly active bleaching earth. In 1959, a joint venture with Girdler Catalyst in Louisville, Kentucky, was formed. Production of Girdler catalysts in Germany started in 1961.

Going Global After 15 years of partnership, Süd-Chemie took over Girdler Catalyst‘s operations in their entirety, including the company‘s share in the Japanese Nissan Girdler Catalyst (NGC). In 1976, Süd-Chemie acquired the Louisville-based Catalyst and Chemicals Inc. (CCI), including partnerships with CCIL, India and CCIFE, Japan. US Girdler and CCI catalyst operations were then merged to form United Catalyst Inc. (UCI). In the Asia-Pacific region, production of CCI catalysts for Indonesia has been handled by PT-Kujang – United Catalysts since the mid-eighties. In 1981, African Catalyst started manufacturing oligomerisation catalysts in Sasolburg, South Africa. Süd-Chemie has been producing zeolite catalysts via Syncat/SC Zeolites in South Africa since 1991. In 1990, Süd-Chemie purchased Houdry process and catalyst manufacturing technology operations from Air Product and Chemical Inc., USA. The Houdry process is used for dehydrogenation in the production of octane boosters, and for dealkylation in the production of pentene. Today, process technology is handled by ABB Lummus Global Inc.

6

Introduction

In 1997, Süd-Chemie acquired the Italian Montecatini Technology, which was to continue under the new name of Süd-Chemie MT S.r.l. The company‘s catalysts are mainly used for oxychlorination in fluid or fixed-bed operation and in the production of terephthalic acid for PET, resins and polyester fibres. Süd-Chemie acquired Prototec Inc., USA in 1992, with a view to expanding its operations in the environmental sector. Prototec specialises in catalysts and equipment for air purification in food preparation and other industries. Today, Süd-Chemie’s environmental solutions include catalysts for virtually all types of air and gas purification. In 2003, Süd-Chemie acquired Scientific Design, Little Ferry, USA, as part of a joint venture with the major Saudi Arabian manufacturer SABIC. Scientific Design specialises in processes involved in the production of ethylene oxide. The global identity of all of these companies is reflected in the commo n name and slogan: Süd-Chemie – Creating Performance Technology ®

7

Introduction

Shapes make the Difference All of Süd-Chemie‘s catalysts are available in a wi de variety of different shapes and sizes, so that the user can always select the optimum catalytic technology to suit his needs. There are basically two different types of catalyst:

• Precipitated catalysts • Carrier catalysts Precipitated catalysts are of identical chemical composition throughout the entire particle, whereas in a carrier catalyst, the active component is impregnated on an inert carrier.

Typical shapes include:

• Tablets • Rings • Ribbed rings • Multiholed rings • Extrusions • Pellets • Spheres • Monolithic structures • Saddles • Foams (ceramic and metallic) • Wire mesh • Wall flow filters • Fibre mats • Screens • Flakes • Granules • Powder

8

Introduction

Tablets A variety of tablet sizes can be produced, depending on the catalyst formulation and the intended application. The most common sizes range from 3 x 3 mm to 9 x 9 mm. Most of our tablets are domed, ensuring less dust formation thanks to more stable edges and a more uniform and dense loading. Smaller tablets generally have greater activity, but a higher pressure drop.

Extrusions Extrusion is the preferred method for precipitated catalysts. The key types of extrusions are:

• Plain extrusion • Ribbed extrusion • TRIAX extrusion • CDS extrusion CDS extrusion creates the most sophisticated extruded shape. CDS stands for Computer Designed Shape, and represents an optimum combination of physical strength, activity, poison resistance and pressure drop. For this reason, Süd-Chemie offers a wide range of catalysts in this shape.

9

Introduction

Rings Rings are the ideal shape for carrier catalysts. The carrier is a strong inert material in a wide variety of ring shapes, such as:

• Raschig ring • Ribbed ring (RR) • 3-holed ring (THS) • 6-holed ring (gutling gun, GG) • 10-holed ring (low differential pressure, LDP shape) • Spoked-wheel (EW shape)

Spheres Spherical catalysts can include both palletised and tabletted, precipitated and carrier catalysts. They can be as small as 1 mm and as large as 75 mm.

Honeycombs and Foams Where an application is sensitive to pressure drop, as is the case for ambient pressure operations, or where a high space velocity is needed, honeycombs and foams - whether ceramic or metallic - are the optimum shape. Honeycombs and similar shapes form the basis of almost all catalysts used for air purification and for the reformer upstream of fuel cells.

10

Introduction

Other Shapes Some catalysts are available in the form of flakes or irregular granules. For application in a fluidised bed or in liquid phase, powder is the ideal shape. Please note that the shapes and sizes listed in this catalogue represent the standard for the respective product. Please contact our sales division for information on non-standard dimensions.

Reduced and Stabilised Catalysts Most catalysts consist of one or more metal oxides. Most of Süd-Chemie’s catalysts can be supplied in any of the following formats:

• oxidic • reduced and dry stabilised (RS version) • reduced and submerged in an organic liquid (R version)

The RS and R versions are safe to transport and ready to use with only a short start-up time.

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Feed Purification Pure and clear Just like old master pieces – brilliance and clarity come from the finest and purest selection of materials. Just like your feeds – only with Süd-Chemie catalysts will you be able to create the valueadded position resulting from high performance products.

Feed Purification

ActiSorb ® Catalyst Series Süd-Chemie developed the ActiSorb® series of catalysts and adsorbents for the purification of almost all hydrocarbon feedstocks. This purification is normally a combination of a reaction using a pre-treatment catalyst, i.e. hydrogenation, followed by adsorption with the ActiSorb® adsorbent. The following table gives a general overview of the different families of ActiSorb® materials.

I C H

•

•

s d n u o p m o C a c i l i S

n e g o r t i N c i n a g r O

H N

N C H

ActiSorb® N

•

•

•

Tonsil® APT-N

•

•

•

ActiSorb® S ActiSorb® CI ActiSorb® F

r u f l u S c i n a g r O

s n e h p o i h T

S O C

S 2 H

•

•

•

•

e n i r o u l F c i n a g r O

F H

•

•

s l a t e M y v a e H

ActiSorb® Hg

•

ActiSorb® 300

•

ActiSorb® Si ActiSorb® O

G-92D

14

s e d i r o l h C c i n a g r O

3

H P

2

O

3

O 2 H

• • •

•

Feed Purification

Sulphur Removal Sulphur in the form of organic compounds can be removed either as such or by hydrogenation to H 2S followed by adsorption of the latter. The ActiSorb® S 7 catalyst is recommended for the removal of H2S, mercaptans, disulphides and thiophens in hydrocarbon feedstreams, ranging from naphtha to middle distillates. The achieved purity is less than 0.1 ppm wt. sulphur. ActiSorb® S 7 Nominal Content [wt.%] NiO

66

Binder

Balance

Shape

CDS Extrusions

Size [mm]

1.5

Hydrodesulphurisation The standard catalysts for the hydrogenation of organic sulphur compounds in hydrocarbon feedstocks are the cobalt-molybdenumtype catalysts from the HDMax 200 series. These catalysts are used in both liquid and gas phase for all types of hydrocarbons, such as naphtha, LPG, natural gas and off-gases. For the hydrogenation of organic nitrogen compounds and/or olefin saturation, our nickel-molybdenum-based HDMax 310 catalyst is recommended. HDMax 200

HDMax 310

CoO

3–5

-

NiO

-

3–6

MoO3

13 – 21

10 – 25

Al2O3

Balance

Balance

Shape

CDS Extrusions TRIAX Extrusions


2.5 – 3

2.5 – 3

Nominal Content [wt.%]

Size [mm]

15

Feed Purification

H2S Removal The ActiSorb® S series of ZnO based adsorbents is used for the removal of sulphur components such as hydrogen sulphide, mercaptans and COS from hydrocarbon feedstreams. ActiSorb® S 2 is the perfect solution when operating at high space velocities and elevated temperatures, while ActiSorb® S 3 is recommended in applications with lower space velocities and higher inlet sulphur concentrations. The maximum bulk density catalyst ActiSorb® S 1 is ideal in applications where the feed contains high inlet sulphur concentrations, and where maximum sulphur pick-up per loaded unit volume is required. ActiSorb® S 1

ActiSorb® S 2

ActiSorb® S 3

ZnO

100

90

90

Al2O3

-

Balance

Balance

Shape

Extrusions

Extrusions

Extrusions

4.5

4.5

4.5


Size [mm]

In some cases, it is necessary to remove the sulphur to a level below 10 ppb H2S. ActiSorb® S 6, a copper-promoted zinc oxide, is placed in the bottom of the standard zinc oxide reactor and removes the remaining H2S to a value < 10 ppb H2S under a wide range of operating conditions. ActiSorb® S 6 Nominal Content [wt.%] CuO

Proprietary

ZnO

Proprietary

Al2O3

Balance

Shape

Tablets T ablets

Size [mm]

16

6x3

Feed Purification

Desulphurisation of natural gas and light hydrocarbon feedstocks is also possible under ambient conditions using activated carbon. G-32J is coconut-shell-based and promoted with copper oxide. It should be noted that propane and C 4+ hydrocarbons are absorbed by the activated carbon, thereby minimising the sulphur pickup capability of G-32J. G-32J Nominal Content [wt.%] CuO

6

Activated Carbon

Balance

Shape

Granules

Size [mm]

1 – 5 and 0.5 – 1

Purification of natural gas containing low concentrations of total sulphur can also be performed by ActiSorb® G 1, a promoted ZnO catalyst. Simultaneous hydrodesulphurisation and H2S pick-up is a feature unique to ActiSorb® G 1. Even when saturated, the ActiSorb® G 1 catalyst fully retains its hydrogenation capabilities. ActiSorb® G 1 Nominal Content [wt.%] CuO

1.5

MoO3

3.5

ZnO + Binder Shape Size [mm]

Balance Extrusions 4.5

17

Feed Purification

COS Hydrolysis The ActiSorb® 410 catalyst selectively promotes the simultaneous hydrolysis of COS and hydrogenation of CS 2. HCN is also hydrolysed. The high selectivity of ActiSorb® 410 means that process gases with very high CO concentrations can be treated. The feed to the COS hydrolysis reactor usually contains nickel and iron carbonyls. These carbonyls decompose on the ActiSorb® 410 catalyst into CO and the respective metals, leading to deactivation of the ActiSorb® 410 catalyst. It is therefore necessary to install a guard reactor with ActiSorb® 400 to decompose any traces of metal carbonyls selectively on the guard catalyst. ActiSorb® 400

ActiSorb® 410

Cr2O3

-

11

K2O

-

6

16

Balance

SiO2

Balance

-

Shape

Spheres

Tablets

5

4.5 x 4.5


AI2O3

Size [mm]

COS and Arsine Removal Refinery feeds and C3 streams from steam crackers often contain both COS and AsH3, and sometimes PH3 traces. CuO catalysts such as ActiSorb® 300 and ActiSorb® 310 are currently used with great success, mainly to purify propylene. Absorption of poisons can be accomplished in either the gas or liquid phase. The product purity achieved is normally below the detectable limit. As a result, the selective hydrogenation catalyst installed downstream is perfectly protected and can pursue its basic activity and selectivity. selectivity. The consumption of polymerisation catalysts is drastic ally reduced with a poison guard. Feed polishing prior to polymerisation is therefore extremely valuable for downstream operations.

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Feed Purification

ActiSorb® 300

ActiSorb® 301

ActiSorb® 310

CuO

41

53

16

ZnO

41

27

-

MnO2

-

-

25

AI2O3

Balance

Balance

Balance

Shape

Tablets

Extrusions

CDS Extrusions

4.8 x 3.2

3

1.5


Size [mm]

Chlorine Removal Süd-Chemie offers a range of adsorbents for the removal of HCl, ammonium chlorides and organic chlorine compounds, depending on the hydrocarbon feedstock and operating conditions. ActiSorb® Cl 2 and ActiSorb® Cl 6 are used for liquid phase applications, while ActiSorb® Cl 2 and ActiSorb® Cl 3 adsorbents are recommended in the gas phase. ActiSorb® CI 2

ActiSorb® CI 3

ActiSorb® CI 6

Na2O

7

-

-

ZnO

-

40

48

Promoter

-

40

25

Binder

-

Balance

Balance

AI2O3

Balance

-

-

Shape

Spheres

Pellets

CDS Extrusions

3–5

4.8

1.5


Size [mm]

Fluorine Removal ActiSorb® F adsorbs organic fluorine compounds and HF in hydrocarbon feedstocks. ActiSorb® F Nominal Content [wt.%] Na2O

0.3

AI2O3

Balance

Shape

Spheres

Size [mm]

3–5

19

Feed Purification

Metal Removal Mercury Removal The catalysts of the ActiSorb® Hg series absorb traces of mercury from all types of feed to non-detectable levels. ActiSorb® Hg catalysts are used for Hg removal from:

• Natural gas • LPG • Mercury – ore – furnace gas • Incinerator vent gas • Vent streams from laboratories • Off-gases in manufacture of electrical devices and operation of power plants

The ActiSorb® Hg 1 catalysts are extremely effective in removing Hg in chlorine plants, and purifying hydrogen given off as a by-product in sodium amalgam decomposition and cell room ventilation air. ActiSorb® Hg 1

ActiSorb® Hg 2

10

15

Activated Carbon

Balance

Balance

Shape

Granules

Granules

Nominal Content [wt.%] S

ActiSorb® Hg 5 Nominal Content [wt.%] Ag AI2O3

Balance

Shape

Spheres

Size [mm]

20

6

2–4

Feed Purification

Silica Removal ActiSorb® Si is a specially promoted alumina which is designed to remove silicon-based antifoaming agents from hydrocarbon feeds. ActiSorb® Si Nominal Content [wt.%] Na2O

0.3

AI2O3

Balance

Shape

Spheres

Size [mm]

3–5

CO Removal Various feed-streams contain CO in concentrations of several ppm up to one percent, which has to be removed to levels below 10 ppb. The type of catalyst is chosen according to the feed, e.g. Ni catalysts to methanate CO in hydrogen streams and CuO-catalysts to remove CO from ethylene and nitrogen by adsorption or by catalytic reaction with addition of air/oxygen.

Removal of CO from Hydrogen In steam cracker plants, the hydrogen typically contains 0.2 - 1% vol. CO, but no CO 2. Ideally, CO-methanation should be carried out at the lowest possible temperature. To accomplish this task, we provide an Ru-catalyst for operating temperatures of approximately 170 °C and Ni-catalysts, which must be operated above 200° C to avoid Ni-carbonyl formation. METH 134

METH 150

NiO

25

-

Ru

-

0.3

Support

Balance

Balance

Shape

Spheres

Tablets

3–6

4.5 x 4.5


Size [mm]

21

Feed Purification

Removal of CO from Ethylene The CuO/ZnO catalyst PolyMax 301 removes CO from polymer grade ethylene both completely and successfully. The tolerable remaining CO level in the ethylene is determined by the polymerisation catalyst applied in the various processes. This purification process is cyclic and re-oxidation of the catalyst is necessary. PolyMax 301 Nominal Content [wt.%] CuO Support Shape Size [mm]

30 Balance Extrusions 3

Removal of CO from Nitrogen CO can be removed from nitrogen using CuO catalysts such as PolyMax 301. Absorptive removal requires periodic re-oxidation of the catalyst, giving a typical scenario of cyclic operation with two catalyst beds. Successful operation requires a well-controlled addition of air for reaction across the reduced catalyst.

Oxygen Removal Removal of Oxygen from Ethylene Reduced copper catalysts are used successfully in order to remove trace oxygen from ethylene. The most suitable catalyst can be chosen in line with the required purity and temperature level. PolyMax 301 is the standard product, serving most applications. PolyMax 301 Nominal Content [wt.%] CuO Support Shape Size [mm]

22

30 Balance Extrusions 3

Feed Purification

Removal of Oxygen from Propylene The following are recommended for trace oxygen removal from propylene streams in the presence of a slight over-stoichiometric quantity of hydrogen: ActiSorb® O 2 for gas phase operation, and OleMax 350 for liquid phase. ActiSorb® O 2

OleMax 350

0.15

0.3

AI2O3

Balance

Balance

Shape

Spheres

CDS Extrusions

3–5

1.5

Nominal Content [wt.%] Pd

Size [mm]

Removal of Oxygen from Isomerates Tetraethylene glycol (TEG) is used in downstream processing of Penex isomerisation units. It is typically removed by means of a water wash. Süd-Chemie developed the highly porous ActiSorb® O 1 for the removal of TEG in fixed-bed operation. ActiSorb® O 1 sustains its adsorption capacity even after repeated regeneration. ActiSorb® O 1 Nominal Content [wt.%] Promoter

Proprietary

AI2O3

-

Shape

Spheres

Size [mm]

3–5

23

Feed Purification

Nitrogen Removal Süd-Chemie produces ActiSorb® N 1 for the removal of NH3 and basic organic nitrogen compounds from hydrocarbon streams. ActiSorb® N 1 Nominal Content [wt.%] H3PO4

Proprietary

Support

Balance

Shape

Spheres

Size [mm]

3–5

Modern liquid-phase alkylation catalysts of the zeolite type are very sensitive to basic compounds such as nitrogen compounds. As benzene is mainly produced by solvent extraction using N-methylpyrolidone (NMP) and N-formylmorphylane (NFM), it may contain nitrogen in a range of between 0.1 – 1.0 ppm. Even such low concentrations of nitrogen can effectively be removed using our special Tonsil® granular products. Tonsil® APT-N

Tonsil® CO-N

100

100

Extrudates

Granules

2–4

0.25 – 1.0

Nominal Content [wt.%] Alumosilicate Shape Size [mm]

24

Feed Purification

Water Removal G-92D is a specially promoted alumina product which is designed to remove polar components, like li ke alcohols and water, from hydrocarbon feedstocks. G-92D Nominal Content [wt.%] Promoter

Proprietary

AI2O3

Balance

Shape

Spheres

Size [mm]

3–5

Ammonia Dissociation Dis sociation NH3 is an undesirable component c omponent often present in off-gases. To To reduce environmental emissions, it is typically dissociated at high temperatures to yield N2 and H2. Due to the extreme temperatures, the application requires a very rugged catalyst. The ReforMax® 117 nickel on MgO carrier catalyst is supplied in an enhanced surface area ribbed ring for maximum activity. ReforMax® 117 Nominal Content [wt.%] NiO

6

AI2O3

Balance

Shape

Ribbed Rings

Size [mm]

30 x 28 x 11

25

Acidic Catalysts (K-Catalysts) The art of packaging Light dancing around the blossom, transparent and well protected: a work of art, or only a flower for the host? What is certain is that illustriously effective cellophane can be especially efficiently produced with specialised K-Catalysts from Süd-Chemie. As can many other products. Discover the possibilities!

Acidic Catalysts

The “K-catalyst” product family is based on the naturally occurring mineral montmorillonite, which is acid-activated to produce the various different K-catalysts. The resulting products are characterised by different acidities, cation exchange capacities and porosities.

Product Description Our proprietary production procedures result in products with high Brönsted acidity:

• KSF • KSF/O • KP 10 or high Lewis acidity:

•K5 • K 10 • K 20 • K 30 • K 40

Acidic Catalysts Our broad portfolio of K-Catalysts allows the opportunity to optimise process efficiencies through distinct pore structures, surface areas and acidities. K-Catalysts are all available as powder, and some as granules.

28

Acidic Catalysts

Applications of K-Catalysts The following table provides help in selecting the right K-catalyst for various different applications.

Application

Catalyst

Alkylatio n/Acy latio n

K 5, K40, K 10, K 2

Esterification/Etherification

KSF, KP 10, KSF/O, K 10

Rearrangements/Isomerisations

K 20, K 30, KP10, KSF/O

Catalyst support material

K 10, K 20, K 30

Polymerisations/Dimerisations

KP 10, K 5, K 10

The K-Catalyst exhibits distinct pore structures, surface areas and acidities and hence shows different reactivity and selectivity to various organic reactions. Therefore our broad portfolio of K-Catalysts offers the opportunity to optimise process efficiencies.

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Zeolites Light and elegant What do zeolite catalysts have to do with fashion? They transform valuable valuable raw materials materials like methanol into polypropylene. Young Young designers develop textile fibres out of these, that are lighter, more robust and breathable than all previous materials. Welcome to the future!

Zeolites

Product Description Süd-Chemie’s Süd-Chemie’s zeolite manufacturing program can basically be broken down into the following types:

• Zeolite Pentasil (MFI) • Zeolite Mordenite (MOR) • Zeolite Beta (BEA) • Custom zeolites

Pentasil MFI

Mordenite MOR

Beta BEA

20 - 500

10 - 200

25 - 250

> 300

> 300

> 500

Chemical Form

Na, NH4, H

Na, NH4, H

Na, NH4, H

Shape

Powder Granules Extrusions



SiO2 /AI2O3 ratio Surface Area [m /g] 2

Zeolite Pentasil is made up of a orthorhombic crystal structure with straight 10-membered ring channels (0.53 x 0.55 nm). These are connected by sinusoidal channels (0.51 x 0.55 nm). Zeolite Mordenite has an orthorhombic crystal structure with straight 12-membered ring channels (0.65 x 0.70 nm) and crossed 8-membered ring channels (0.28 x 0.57 nm). Zeolite Beta has a tetragonal crystal structure with straight 12-membered ring channels (0.66 x 0.67 nm) and crossed 12-membered ring channels (0.56 x 0.56 nm).

32

Zeolites

Applications of Zeolite Catalysts Zeolite-based catalysts are used in a huge number of applications. These include the following, among many others:

• Isomerisation of C5 /C6 paraffins • Isomerisation of waxes and lube oils • Xylene isomerisation • Toluene disproportionation • Shape-selective hydrocracking reactions such as catalytic dewaxing of middle distillates • Conversion of olefins to petrol and diesel • Conversion of methanol to petrol • Conversion of methanol to propylene • NO x removal • N2O removal • VOC removal • Isomerisation of dichlorbenzenes • Alkylation of benzene • Transalkylation of C9+ aromatics • Selective methylamine synthesis • Organic rearrangement reactions The zeolite catalysts for these reactions are described in the respective chapters.

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Catalysts for Petrochemical Industry Safeguarding your value position Art needs to be protected – so does your value position. Just like corner guards made of polystyrene. A material for the production of which catalyst solutions from Süd-Chemie are the first choice. Because they efficiently and cost-effectively transform petrochemical raw materials such as styrene and benzene, with minimal impact to the environment – for your benefit.

Petrochemical Industry

BTX Chemistry Ethylbenzene Production The EBUF® catalyst is the fruit of a joint development between Süd-Chemie and a major oil company. It is the optimum catalyst for vapour phase alkylation units, as it greatly reduces by-product formation in terms of xylenes and PEBs, thereby improving the overall cost efficiency of styrene production. EBUF® is also available in CDS extrusions for maximum throughput at low pressure drop. EBUF®-1

EBUF®-2

Zeolite

MFI

MFI

Shape

Extrusions

CDS Extrusions

1.5

2.5


Size [mm]

Toluene Disproportionation and C9A+ Transalkylation TDP-1 emerged as the result of cooperation with a ma jor oil and petrochemicals company, where TDP-1 has demonstrated its clear superiority over traditional catalysts, e. g. in terms of a short break-in period after start-up to obtain full performance. TDP-1 is also successfully used in commercial operation for transalkylation of C9+ aromatics, based on its high xylene yields and transalkylation activity at very high levels of C9A+ in the feed. TDP-1 Nominal Content [wt.%] Zeolite

MOR

Shape

Extrusions

Size [mm]

36

1.5


Xylene Isomerisation Today’s xylene isomerisation processes reflect two different strategies in terms of ethylbenzene co-processing: dealkylation to benzene and light gases versus isomerisation to xylenes, with the dealkylation process being generally accepted because of its greater cost efficiency. Our range includes ISOXYL catalysts for all possible dealkylation processes. This family of isomerisation catalysts boasts maximum activity and minimum xylene losses, regardless of the user‘s preferences in terms of process type. ISOXYL Nominal Content [wt.%] Promoter

Proprietary

Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

37


High Purity Aromatics Benzene, toluene and xylene (BTX) are typically produced by distillation and/or solvent extraction processes from reformate streams. The various raw aromatic compounds contain small amounts of olefins, which are removed effectively thanks to Süd-Chemie’s clay treatment technology using the Tonsil® CO family. We can provide tailored qualities to treat extracted benzene, toluene, xylene and mixed aromatics. The extruded products of the Tonsil® APT family significantly improve handling properties and cost performance. The following table outlines product recommendations for the treatment of BTX streams:

Application

Tonsil ® CO 6x6 G

Tonsil ® CO 6x6 GS

Tonsil® CO 6x0 G

Benzene/Toluene

Mixed Xylenes C8 /C9+ Aromatics

Xylene Isomerisation Recycle

100

100

100

Granules

Granules

Granules

0.25 – 1.0

0.25 – 1.0

0.25 – 1.0

Tonsil ® APT - BT

Tonsil® APT - mX

Tonsil® APT - pX

Benzene/Toluene

Mixed Xylenes C8 /C9+ Aromatics

Xylene Isomerisation Recycle

100

100

100

Extrusions

Extrusions

Extrusions

3–5

3–5

3–5

Nominal Content [wt.%] Alumosilicates Shape Size [mm]

Application Nominal Content [wt.%] Alumosilicates Shape Size [mm]

38


Styrene Production The majority of styrene produced in the world today is made by dehydrogenation of ethylbenzene (EB) using one of a family of Süd-Chemie STYROMAX ® catalysts. These include the following:

STYROMAX ® 3

Still the most widely used catalyst in the American and European markets. It is very physically rugged and has demonstrated run-lengths of longer than 42 months. STYROMAX ® 3 offers an excellent balance of activity and selectivity, while being extremely cost-effective. It can be used at steam/oil levels down as far as 1.15 wt./wt.

STYROMAX ® 5

Widely used in Asia, STYROMAX ® 5 is very similar to STYROMAX ® 3 in terms of performance. It can also be used at all steam/oil levels above 1.15.

STYROMAX ® Plus 5 More active and more selective than STYROMAX ® 5, this is the most common catalyst in use in Asia. STYROMAX ® Plus 5 is commercially tried and tested at steam/oil levels down as far as 1.15 wt./wt. It offers the best combination of selectivity and activity available in the world today.

STYROMAX ® 6

Essentially the same performance as STYROMAX ® Plus 5. It is physically stronger than STYROMAX ® 3 and features an exceptionally low attrition rate. It can also be used at all steam/oil levels above 1.15.

STYROMAX ® 7

State-of-the-art catalyst for ultra-low steam/oil operation. Has been extensively tested in adiabatic pilot plants at steam ratios as low a 0.9 wt./wt.

All STYROMAX ® catalysts are available in various different sizes and shapes. Standard sizes are 3.0 mm smooth extrusion, 3.5 and 4.5 mm patented ribbed extrusions. Custom sizes and shapes are available upon request.

39


Phenylacetylene Hydrogenation Small quantities of phenylacetylene are formed over iron oxide based ethylbenzene dehydrogenation catalysts. These can have a negative effect on certain styrene polymerisation processes. Phenylacetylene is hydrogenated over catalyst HDMax PA to styrene at a very high selectivity in the liquid phase. HDMax PA Nominal Content [wt.%] Pd

0.3

Al2O3

Balance

Shape

Spheres

Size [mm]

2–4

Cumene Synthesis The phosphoric acid on kieselguhr catalyst PolyMax 131 has been successfully used for decades to alkylate benzene with propylene to form cumene. This catalyst is capable of working under a wide range of different operating conditions, depending on feedstock type and plant design. PolyMax 131 is manufactured in a strong extruded shape which gives it greatly increased resistance to attrition losses. PolyMax 131 Nominal Content [wt.%] Short Acid as P2O5

19

Total Acid as P2O5

65

Shape Size [mm]

40

Pellets 6–7


Alkane Dehydrogenation and Dealkylation These catalysts are offered for use in Houdry® Catofin® process plants licensed by ABB Lummus Global Inc. The composition of these catalysts is proprietary.

Dehydrogenation catalysts Propane to propylene

HOUDRY ® CATOFIN® and CATOFIN® PS

i-butane to i-butylene

HOUDRY ® CATOFIN® ES (Extended Stability) HOUDRY ® CATOFIN® HY (High Yield)

n-butane to butadiene

HOUDRY ® CATADIENE®

i-pentane to isoprene


Dealkylation catalysts Pyrolysis petrol to benzene

HOUDRY ® PYROTOL®

Coke oven light oil to benzene

HOUDRY ® LITOL®

Toluene to benzene

HOUDRY ® DETOL®

Steam Cracker Plants Catalytic selective hydrogenation of acetylenes and dienes in the presence of olefins represents standard procedure for purifying olefin streams in steam cracker plants . High selectivity is required to gain olefins from the hydrogenated acetylenes and dienes while achieving high purity products. Olefin streams to be catalytically purified may be broken down into:

Front-end systems

with C2 gases up to raw gas also containing hydrogen, methane, CO and sometimes sulphur

Tail-end systems

with concentrated ethylene/ethane mixtures and propylene/propane mixtures

C4 and C5 cuts may be selectively hydrogenated or, alternatively, completely saturated. Hydroprocessing of aromatic concentrates such as pyrolysis gasoline or dripolene is also possible.

41


Front-End Hydrogenation Sulphur-free Gases The OleMax 250 family of front-end hydrogenation catalysts is characterised by high selectivity in the hydrogenation of acetylenes and dienes in raw olefin, C3-minus and C2-minus streams. These catalysts are suitable for use in isothermal tubular reactors as well as for adiabatic beds. They are regenerated either by steam/air treatment in situ or with air ex situ. OleMax 251 is the ideal choice for streams with low and/or fluctuating CO levels. New versions of OleMax 250 series are under development and soon to be introduced to the industry. OleMax 250

OleMax 251

(G-83 A)

(G-83 C)

0.018

0.018

-

0.05

Al2O3

Balance

Balance

Shape

Tablets

Tablets

4x4

4x4

Nominal Content [wt.%] Pd Promoter

Size [mm]

Sulphur-bearing Gases Catalysts in the OleMax 100 family selectively hydrogenate acetylenes and dienes in sulphur-bearing cracked gas streams. Selection from among the following types depends on the expected sulphur content of the gas stream and on plant design conditions. OleMax 100 types are resistant to deactivation by traces of heavy metals often found in these streams. OleMax 101

OleMax 102

OleMax 103

2.6

1.3

0.6

1–2

1–2

1–2

SiO2-Al2O3

Balance

Balance

Balance

Shape

Spheres

Spheres

Spheres

8

8

8

Nominal Content [wt.%] NiO Multi-Promoter

Size [mm]

42


C2 Tail-End Hydrogenation Acetylene hydrogenation in an ethylene/ethane stream is performed with almost stoichiometric addition of hydrogen. The Ag-promoted OleMax 200 family catalysts ensure outstanding performance, combining high ethylene gain with long cycles, even in plants with highseverity cracking. The product purity achieved is typically below 0.3 ppm acetylene. In-situ steam/air treatment is the preferred way of regenerating the catalysts. OleMax 201

OleMax 203

OleMax 204

(G-58 C)

(G-58 D)

(G-58 E)

Pd

0.03

0.018

0.047

Ag

0.18

0.05

0.28

Al2O3

Balance

Balance

Balance

Shape

Spheres

Tablets

Spheres

2–4

4x4

3–5


Size [mm]

C3 Tail-End “Gas Phase” Hydrogenation The conventional method for the removal of methylacetylene and propadiene (MAPD) from propylene/propane streams is selective hydrogenation over a Pd based catalyst from the OleMax 300 family. The aim is to increase the propylene concentration and to decrease MAPD to below 10 ppm. Typically, purification is performed with a molar ratio of hydrogen to MAPD of between 1:1 and maximum 1.5:1. The Pd-catalysts are regenerable with steam/air in situ. OleMax 301

OleMax 302

(C31-1-01)

(G-55 B)

0.03

0.03

-

Proprietary

Al2O3

Balance

Balance

Shape

Spheres

Spheres

3–5

3–5

Nominal Content [wt.%] Pd Promoter

Size [mm]

43


C3 Tail-End “Liquid Phase” Hydrogenation It is common practice in steam cracker plants to hydrogenate the higher olefin streams selectively in liquid phase by means of Pd catalysts with a Pd content of 0.1 – 1.0 wt.%, where gas phase hydrogenation catalysts typically consist of Pd on alumina in a concentration of only 0.01 – 0.1 wt.% palladium. The temperature range applied varies from 10 – 200° C depending on the carbon number and the pressure of the olefin stream. For C3 cut hydrogenation, the aim is to selectively hydrogenate up to 7% methylacetylene and propadiene in a propylene stream with an increase in propylene and suppression of by-product formation. OleMax 350

OleMax 353

(G-68 HX)


0.3

0.22

-

-

Al2O3

Balance

Balance

Shape

CDS Extrusions

CDS Extrusions

1.5

1.5

Promoter

Size [mm]

OleMax 350 is the proven catalyst for liquid phase MAPD processes. Using proprietary new techniques to control Pd dispersion irrespective of carrier type, OleMax 350 is significantly more active and more selective than the industry benchmark catalyst without requiring promoters.

C4 Cut Hydrogenation The steam cracker C4 cut consists of approximately 50 wt.% 1.3-butadiene and 1 wt.% acetylenes in a mixture of butenes and butanes. Purification of this stream necessitates several hydrogenation steps depending upon the further use of the stream.

44


Vinylacetylene Hydrogenation The crude C4 stream typically contains 0.5 – 2 wt.% vinylacetylene and ethylacetylene. These components can drastically impact the efficiency of the butadiene extraction solvent system. OleMax 400

OleMax 353

(G-68 G)


0.2

0.22

Al2O3

Balance

Balance

Shape

Spheres

CDS Extrusions

2–4

1.5

Size [mm]

Selective Butadiene Hydrogenation OleMax 452 is used for butadiene hydrogenation in combination with high butene-1 to butene-2 isomerisation activity. G-68E is used when low isomerisation is required. G-58A hydrogenates 1.3-butadiene with no butene-1 isomerisation and no butene-1 loss. OleMax 452 (T-2464 B)


0.5

Al2O3

Balance

Shape

CDS Extrusions

Size [mm]

1.5

45


C4 /C5 Cut Total Hydrogenation Total saturation of C4 and/or C5 streams is carried out over the Pdbased catalyst OleMax 450. OleMax 450

OleMax 452

(G-68 C)

(T-2464 B)

Pd

0.3

0.5

Pt

-

-

Al2O3

Balance

Balance

Shape

Spheres

CDS Extrusions

2–4

1.5


Size [mm]

Hydrogenation of Pyrolysis Gasoline First Stage Diene Hydrogenation OleMax 600 and OleMax 601 are used in the first-stage hydrogenation of the pyrolysis gasoline treatment unit to hydrogenate the dienes selectively. For high-severity cases, OleMax 601 catalyst is the ideal type. For OleMax 600, a newly enhanced spherical carrier significantly improves both catalyst activity and physical durability. These Pd catalysts can be regenerated by in-situ steam/air treatment or hot hydrogen stripping. OleMax 600

OleMax 601

(G-68 C)

(G-68 C-1)

0.3

0.4

Al2O3

Balance

Balance

Shape

Spheres

Spheres

2–4

1.2 – 2.8


Size [mm]

46


Second-stage Olefin Hydrogenation and Sulphur Conversion Second-stage hydrogenation in commercial pyrolysis gasoline units often utilises a mixed catalyst loading. Typically, the reactor loading consists of:

Top 30% Bottom 70%

NiMo catalyst OleMax 807 CoMo catalyst OleMax 806

OleMax 807 is the active for olefin saturation and conversion of organic nitrogen compounds, whereas OleMax 806 converts organic sulphur compounds such as thiophenes, disulphides and mercaptanes to below 1 ppm. OleMax 807

OleMax 806

(C20-7-06)

(C20-6-04)

NiO

5.0

-

CoO

-

5.0

MoO3

20.0

20.0

Al2O3

Balance

Balance

Shape

CDS Extrusions

CDS Extrusions

1.5

1.5


Size [mm]

Conversion of Methanol to Propylene (MTP) The possibility of producing methanol in large quantities by means of processes such as LurgiMegaMethanol means that this chemical can be used as a raw material for olefin production. The MTPROP® catalyst converts methanol to propylene in the presence of steam. The highly selective catalyst favours the formation of propylene. By-products are gasoline with a high RON number, LPG and fuel gas. MTPROP® Nominal Content [wt.%] Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

47

Catalysts for the Production of Chemicals A masterpiece only really shines in candlelight To ensure it stays that way, Süd-Chemie develops and produces catalysts for wax production among other applications. We offer a wide variety of products in the syngas and speciality chemical sector at the highest quality.

Production of Chemicals

Süd-Chemie supplies catalysts for intermediates in the wide-ranging field of performance chemicals. Süd-Chemie produces catalysts for alcohols and manufactures resins, rosins and waxes. It also covers catalysts for caprolactam and nylon products, the catalysts for natural and related products such as vitamins and fragrances, as well as oxidation catalysts. Furthermore all relevant synthesis gas catalysts are covered for the production of ammonia, methanol, carbon monoxide and hydrogen for a variety of applications. Most of the catalysts mentioned in this section are available in the oxidic form als well as in the pre-reduced and stabilised (RS) form.

Production of Ammonia and Methanol The production of ammonia or methanol involves the use of several key unit operations for which Süd-Chemie supplies catalysts. These are:

• Feedstock purification • Prereforming • Steam reforming • Secondary reforming • Autothermal reforming • CO conversion • Methanation • Ammonia synthesis • Methanol synthesis

50


Prereforming A prereformer is an adiabatic fixed-bed reactor upstream of the primary reformer. It allows increased flexibility in the choice of feedstock, increased lifetime of the steam reforming catalyst and tubes, and the option of increasing the overall plant capacity. Furthermore it allows an operation at lower steam/carbon ratios. ReforMax® 100 is a prereforming catalyst designed to handle the entire range of hydrocarbon feedstocks from natural gas up to and including LPGs and naphthas. ReforMax® 100 Nominal Content [wt.%] NiO

56

Support and Promoter

Balance

Shape

Tablets

Size [mm]

4.5 x 4.5

Steam Reforming Selection of the optimum catalyst depends on several factors, including furnace design, severity of service, and the type of hydrocarbon processed. Our standard catalysts are shown in the table below. ReforMax® 330 LDP

ReforMax® 210 LDP

ReforMax® 250

NG

NG/LPG

Naphtha

NiO

14

18

25

K2O

-

1.6

8.5

Carrier

CaAl12O19

CaK 2 Al22O34

Calciumaluminate

Shape

10 Holed Ring

10 Holed Ring

Multiholed Ring

19 x 16

19 x 12

16 x 16

Typical feed Nominal Content [wt.%]

Size [mm]

51


Secondary Reforming The optimum catalyst for an air-blown secondary reformer depends on the design of the burner and the distance between burner tip and top catalyst layer. If hexagonal target bricks are not used, we recommend installation of a top layer of ReforMax ® 400 GG to serve as an active heat shield. This material is also ideal for a bottom active support layer where extreme short loadings are required and/or high purity inert supports have been used in the past. ReforMax® 400 LDP catalyst is used for the bulk of the reactor loading. ReforMax® 400 GG

ReforMax® 400 LDP

12

12

Nominal Content [wt.%] NiO Carrier Shape Size [mm]

α-Al

O3

2

CaAl12O19

6 Holed Ring

10 Holed Ring

32 x 17

19 x 16

Autothermal Reforming Oxygen-blown autothermal reformers require a mixed loading of catalysts, comprising an active heat shield and a reforming catalyst of excellent physical stability and thermoshock resistance. The standard catalyst loading is approx. 5 – 10% of ReforMax® 420 on top of ReforMax® 330 LDP catalyst. ReforMax® 420

ReforMax® 330 LDP

NiO

8

14

Carrier

α-Al


Shape Size [mm]

52

O3

2

CaAl12O19

Extrusions

10 Holed Ring

30

19 x 16


CO Conversion Most ammonia plants convert CO to CO2 by high-temperature CO conversion followed by low-temperature CO conversion. For special process design, it can be advantageous to combine these two steps to form one isothermal or adiabatic step called „mediumtemperature CO conversion“ (MTS).

High-temperature CO Conversion The HTS catalyst ShiftMax® 120 combines high activity with extremely good physical robustness. In addition, this catalyst is very effective in preventing Fischer-Tropsch by-product formation when operating at low steam conditions. ShiftMax® 120 Nominal Content [wt.%] Fe2O3

80

Cr2O3

8.5

CuO

2

Shape Size [mm]

Tablets 6x6

53


Low-temperature CO Conversion The LTS catalysts ShiftMax® 230 and 240 are next-generation products that offer unparalleled activity for water-gas shift, resulting in higher CO conversion for longer life, enhanced resistance to poisons, and exellent physical strength. The promoter in ShiftMax® 240 suppresses the formation of methanol by more than 95% compared to standard LTS catalysts. ShiftMax® 230

ShiftMax® 240

CuO

58

57

ZnO

31

31

Al2O3

11

11

-

1

Tablets

Tablets

4.8 x 3.2

4.8 x 3.2


Promoter Shape Size [mm]

Methanation Depending on the severity and product purity requirements of the application, Süd-Chemie supplies two different types of methanation catalysts. METH 134 consists of alumina supported NiO. For extremely lowtemperature applications, i.e. T < 170° C, Süd-Chemie provides METH 150, a catalyst made up of ruthenium on alumina. METH 134

METH 150

NiO

25

-

Ru

-

0.3

Support

Balance

Balance

Shape

Spheres

Tablets

3–6

4.5 x 4.5


Size [mm]

54


Ammonia Synthesis AmoMax 10 is a wustite-based ammonia synthesis catalyst that features significantly higher activity than magnetite-based catalysts. This high activity level is also evident at low operati ng temperatures, allowing improved conversion at thermodynamically more favorable conditions. AmoMax 10 is available in oxide and pre-reduced, stabilised form. AmoMax 10 Nominal Content [wt.%] Fe FeO

98

Promoter

Balance

Shape

Granules

Size [mm]

-

Methanol Synthesis For the synthesis of methanol from carbon oxides and hydrogen, Süd-Chemie produces the MegaMax® 700 catalyst, which is used in isothermal reactors (Lurgi-type) and all other plant designs, such as adiabatic quench type reactors. MegaMax® 700 has extremely good low-temperature activity, which allows it to be operated at more thermodynamically favorable conditions. This catalyst also has excellent selectivity, even with high CO-content feed gas. MegaMax® 700 Nominal Content [wt.%] CuO

Proprietary

ZnO

Proprietary

Al2O3

Proprietary

Shape

Tablets

Size [mm]

6x4

55


Methanol Reforming Hydrogen and carbon monoxide can be produced by means of steam-reforming of methanol, which is performed with ReforMax® M. ReforMax® M Nominal Content [wt.%] CuO

66

ZnO

23

Al2O3

Balance

Shape

Tablets

Size [mm]

6x4

Production of Sulphuric Acid The conversion of sulphur dioxide to sulphur trioxide is the catalytic step in the production of sulphuric acid. Süd-Chemie‘s C116 series encompasses catalysts featuring different formulations and innovative shapes, covering all operating conditions in the sulphuric acid process. C116

C116 HV

C116 CS

V2O5

6.5 – 7.5

7.5 – 8.5

6.5 – 7.5

K2O

9.5 – 11.0

10.0 – 11.5

Proprietary


Shape Size [mm]

56

Ribbed Rings/Extrusions 9


Production of Alcohols Oxo Alcohols Oxo alcohol process chains typically start with the fine-cleaning of short chain olefins like propene or the desulphurisation of C7 to C11 olefins for higher alcohols. They include the hydrogenation step from crude aldehyde to alcohol and generally finish with fine-cleaning, which reduces the carbonyl value of the finished alcohol to a certain specified level. The following catalysts are available for hydrogenation:

G-22 Series G-22

G-22/2

CuO

41

47

Cr2O3

43

34

BaO

12

6

SiO2

-

Balance

Tablets

Tablets/Powder

4.5 x 4.5

4.5 x 4.5

G-99B-0

G-99C-0

CuO

47

47

Cr2O3

46

46

MnO2

4

4

BaO

2

2

Tablets

Tablets

3x3

5x3


Shape Size [mm]

G-99 Series Nominal Content [wt.%]

Shape Size [mm]

57


T-2130 A copper zinc oxide catalyst, entirely Cr-free, which is used in the hydrogenation of butyraldehyde and 2-ethyl-hexenal. T-2130 Nominal Content [wt.%] CuO

33

ZnO

66

Shape Size [mm]

Tablets 6x3

T-4489 A Cr-free, copper- and alumina-based hydrogenation catalyst for gas phase hydrogenations of oxo aldehydes. High acid stability comparable to standard copper chromites. T-4489 Nominal Content [wt.%] CuO

56

MnO2

10

Al2O3

Balance

Shape

Tablets

Size [mm]

3x3

T-4361 This promoted nickel on silica catalyst offers high selectivity. It is usually applied in specific trickle phase oxo aldehyde hydrogenation processes. T-4361 Nominal Content [wt.%] NiO

68

CuO

3

Support

Balance

Shape

Tablets

Size [mm]

58

5x3


G-134 The G-134 catalyst series are extruded nickel catalysts with a high surface area and mixed silica and alumina support. Their rugged physical properties means that these catalysts can be supplied in small particle sizes or in CDS shape. G-134 type catalysts demonstrate excellent activity in the fine-cleaning of oxo compounds. G-134 A Nominal Content [wt.%] NiO

66

SiO2

28

Al2O3

Balance

Shape

CDS Extrusions/Extrusions

Size [mm]

1.5

G-49B A nickel-on-kieselguhr catalyst which is mainly used for oxo finecleaning applications. G-49B Nominal Content [wt.%] NiO

66

SiO2

Balance

Shape

Tablets

Size [mm]

5x3

G-69 This zirconium promoted nickel-on-kieselguhr catalyst is similar to G-49 in both composition and application. Zirconium improves low-temperature activity. G-69 Nominal Content [wt.%] NiO

74

ZrO2

2

Support

Balance

Shape

Tablets

Size [mm]

5x3

59


G-103 The outstanding feature of this cobalt catalyst is the considerable strength of the tablet. It is mainly used for reduction of oxo aldehydes: for example, in the first stage of the Courier-Kuhlmann process. G-103 Nominal Content [wt.%] CoO

39

SiO2

Balance

Shape

Tablets

Size [mm]

6x6

T-4405 This is a catalyst containing a high percentage of cobalt, produced in the form of mechanically strong extrusions. It is ideal for use in the last hydrogenation stage of Courier-Kuhlmann oxo alcohol set-ups, for example. T-4405 Nominal Content [wt.%] CoO

63

SiO2

24

Al2O3

Balance

Shape

Extrusions

Size [mm]

3.0

G-67 This catalyst contains cobalt supported on a zirconium-promoted kieselguhr. G-67 A Nominal Content [wt.%] CoO

68

ZrO2

Promoter

SiO2

Balance

Shape Size [mm]

60

Extrusions 3


Fatty Alcohols and Natural Detergent Alcohols (NDA) Natural detergent alcohols or fatty alcohols are sourced from natural oils, mainly lauric. They can be produced either by direct hydrogenation of the corresponding fatty acid, hydrogenation of the corresponding methyl esters (FAME), or hydrogenation of wax esters - the most recent process variant. The catalysts are applied in slurry processes as oxidic powders or i n fixed-bed processes. They are generally prereduced and stabilised.

G-99 Series The G-99-series are copper chromite catalysts, manganesepromoted, with increasing barium contents. The catalysts are highly poison resistant, especially against chlorine and sulphur, and feature excellent separation properties. They are supplied in the form of oxidic powders for slurry applications. The type of catalyst to be used must be selected with care, depending on the sulphur and chlorine level of the different feeds and on the separation system. For a detailed recommendation, please contact our technical service. For fixed-bed applications, G-99B-0 is used in tablet form. G-99B-0

G-99B-13

CuO

47

48

Cr2O3

46

44

MnO2

4

6

BaO

2

1

Tablets

Powder

3x3

-


Shape Size [mm]

61


T-4489 This is a chromium-free alumina-based manganese-promoted hydrogenation catalyst for slurry applications which can be used instead of copper chromite catalysts. T-4489 Nominal Content [wt.%] CuO

56

MnO2

10

Al2O3

Balance

Shape

Powder

Size [mm]

-

T-2130 A copper/zinc-oxide-based catalyst which is recommended for methyl ester hydrogenations. T-2130 Nominal Content [wt.%] CuO

33

ZnO

66

Shape

Tablets

Size [mm]

6x3

T-4419/T-4421 Copper chromite catalysts with an exceptionally high copper-to-chromium ratio. They are recommended for specific FAME hydrogenation processes. T-4419

T-4421

CuO

78

66

Cr2O3

20

30

Shape

Tablets

Tablets

4.5 x 4.5

4.5 x 4.5


Size [mm]

62


T-4489 The tabletted form of the T-4489 is recommended for wax ester hydrogenation processes. T-4489 Nominal Content [wt.%] CuO

56

MnO2

10

Al2O3

Balance

Shape

Tablets

Size [mm]

3x3

Furfuryl Alcohol Furfuryl alcohol can be sourced by the hydrogenation of furfural based on natural products, or as a by-product from the hydrogenation of maleic acid or maleic acid esters. For the hydrogenation of furfural to furfuryl alcohol we supply copper chromite catalysts which are highly heat resistant and – in the form of tablets – regenerable.

G-22F This barium-promoted copper catalyst is developed especiall y for the fixed bed-hydrogenation of furfural. The catalyst features high selectivity and extremely low sylvan make. G-22F Nominal Content [wt.%] CuO

38

Cr2O3

37

BaO

11

SiO2

Balance

Shape

Tablets

Size [mm]

3x3

63


G-99D-0 This is the optimum catalyst for slurry phase furfural hydrogenations. The catalyst is a copper chromite. Manganese-promoted with a high surface area of 70 – 80 m2 /g, it features high activity and excellent separation properties. G-99D-0 Nominal Content [wt.%] CuO

46

Cr2O3

44

MnO2

4

Shape

Powder

Size [mm]

-

Production of Diols The production of diols (bi-functional alcohols) is based ei ther on direct hydrogenation of the corresponding anhydrides in the gas phase, or on hydrogenation of the methyl esters of the respective acids in the gas phase, or in the liquid or trickle phase. The hydrogenation is carried out in fixed-bed reactors.

T-4489 This is an alumina-based copper catalyst with high aci d resistance and tailor-made pore size distribution to achieve optimum selectivity. By variation of the standard T-4489, selectivity can be shifted either in the direction of the diols, the intermediate γ-butyrolactone, or THF. The catalyst is only available for specific processes. For a detailed recommendation, please contact us. T-4489 Nominal Content [wt.%] CuO

56

MnO2

10

Al2O3

Balance

Shape

Tablets

Size [mm]

64

3x3


T-2130 This copper/zinc-based catalyst is perfect for the hydrogenation of maleic acid dimethyl esters. T-2130 Nominal Content [wt.%] CuO

33

ZnO

66

Shape Size [mm]

Tablets 6x3

T-4322 This copper/zinc catalyst is used for the gas-phase hydrogenation of maleic acid anhydride. T-4322 Nominal Content [wt.%] CuO

64

ZnO

24

Al2O3

Balance

Shape

Tablets

Size [mm]

6x4

T-4466 This is a high-acid stable copper chromite catalyst. It can be used in the hydrogenation of maleic acid diesters with high residual acid contents. T-4466 Nominal Content [wt.%] CuO

53

Cr2O3

45

Shape

Tablets

Size [mm]

3x3

65


Production of Cyclohexyldimethanol (CHDM) For the hydrogenation of dimethyl-ester to the corresponding dimethanol as part of the Eastman-Kodak process, copper chromium, copper zinc, or copper alumina may be used as catalysts. T-4489

T-2130

T-4466

CuO

56

33

53

ZnO

-

66

-

MnO2

10

-

-

Cr2O3

-

-

45

Al2O3

Balance

-

-

Shape

Tablets

Tablets

Tablets

3x3

3x3

3x3


Size [mm]

Production of Alkyl Amines Alkyl amines are typically made by amination of alco hols or aldehydes followed by hydrogenation.

66


Amination of Alcohols For methyl amines, alumosilicates and zeolites are used as catalysts. Amination of alcohols is generally used to produce short-chain alkyl amines. For ethylamines and propylamines, on the other hand, nickel or cobalt catalysts are preferred. For long chain amines, copper catalysts or copper chromites are used.

Nickel Catalysts NiSAT ® 320 tablets demonstrate high mechanical stability in fixed-bed processes. NiSAT® 320

NiSAT® 300

NiO

66

66

SiO2

-

28

Al2O3

-

Balance

Support

Balance

-

Shape

Powder

Extrusions

-

1.5


Size [mm]

Cobalt Catalysts Cobalt catalysts are used when high selectivity, especially towards di- and tri-alkyl amines, is required. G-62

G-67

45

68

Promoter

-

Proprietary

Support

Balance

Balance

Shape

Tablets

Extrusions

4.5 x 4.5

3.0

Nominal Content [wt.%] CoO

Size [mm]

67


Nitrile Hydrogenation Nitrile hydrogenation is basically conducted with long-chain nitriles, especially fatty nitriles. Nickel catalysts are used for slurry application. Where the application of powder is to be avoided, NiSAT ® 320 and G-95C pastilles are used, with the reduced powder being embedded into di-stearyl-amine. NiSAT® 320

G-95C

NiO

70

35

SiO2

Balance

Balance

Shape

Powder

Pastilles

-

-


Size [mm]

Hydrogenation of Nitro-Compounds to Anilines The hydrogenation of nitrobenzene to aniline is carried out either in a discontinuous slurry process based on nickel catalysts, or in isothermal gas phase processes based on copper catalysts. Attacks on the aromatic ring and side reactions to diphenylamine must be avoided. The silica-based reduced nickel powder NiSAT ® 320 exhibits excellent separation properties and fair activity for slurry application. NiSAT® 320

NiSAT® 330

NiO

66

83

SiO2

Balance

-

-

Balance

Powder

Powder

-

-


Support Shape Size [mm]

The silica-based nickel catalyst powder NiSAT ® 330, with its coarse primary particle size, is ideal for easy separation. The catalyst has a very low iron content and thus excellent selectivity.

68


The copper chromite catalyst G-99B-0 is used for isothermal gasphase hydrogenation of nitrobenzene. It demonstrates perfect selectivity even under SOR conditions and is also particularly attractive due to its low carbon deposits and long life. G-99B-0 Nominal Content [wt.%] CuO

47

Cr2O3

46

MnO2

4

BaO

2

Shape Size [mm]

Tablets 5x5

Production of N-Alkylates This area covers not just the reductive N-alkylation of aniline derivates, with iso-propanol, for example, but also the reductive alkylation of an unsaturated secondary amine with formaldehyde or the reductive alkylation of fatty amines to saturated tertiary amines. These reactions can be carried out with copper-based catalysts, mainly copper chromites, or in some cases with nickel catalysts containing low content of nickel. Selection must be based on the process conditions and equipment used; for this reason, please contact us for details.

69


Caprolactam from Benzene This process involves the following steps: Benzene is firstly hydrogenated to cyclohexane. Cyclohexane is then oxidised to a mixture of cyclohexanol and cyclohexanone. The cyclohexanol is dehydrogenated to cyclohexanone. After the oxime is formed, caprolactam is obtained by performing a Beckman rearrangement. For the hydrogenation of benzene to cyclohexane, nickel catalysts are applied in either continuous slurry processes or isothermal fixed-bed processes, the latter being more common. NiSAT ® 320 RS powder is used for the slurry process, while for the fixed-bed process we recommend using our NiSAT ® 200 catalyst in RS form. NiSAT® 320

NiSAT® 200

NiO

70

47

SiO2

Balance

Balance

Shape

Powder

Tablets

-

6x6


Size [mm]

The oxidation of cyclohexane to form a cyclohexanone/cyclohexanol mixture is performed with cobalt catalysts such as cobalt octanoate. Dehydrogenation of the cyclohexanol portion can be performed either in a high-temperature process of up to 400° C with a calcium zinc catalyst, namely T-4004, or at medium temperatures of around 230 – 300° C with a copper/zinc catalyst such as G-132A RS. T-4004

G-132A

Nominal Content [wt.%] CaO

19

-

CuO

-

33

ZnO

Balance

Balance

Shape

Tablets

Tablets

6x6

6x3

Size [mm]

70


For the transformation of oxime to caprolactam via Beckman rearrangement, we provide a special catalyst which is available on request. A second route to cyclohexanone is based on phenol. The catalyst performing this reaction is a Pd catalyst which is also available on request from Süd-Chemie.

C12-Lactam (Lauryllactam) After the trimerisation of butadiene to cyclododecatriene (CDT), epoxidation followed by two-step hydrogenation produces cyclo-dodecanol. Nickel-based catalysts are used for the trimerisation stage. Nickel and palladium catalysts are recommended for the subsequent hydrogenation steps. For the dehydrogenation of cyclododecanol to the corresponding cyclic ketone, meanwhile, a copper/zinc-based catalyst like PolyMax 301 is used. PolyMax 301 Nominal Content [wt.%] CuO

31

ZnO

Balance

Shape Size [mm]

Extrusions 3

Nylon-6,6 The starting material is typically butadiene. Addition o f HCN is performed via copper chloride, the resulting dinitrile being hydrogenated to hexamethylene diamine. Raney-nickel catalysts are generally used in a slurry phase reaction, while the highly selective promoted T-4424 catalysts are recommended for fixed-bed operations. T-4424 Nominal Content [wt.%] CoO

43

MnO2

5

SiO2 /MgO

Balance

Shape

Tablets

Size [mm]

6x3

71


Resins and Rosins These substances are hydrogenated in order to remove unsaturates over Ni-, Pd- or Cu-based catalysts.

Nickel Catalysts NiSAT® 300

NiSAT® 320

NiSAT® 330

NiO

66

70

84

SiO2

28

-

-

Al2O3

Balance

-

-

-

Balance

Balance

Extrusions

Powder

Powder

1.5

-

-



Palladium Catalysts H2Max 50

MPT 3

MPT 5

MPT 10

0.5

3

5

10

Activated Carbon

Balance

Balance

Balance

Balance

Shape

Granules

Granules

Granules

Granules

-

-

-

-


Size [mm]

72


Copper Catalysts Mainly supplied for fixed-bed processes. The relevant types are copper chromites and copper/zinc catalysts. G-132A

G-99B-0

CuO

33

47

Cr2O3

-

46

MnO2

-

4

BaO

-

2

ZnO

Balance

-

Shape

Tablets

Tablets

6x3

5x5


Size [mm]

Selection of the catalyst depends very much on the type of resin and the molecular weight of the polymer. For abietinic resins, for example, palladium catalysts are ideal, where as for specific C5 petroleum resins, nickel powders may be more effective. In some cases it is advisable to use catalysts with a caustic promoter or promoted with zirconium. Those types are available on request.

Treatment of Fischer-Tropsch Waxes A special case in the hydro-treatment of high molecular compounds is the treatment of Fischer-Tropsch waxes. FT waxes typically contain carbonylic unsaturates which are sometimes conjugated giving the wax a faint yellow coulour. This colour has to be removed for a variety of applications. Furthermore, FT waxes can contain traces of iron which are typically removed prior to a hydro-genation treatment with ActiSorb® 400. ActiSorb® 400

NiSAT® 300

NiSAT® 340

NiO

-

66

70

MgO

-

-

8

Al2O3

16

Balance

Balance

SiO2

Balance

28

20

Shape

Spheres

CDS Extrusions

Extrusions

5

1.5

3


Size [mm]

73


Hydrogenation of Sugars Conventionally, Raney-nickel catalysts are used for the batch-type hydrogenation of glucose to sorbitol. Using supported nickel or ruthenium catalysts offers handling advantages and the benefit of high selectivity. The use of specially promoted Ni-catalysts leads to stereo-selective hydrogenation of sugar molecules suitable for new applications.

Nickel-type catalysts NiSAT® 300

NiSAT® 330

NiSAT® 350

NiO

66

70

64

MgO

-

8

-

WO3

-

-

4

Al2O3

Balance

Balance

10

SiO2

28

20

27

CDS Extrusions

Extrusions

Extrusions

1.5

3

3


Shape Size [mm]

Ruthenium-type catalysts MRT Nominal Content [wt.%] Ru

0.1 – 5

Activated Carbon

Balance

Shape

Granules

Size [mm]

2–5

Cracking of Sugars Sugar cracking can produce valuable chemical products in the C2 – C4 range, like butanediols, THF, propanediols, ethylene glycols etc. Tests showed promising results with nickel and ruthenium catalysts. Details are available upon request.

74


Dehydration, Cyclisation and Polycondensation Processes Dehydration of alcohols produces olefins, but may also lead to the formation of cyclic products. Depending on the reaction to be performed, we can supply either modified montmorillonites, specific zeolites, or zirconia-, titania-, or niobia-based catalysts. As this is an extremely large area – including, for example, the polymerisation of THF – we would ask you to contact us to discuss your specific requirements.

Dehydrogenation and Oxidation Dehydrogenation of alcohols to their corresponding ketones or aldehydes covers sophisticated areas such as the dehydrogenation of lauric alcohol for the fragrance industry, but also the broad area of the dehydrogenation of cyclohexanol to cyclohexanone to produce, ultimately, caprolactam for nylon-6. We also provide catalysts for the dehydrogenation of cyclododecanol to create lauryllactam and nylon-12 as final products. Catalysts used in this area are: CuO

Cr2O 3

ZnO

PolyMax 172

•

T-4004

•

T-2130

•

G-13

•

•

G-22

•

•

T-4419

•

•

T-4421

•

•

•

CaO

Promoter •

• •

•

75


Sophisticated Uses Very often, a catalytic step is required in the manufacturing of chemicals from starch, the production of vitamins, the composition of fragrances and aromas, food additives, and the production of bio-fuels and so-called bio-solvents. For all of these diverse applications, we have a range of experience, allowing us to help you to choose the right catalysts. In most cases, the catalysts are based on nickel, copper or noble metals. We are always ready to discuss your particular requirements, and are confident that we can provide an optimum solution.

Production of Ethylenedichloride (EDC) Catalysts for the production of EDC from ethylene in a fluid-bed reactor operate with either air- or oxygen- based technology. Key features of these catalysts include high activity and stability during operation, meaning no loss of active compounds and no significant variation in surface area. There is practically no tendency towards sticking among the individual catalyst particles during commercial use of the OXYMAX ® catalyst series.

OXYMAX ® catalyst series OXYMAX® A

OXYMAX® B

5

5

Support

Balance

Balance

Shape

Powder

Powder

-

-

Nominal Content [wt.%] CuO

Size [mm]

76


Production of Formaldehyde Iron/molybdenum-based catalysts are used for the oxidation of methanol to formaldehyde in fixed-bed tubular reactors. These catalysts are available in different tabletted ring shapes, with optimisation of pellet efficiency (optimal equivalent diameter) and minimisation of pressure drop across the catalyst bed. They can be used in a broad range of methanol concentrations, thus meeting the requirement of state-of-the-art formaldehyde plants. There is also a variety of options for catalyst dilution with inert material. Dilution of the formaldehyde catalyst ensures optimised catalyst activity to maximise the lifetime of the charge of the formaldehyde catalyst loaded to the tubular reactor. FAMAX® J5

FAMAX® MS FAMAX® HS FAMAX® TH

Nominal Content [wt.%] MoO3

54

54

54

54

Fe2O3

12

12

12

12

Shape

Rings

Rings

Rings

Triholed Ring

4x4x2

4.5 x 4.5 x 2

5x5x2

5.5 x 5

Size [mm]

Production of Hydrogen Peroxide For the production of H2O2 via the anthraquinone processes in slurry phase, catalysts in powder form with 2% palladium, well dispersed on a proprietary carrier, are used. The catalysts are produced in several different formats with different particle size distributions. In particular, the catalysts contain an extremely low fines content, ensuring minimal catalyst consumption during production of H2O2. H2Max 5

H2Max 5/S

H2Max HAR

2.0

2.0

2.0

Support

Balance

Balance

Balance

Shape

Powder

Powder

Powder

< 250

> 98

> 95

> 95

< 63

<2

<2

<2


Size [µm]

77


Production of Vinylacetatmonomer (VAM) Zinc acetate on activated carbon is used for the synthesis of vinyl acetate from acetylene in fixed-bed tubular reactors. Both the improved manufacturing process and the selected carbon carrier ensure high catalyst activity and excellent attrition resistance. MAVC

MAVC/C

15

15

Balance

Balance

Extrusions

Extrusions

4

3

Nominal Content [wt.%] ZnO Activated Carbon Shape Size [mm]

Production of Phthalic Anhydride (PA) Süd-Chemie‘s multi-layer PA catalyst series PHTHALIMAX ® is supplied for standard, medium or high o-Xylene loading. Performance losses in the oxidation reaction from o-Xylene to Phthalic Anhydride (PA) are directly related to the formation of under-oxidation and over-oxidation products. PHTHALIMAX ® is designed to operate in the optimum oxidation range, resulting in excellent PA yields (low COx formation) and superior PA quality. Our patented catalyst loading technique saves time and, more importantly, affords greater precision compared to conventional catalyst loading systems. PHTHALIMAX® multi-layer catalyst Nominal Content [wt.%] V2O5

Proprietary

TiO2

Proprietary

Promoters

Proprietary

Carrier

Steatite

Shape

Rings

Size [mm]

78

8x6x5

PHTHALIMAX®-M series

for medium OX load

PHTHALIMAX®-S series

for standard OX load

PHTHALIMAX®-H series

for high OX load


Purification of Terephthalic Acid (PTA) Purification of terephthalic acid in a fixed bed reactor is achieved by hydrogenation of the coloured by-products to uncoloured and water-soluble by-products. The main impurity to be hydrogenated is 4-carboxybenzaldehyde. The catalysts applied are precious-metal-based catalysts on granular carbon with highly dispersed Pd, assuring long-term stable catalyst activity. H2Max 50

H2Max HD

0.5

0.5

Activated Carbon

Balance

Balance

Shape

Granules

Granules

3–6

3–6


Size [mm]

79

Catalysts for the Oil Refinery Industry Making things happen together Even the best idea is only as good as its implementation. The fitting technology is just as important here as the right partner. That is why Süd-Chemie works closely on location with responsible persons in the oil refinery industry. And the successes are impressive. We offer you a broad product pallet of solutions that set benchmarks in many areas.

Oil Refinery Industry

Fuel Technology For the production of transportation fuels, Süd-Chemie supplies special catalysts with superior catalytic properties. These are largely sophisticated, high-value zeolite products. Over just a short period of time, we have diversified our activities in this area and developed new catalyst formulations with outstanding catalytic performance compared to products available on the market. This exceptional standard of quality and performance is the fruit of our intensive cooperation with engineering partners and refineries. As a consequence, Süd-Chemie, together with its partners, is in a position not only to supply the catalyst, but to offer a full package consisting of both the catalyst plus process technology for petrol and diesel production.

Conversion of Methanol to Dimethylether (DME) For the conversion of methanol to dimethylether, Süd-Chemie supplies the alumina-based SynMax® 100 catalyst, which is fully regenerable. SynMax® 100 Nominal Content [wt.%] Promoter

Proprietary

Al2O3

Balance

Shape

Tablets

Size [mm]

4.5 x 4.5

Conversion of Methanol to Gasoline (CMG) The conversion of methanol to DME is the first step in what is known as the CMG process. CMG-1 is used for the conversion of DME to hydrocarbons in the petrol range. CMG-1 is a zeolite-based catalyst which can be fully regenerated in situ. CMG-1 has proven to be a cost-effective alternative for the production of high quality petrol blending compounds from methanol. CMG-1 Nominal Content [wt.%] Zeolite

MFI

Shape

Extrusions

Size [mm]

82

1.5


Conversion of Olefins to Diesel and Petrol (COD) The COD-9 catalyst is a fully regenerable zeolite-based catalyst, developed for the conversion of olefins to diesel and petrol fuels. The COD process with Süd-Chemie’s catalyst has proven to be a costeffective alternative in producing high quality synthetic diesel from olefins. The high cetane number and low aromatics content meet the environmental needs of tomorrow. COD-9 Nominal Content [wt.%] Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

Conversion of Paraffins to Aromatics (CPA) For the conversion of light paraffins to aromatics in the petrol boiling range, Süd-Chemie has developed the CPA catalyst as an advanced catalytic solution. This zeolite-based catalyst stands out due to its high activity, perfect for the conversion of paraffins, especially LPG or gas condensate feedstocks, to produce a high octane petrol range product with a high aromatics content. Thanks to its outstanding thermomechanical stability, CPA 100 can be regenerated repeatedly in-situ. CPA 100 Nominal Content [wt.%] Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

83


Hydrotreating HDMax hydrotreating catalysts are used with the full range of liquid hydrocarbon feedstocks from light naphtha to vacuum distillates. In order to upgrade the middle distillate feedstocks, the catalysts applied have to convert organic sulphur or nitrogen compounds to hydrogen sulphide or ammonia. It is often necessary to remove heavy metals and saturate di-olefins. Different types of catalysts have been designed to cope more effectively with the feedstock to be treated. For deep hydrodesulphurisation, Süd-Chemie supplies cobalt oxide/molybdenum oxide on alumina-based catalysts: our HDMax 200 products. Nickel oxide/molybdenum oxide on alumina-based catalysts can also be used for hydrodenitrogenation and feedstock saturation: our HDMax 300 products. Our HDT catalysts are available in different shapes. The most advanced of these in hydroprocessing catalysts is the CDS shape. HDMax 220

HDMax 310

CoO

3–5

-

NiO

-

5.2

MoO3

13 – 21

23

Al2O3

Balance

Balance

Shape



1.5

1.5


Size [mm]

84


Petrol Production C5 /C6 Isomerisation HYSOPAR® is a platinum-promoted zeolite-based catalyst for isomerisation of C5/C6 feedstocks. It is the product of a joint development between CEPSA Research (Spain) and Süd-Chemie. HYSOPAR® has demonstrated its excellent performance in numerous isomerisation applications. For very clean feeds and specific operating conditions, Süd-Chemie provides HYSOPAR® SA, a noble-metal-promoted zirconium oxide catalyst. HYSOPAR®

HYSOPAR® SA

0.30 – 0.40

0.30 – 0.5

MOR

-

-

Balance

Extrusions

Extrusions

1.5

1.5

Nominal Content [wt.%] Pt Zeolite ZrO2 Shape Size [mm]

Süd-Chemie provides the entire isomerisation technology process package, encompassing both basic engineering and catalysts.

C4 Selective Hydroisomerisation SHUMax 105 is a highly selective and active hydroisomerisation catalyst which simultaneously hydrogenates butadiene and hydroisomerises 1-butene to 2-butene from a C4 cut in order to upgrade the alkylate quality. The CDS shape guarantees superior performance, ensuring almost complete butene retention, even at a conversion level approaching the thermodynamic equilibrium. SHUMax 105 is a noble metal impregnated catalyst, available in different variations, and tailored to the specific needs of the refiner. SHUMax 105 Nominal Content [wt.%] Pd

0.5

Al2O3

Balance

Shape

CDS Extrusions

Size [mm]

1.3

85


Naphtha Dearomatisation – NiSAT ® NiSAT ® catalysts are used in the dearomatisation of low-sulphur refining feedstocks, such as naphtha boiling range feedstocks. It is especially important to remove benzene from aromatic petrol pool blending compounds to meet the required environmental regulations for gasoline. NiSAT ® catalysts are manufactured in different shapes, such as plai n or CDS extrusions, and are available in reduced and stabilised versions. NiSAT® 200

NiSAT® 310

NiSAT® 400

43

66

77

Support

Balance

Balance

Balance

Shape

Tablets

Extrusions CDS Extrusions

Extrusions

6x6

1.5

1.5

Nominal Content [wt.%] NiO

Size [mm]

Middle Distillate Upgrade For middle distillate refining, our catalysts cover all major applications.

• Deep hydrodesulphurisation • Saturation • Stabilisation • Aromatics and PNA saturation • Cetane improvement • Mild hydrocracking • Clay treating • Dewaxing of gas oil fractions • Dewaxing/conversion of heavy stocks

86


Hydrotreating of Middle Distillates HDMax hydrotreating catalysts are used with the full range of liquid hydrocarbon feedstocks from light naphtha to vacuum distillates. In order to upgrade the middle distillate feedstocks, the catalysts applied have to convert organic sulphur or nitrogen compounds to hydrogen sulphide or ammonia. It is often necessary to remove heavy metals and saturate di-olefins. Different types of catalysts have been designed to cope more effectively with the feedstock to be treated. For deep hydrodesulphurisation, Süd-Chemie supplies cobalt oxide/molybdenum oxide on alumina-based catalysts: our HDMax 220 products. Nickel oxide/molybdenum oxide on alumina-based catalysts can also be used for hydrodenitrogenation and feedstock saturation: our HDMax 310 products. Our HDT catalysts are available in different shapes. The most advanced of these in hydroprocessing catalysts is the CDS shape. HDMax 220

HDMax 310

CoO

3–5

-

NiO

-

5.2

MoO3

13 – 21

23

Al2O3

Balance

Balance

Shape



1.5

1.5


Size [mm]

87


Dearomatisation (Sulphur-free Feedstock) – NiSAT® NiSAT ® hydrogenation catalysts have a proven track record in the dearomatisation of low-sulphur refining feedstocks, such as kerosene, diesel or white oils. As the smoke point of jet fuels often needs to be improved, it is not necessary to operate aromatics saturation units. For maximum dearomatisation activity, NiSAT ® is available in the form of CDS extrusions. NiSAT® 200

NiSAT® 310

NiSAT® 400

43

66

77

Support

Balance

Balance

Balance

Shape

Tablets


Extrusions

6x6

1.5

1.5


Size [mm]

Dearomatisation (Sulphur-bearing Feedstock) – ASAT® Efficient low-temperature dearomatisation of middle distillates is usually accomplished with noble metal catalysts rather than nickel catalysts. The latter suffer from an affinity to sulphur, leading to their subsequent deactivation. New catalyst systems with dual noble metal function have recently emerged on the market. These are supposed to be tolerant to much higher levels of sulphur than standard platinum catalysts. The most recent development in this family of HDAr catalysts is the ASAT ® catalyst series. ASAT ® is a noble-metal-promoted zeolite catalyst, which offers HDS, HDN and HDAr service as a trifunctional catalyst. Its most outstanding feature is its extreme tolerance of sulphur (up to 500 ppm wt.).

88


These catalysts feature outstanding capabilities for upgrading middle distillate cuts, converting sulphur down to ppm level, PNA and total nitrogen to non-detectable level, and reducing total aromatics from 40% to less than 5%. ASAT ® catalysts can thus easily convert light cycle oil (LCO) to “sulphur-free” diesel fuel in a one-stage unit. ASAT® LS

ASAT®

Proprietary

Proprietary

Al2O3

Zeolite

CDS Extrusions

Extrusions

1.5

1.5

Nominal Content [wt.%] Noble Metal Support Shape Size [mm]

Mild Hydrocracking The catalyst MHC-100 is used in vacuum gas oil treatment to produce a product distribution favouring increasing yields of middle distillates, such as diesel fractions. Petrol production is minimised when using the MHC-100 catalyst. MHC-100 is a nickel oxide/molybdenum oxide on alumina-based catalyst. MHC-100 Nominal Content [wt.%] NiO

Proprietary

MoO3

Proprietary

Al2O3

Balance

Shape

TRIAX Extrusions

Size [mm]

1.5

89


Dewaxing Dewaxing of Gas Oils and Kerosene HYDEX ®-G is used for selective hydrocracking of long-chain normal paraffins. It is suitable for all kinds of high-sulphur middle distillates, such as kerosene and gas oil, particularly in combined operation with an HDS catalyst. HYDEX ®-G is a fully regenerable, metal-impregnated, zeolite-based catalyst. HYDEX®-G Nominal Content [wt.%] Promoter

Proprietary

Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

Dewaxing of Waxy Stocks HYDEX ®-C is a fully regenerable zeolite-based dewaxing catalyst designed for use in conversion units. It is a metal-impregnated, highly shape-selective catalyst for the hydrocracking of long chain paraffins. Product quality has been considerably improved in terms of pour, cloud and cold filter plugging point. It also features a lower boiling range. Typical feedstocks for HYDEX ®-C are waxy atmospheric and vacuum gas oil cuts. HYDEX®-C Nominal Content [wt.%] Promoter Zeolite

MFI

Shape

Extrusions

Size [mm]

90

Proprietary

1.5


Kerosene Sweetening – Clay Treater Süd-Chemie‘s tailored Tonsil® CO products are perfectly suited to solving colour-related problems and/or extending the cycle length. Tonsil® CO-Jet Nominal Content [wt.%] Alumino Silicate Shape Size [mm]

100 Granules 0.25 – 1.25

Wax and Lube Oil The first step in the manufacture of lubricants involves separating the individual fractions according to viscosity and boiling range specifications. The raw lube oil fractions from most crude oils contain components which have undesirable characteristics for the finished lubricant. These must be removed or converted by means of processes such as extraction, hydrodewaxing or hydrotreating. Undesirable characteristics include high pour points, high cloud points, large viscosity changes with temperature (low VI), poor oxygen stability, poor colour, high organic acidity and high carbon and sludge-forming tendencies. Süd-Chemie’s lube oil processing catalysts help the refiner to meet specifications with regard to these crucial lube oil properties.

Dewaxing of Lube Oil HYDEX ®-L, a zeolite-based catalyst, selectively hydrocracks waxy molecules to short-chain products, leaving valuable lube oil components unchanged. HYDEX ®-L is a fully regenerable catalyst. HYDEX®-L Nominal Content [wt.%] Promoter

Proprietary

Zeolite

MFI

Shape

Extrusions

Size [mm]

1.5

91


Hydrotreating and Hydrofinishing HDMax 510, a hydrotreating catalyst, was developed primarily for severe hydrotreating operation of waxes and lube oil stocks. Its macroporous structure is best suited to improving colour and oxygen stability, as well as lowering the organic acidity of the product. HDMax 510 is a robust nickel oxide/molybdenum oxide catalyst. It is available in CDS shape. HDMax 520 is best suited to hydrofinishing reactions aimed at removing chemically active compounds which affect colour and colour stability. Due to its specific macroporous structure and acidic properties, the HDMax 520 hydrofinishing catalyst produces water-clear white oils. The HDMax 310 catalyst is the standard catalyst for efficient and high quality VGO products. HDMax 510

HDMax 520

HDMax 310

NiO

5

5

5.2

MoO3

22

-

23

WO3

-

22

-

Balance

Balance

Balance

CDS Extrusions

CDS Extrusions

TRIAX Extrusions

1.5

1.5

1.3



92


Hydrogenation of Olefins NiSAT ® hydrogenation catalysts are used in oil refining as well as in lube oil applications. As NiSAT ® catalysts are robust, versatile aromatic hydrogenation catalysts, they are well established in the manufacture of medical-grade white oils, as well as for low-sulphur kerosene aromatics saturation and chemical intermediate production. NiSAT ® catalysts are manufactured in a variety of different shapes, such as plain or CDS extrusions, and are available in reduced and stabilised versions. NiSAT® 200

NiSAT® 310

NiSAT® 400

43

66

77

Support

Balance

Balance

Balance

Shape

Tablets


Extrusions

6x6

1.5

1.5


Size [mm]

Lube Oil and Wax Bleaching The various Tonsil® bleaching earths are widely approved, highly active absorbents for liquid-phase purification of heavy hydrocarbon fractions and waxes. They promise economical decolourisation and complete removal of colour bodies, surfactants, residual gums and other trace impurities. Tonsil® Optimum

Tonsil® Standard

100

100

Powder

Powder

75% < 63 µm

75% < 63 µm

Nominal Content [wt.%] Alumino Silicate Shape Size

93


Oligomerisation Production of Polypetrol and Higher Olefins Solid phosphoric acid catalysts are primarily used for the oligomerisation of propylene and/or butylene to high octane petrol or higher molecular weight polymers. PolyMax 843 catalysts can be operated in tubular and chambertype reactors. PolyMax 843

PolyMax 845

Short Acid as P2O5

18

18

Total Acid as P2O5

54

60

Pellets

Pellets

6.0 – 7.5

5.5 – 7.0


Shape Size [mm]

Butylene Dimerisation A further application of PolyMax 843 catalysts is the dimerisation of butylene to i-octene, which can be further hydrogenated to i-octane. Idled MTBE or catpoly units can be retrofitted for such processes with minimal capital expenditure.

i-Octene Hydrogenation It may be advantageous to introduce i-octanes to the petrol pool. The catalyst HDMax 800 is used for the hydrogenation of i-octene to i-octane. HDMax 800 Nominal Content [wt.%] Pt Al2O3

Balance

Shape

Tablets

Size [mm]

94

0.3

4.5 x 4.5


Purification of FCC Off-Gases The OleMax 100 series of catalysts is used for the purification of FCC off-gases. OleMax 100 series removes acetylene, MAPD, oxygen, NOx, arsin and other impurities to enable the refiner to recover highpurity ethylene, propylene and hydrogen from the FCC off-gas. Selection from among the following types depends on the sulphur content of the gas stream and plant design conditions. OleMax 100 types are resistant to deactivation by traces of heavy metals often found in these streams. OleMax 101

OleMax 102

OleMax 103

2.6

1.3

0.6

1–2

1–2

1–2

SiO2-Al2O3

Balance

Balance

Balance

Shape

Spheres

Spheres

Spheres

8

8

8

Nominal Content [wt.%] NiO Multi-Promoter

Size [mm]

95


Hydrogen Production The production of hydrogen involves the use of several key unit operations for which Süd-Chemie supplies catalysts. These are:

• Feedstock purification • Prereforming • Fired reformer • CO conversion • Methanation • Sour gas shift • Methanol reforming Typically, two or more of these processing units are involved in virtually all plant configurations.

Prereforming A prereformer is an adiabatic fixed-bed reactor upstream of the primary reformer. It allows increased flexibility in the choice of feedstock, increased life time of the steam-reforming catalyst and tubes and the option of increasing the overall plant capacity. Furthermore, it operates at lower steam/carbon ratios. ReforMax® 100 is a prereforming catalyst designed to handle the entire range of hydrocarbon feedstocks from natural gas up to and including LPGs and naphthas. ReforMax® 100 Nominal Content [wt.%] NiO Support and Promoter

Balance

Shape

Tablets

Size [mm]

96

56

4.5 x 4.5


Fired Reformer Selection of the optimum catalyst depends on several factors, including furnace design, severity of service, and the type of hydrocarbon processed. To cover all possible combinations, Süd-Chemie offers a wide variety of steam-reforming catalysts, comprising a range of different carriers, shapes and chemical compositions. ReforMax® 330 LDP

ReforMax® 210 LDP

ReforMax® 250

NG

NG/LPG

Naphtha

NiO

14

18

25

K2O

-

1.6

8.5

Carrier

CaAl12O19

CaK 2 Al22O34

Calciumaluminate

Shape

10 Holed Ring

10 Holed Ring

Multi Holed Ring

19 x 16

19 x 12

16 x 16

Typical Feed Nominal Content [wt.%]

Size [mm]

High-temperature CO Conversion The HTS catalyst ShiftMax® 120 combines high activity with extremely good physical robustness. In addition, this catalyst is very effective in preventing Fischer-Tropsch by-product formation when operating at low steam conditions. ShiftMax® 120 Nominal Content [wt.%] Fe2O3

80

Cr2O3

8.5

CuO

2

Shape Size [mm]

Tablets 6x6

97


Low-temperature CO Conversion The LTS catalysts ShiftMax® 230 and 240 are next-generation products that offer unparalleled activity for water-gas shift, resulting in higher CO conversion for longer life, enhanced resistance to poisons, and exellent physical strength. The promoter in ShiftMax® 240 suppresses the formation of methanol by more than 95% compared to standard LTS catalysts. ShiftMax® 230

ShiftMax® 240

CuO

42

42

ZnO

47

47

Al2O3

9

9

Promoter

-

2

Tablets

Tablets

4.8 x 3.2

4.8 x 3.2


Shape Size [mm]

Medium-temperature CO Conversion Medium-temperature CO conversion (MTS) is carried out in an isothermal system or adiabatic reactor, with exit temperatures of around 300° C. The ShiftMax® 300 catalyst is a stabilised copper/zinc catalyst featuring excellent stability of the Cu crystallites. ShiftMax® 300 Nominal Content [wt.%] CuO

20

ZnO

58

Promoter

11

Al2O3

Balance

Shape

Tablets

Size [mm]

98

6x3


Methanation Depending on the severity and product purity requirements of the application, Süd-Chemie supplies two different types of methanation catalysts. METH 134 consists of NiO on alumina. For extremely low-temperature applications, i.e. T < 170° C, Süd-Chemie provides METH 150, a catalyst made up of ruthenium on alumina. METH 134

METH 150

NiO

25

-

Ru

-

0.3

Support

Balance

Balance

Shape

Spheres

Tablets

3–6

4.5 x 4.5


Size [mm]

Sour Gas Shift CO conversion downstream of gasification units can be carried out without prior removal of the sulphur compounds. For this sour gas shift, we supply the stabilised CoMo catalyst ShiftMax® 800. ShiftMax® 800 Nominal Content [wt.%] CoO

3.5

MoO3

14

Support and Promoter Shape Size [mm]

Balance Extrusions 3.0

99


Methanol Reforming Hydrogen and CO can be produced by means of steam-reforming of methanol which is performed with ReforMax® M. ReforMax® M Nominal Content [wt.%] CuO

66

ZnO

23

Al2O3

Balance

Shape

Tablets

Size [mm]

6x4

Sulphur Recovery HDMax 213 catalysts are used to promote the hydrogenation of elemental sulphur vapour and sulphur dioxide, as well as the hydrolysis of carbonyl sulphide and carbon disulphide to hydrogen sulphide. They are used successfully to raise the overall conversion in Cla us units to levels in excess of 99.9%. HDMax 213 can be employed in a variety of processes, such as:

• BSRP processes • SCOT processes • RESULF processes • CLINSULF processes • SULFREEN processes

100


Tail Gas Treating HDMax 213 and 214 catalysts are robust, stabilised alumina extrusions impregnated with cobalt oxide and molybdenum oxide. They simultaneously promote the hydrolysis of COS and hydrogenation of CS2 to H2S. HDMax 213

HDMax 214

CoO

2.0

3.5

MoO3

7.3

14.0

Proprietary

Proprietary

Al2O3

Balance

Balance

Shape

CDS Extrusions

Extrusions

3.0

3.0


Promoter

Size [mm]

Claus Sulphur Recovery The SynMax® 200 Claus catalysts are delivered as smooth spheres. Their optimised pore size distribution offers advantages such as superior crush strength, low attrition loss and high activity. SynMax® 200 catalysts have been developed for standard sulphur recovery plants as well as units operating near or below the sulphur dewpoint, for instance in second- or third-stage operation. SynMax® 200 Nominal Content [wt.%] Al2O3

100

Shape

Spheres

Size [mm]

3–5

101

Air Purification No Smoking Smoke is harmful to both masterpieces and the environment. That is why Süd-Chemie offers the highest quality catalysts for air purification. And everyone benefits: our customers, their neighbours, and the atmosphere.

Air Purification

Süd-Chemie’s EnviCat® product line of standard and customised catalysts for air purification is available in both-pelletised and honeycomb forms. Using precious metals or base metals as active components, a wide variety of applications is covered: treatment of VOC emissions from chemical, petrochemical and semiconductor industry, emission control for internal combustion engines and purification of indoor-air. Customised catalysts are designed based on the following criteria: Catalyst suitability/dimension, conversion rates, warranty period, pressure drop, catalyst arrangement. The most commonly used shapes and forms are:

• Monolithic structures (metallic and ceramic honeycombs) • Foams (ceramic and metallic) • Wall flow filters • Pellets (tablets, extrusions, spheres) • Saddles • Wire mesh • Fiber mats • Screens • Other custom shapes and forms

104

Air Purification

Industrial Off-Gas Treatment VOCs (Volatile Organic Compunds) and other pollutants are emitted during various industrial processes and need to be eliminated. Compared to alternative technologies, the economical advantage of low operating costs, makes catalytic incineration the smart choice for many plants.

Oxidation of Volatile Organic Compounds (VOC) Catalyst

Carrier

EnviCat® VOC

Ceramic & Metallic Monolith 100-400 cpsi

•

Industrial VOC

EnviCat® VOC

Spheres

•

Industrial VOC

EnviCat® DOC


•

Sulfur tolerant SO2 selective

EnviCat® N-150 EnviCat® VOC

Extrusions, Tablets, Powder or Special High Resistent Spheres

PRO*ECOLITH

Ceramic Honeycomb 50-100 cpsi

•

VOC & CO for RTO/RCO

PRO*RCO

Ceramic Saddle

•

VOC & CO for RTO/RCO

Precious Metals

Base Metals

•

Application

EtO, NH3, Volatile Nitrogen Compounds, Higher Poison Tolerance

DeNOx and N2O Reduction Catalyst

Carrier

EnviCat® N2O-1

Zeolite

Medium Temperature Gas Decomposition

EnviCat® N2O-2

Zeolite

Low Temperature Gas Catalytic Reduction

EnviCat® N-150

Tablets

EnviCat® NO-1

Zeolite

Precious Metals

Base Metals

•

Application

Low Temperature SCR Selective Catalytic Reduction of NO x

Carbon Monoxide (CO) Oxidation Catalyst

Carrier

EnviCat® N-140

Extrusions

EnviCat® CO

Ceramic & Metal Monolith, Pellets

Precious Metals

Base Metals

• •

Application Gas Masks, Ambient Temperature High Space Velocity

105

Air Purification

Desulfurisation and Deodorisation Catalyst

Carrier

EnviCat® N-IDS G72E EnviCat® NKH

Extrusions, Homogeneous Honeycomb

•

H2S, COS

EnviCat® KGC

Powder

•

Toilet Deodorisation

EnviCat® N-500

Extrusions

•

Ammonia, Amines

Precious Metals

Base Metals

Application

Ozone Destruction Catalyst

Carrier

EnviCat® NKH-2

Homogeneous Honeycomb 500 cpsi

•

Ambient Temperature, High Concentration O3

EnviCat® N-140 EnviCat® N-150 EnviCat® MN280

Extrusions, Spheres, Powders

•

Ambient Temperature, Improved Moisture Tolerance

PRO*AOD

Ceramic & Metallic Monoliths

•

Airplane Ozone, High Space Velocity

Precious Metals

•

Base Metals

Application

Oxidation of Halogenated Hydrocarbons Catalyst

Carrier

EnviCat® HHC

Ceramic Honeycomb

•

Industrial HVOC, SVE, Dioxin, etc.

EnviCat® HHC

Spheres

•

Industrial HVOC, SVE, Dioxin, etc.

Precious Metals

Base Metals

Application

Traffic Tunnel Air Purification Catalyst

Carrier

EnviCat® KN-44

Extrusions

Precious Metals

Base Metals

•

Application Tunnel Air Purification

Purification of Industrial Gases Süd-Chemie provides a variety of catalysts containing noble metals for the removal of trace impurities in a wide range of gases such as oxygen, hydrogen, nitrogen and argon.

106

Catalyst

Carrier

EnviCat® G133

Spheres, Tablets

Precious Metals

•

Base Metals

Application Removal of trace Impurities

Air Purification

Semiconductor Industry Süd-Chemie offers cutting-edge technology for the adsorption of toxic and corrosive gases such as SiH4, AsH3, PH3, HCI, NH3, NF3 and many others encountered in the semiconductor industry. For fixed bed adsorber systems, these products are the leading choice for the cost-effective protection of our environment. Catalyst

Carrier

EnviCat® N-150

Tablets or Extrusions

Precious Metals

Base Metals

Application

•

Hydrides Halogens

EnviCat® N-600

Extrusions

•

EnviCat® N-500

Extrusions

•

Ammonia & Amines

Power Generation On-site power generation is becoming more and more important across the globe. The main sources of decentralised power supply include stationary gas & diesel engines and gas turbines. Catalytic emission control systems are used extensively.

Engine Emissions Catalyst

Carrier

EnviCat® TWC


•

NSCR for Stoichiometric Engines, e.g. NG

EnviCat® CO EnviCat® VOC


•

OxiCat for NG Engines

EnviCat® DOC


•

Diesel Oxidation Catalyst

EnviCat® DPF

Ceramic Monolith

•

Catalysed Diesel Filter for Low Temperature Soot Ignition

Precious Metals

Base Metals

Application

Natural Gas Combustion Catalyst

Carrier

EnviCat® NG

Ceramic & Metallic Monolith

Precious Metals

•

Base Metals

Application Ignition (light-off)

107

Air Purification

Mobile Engines Efforts to reduce pollution caused by mobile engines are increasing worldwide. EnviCat® catalysts offer technical solutions for engines running on Diesel, Natural Gas or Petrol.

Diesel and Natural Gas Engine Emissions Catalyst

Carrier

EnviCat® TWC


•

NSCR for Stoichiometric Engines, e.g. NG

EnviCat® DOC


•

Diesel Oxidation Catalyst

EnviCat® DPF

Ceramic Monolith

•

Catalysed Diesel Filter for Low Temperature Soot Ignition

Precious Metals

Base Metals

Application

Two-Wheeler Engine Exhaust Catalyst

Carrier

SCIL-TWC

Metal Honeycomb 50-200 cpsi

SCIL-TWC

108

Perforated Tube

Precious Metals

Base Metals

Application

•

Motorcycles, Scooters, Mopeds and other 2 & 4 - stroke small engines

•

Motorcycles, Scooters, Mopeds and other 2 & 4 - stroke small engines

Air Purification

Indoor Air More than 80% of our life takes place indoors. Süd-Chemie develops catalysts and adsorbents to purify indoor air. This comprises purification of restaurant and wood stove emissions, as well as products for in-house use, such as odour and smoke abatement for kitchen stoves. Catalyst

Carrier

PRO*BROIL

Metallic Monolith 50-100 cpsi

EnviCat® AKH

Homogeneous Honeycomb 36-220 cpsi

EnviCat® SCOSE

Ceramic Honeycomb 64 cpsi

•

CO, PM & VOC Smoke Elimination in Kitchen Stoves

Long Life Long Life Plus PRO-ECO-CAT

Ceramic Honeycomb 16-25 cpsi

•

Wood Stove Off-Gas: CO, PM & VOC Reduction

Precious Metals

•

Base Metals

Application CO, PM & VOC Reduction in Restaurant Exhaust Odour Abatement at Room Temperature

109

Reduction of Iron Ore Production of Town Gas Inert & Support Material Cool and noble Sparkling champagne is as much part of a private viewing as is the colour in a p ainting. What a pleasure when an elegant cooler ensures the perfect temperature. How was that elegant metal produced? With the help of Süd-Chemie and their catalysts for iron ore reduction, of course.

Iron Ore, Town Gas

Reforming for Direct Reduction of Iron Ore Süd-Chemie supplies the complete portfolio of catalysts specifically formulated for direct reduction of iron (DRI) reforming furnaces. Our cooperation with MIDREX has produced catalysts comprising NiO as the active component on rugged carriers such as MgO, α-Al2O3 or calcium-aluminate.

Production of Town Gas The conversion of naphtha into town gas requires a special type of nickel catalyst, ReforMax® 450 LDP, which is able to withstand the severe conditions in these cyclic reformers. Downstream of the cyclic reformers, there is the option of installing a CO conversion using the standard HTS catalyst ShiftMax® 120. ReforMax® 450 LDP Nominal Content [wt.%] NiO

8

Carrier

CaAl12O19

Shape

10 Holed Ring

Size [mm]

19 x 16

ShiftMax® 120 Nominal Content [wt.%] Fe2O3

80

Cr2O3

8.5

CuO

2

Shape Size [mm]

112

Tablets 6x6

Support Material

Inert and Support Material Inert balls are used both on support screens and to hold down the catalyst top layer. The inert material closest to the catalyst must not exceed double the minimum dimension of the catalyst. Süd-Chemie’s inert material is rugged, chemically inert and temperature stable. Its high crush strength and low attrition loss ensure lengthy service and trouble-free operation. Various sizes required for the different screen and catalyst sizes are available. Support 222

Support 346

27

99

SiO2

Balance

0.1

Fe2O3

1.0

0.1

Shape

Spheres

Spheres

3/6/12/19/25

3/6/12/19/25

Nominal Content [wt.%] Al2O3 + TiO2

Size [mm]

113

Custom Catalysts – À la Carte Catalysts And what can we get for you? Whether large or small, ring shaped, as powder or granules: Süd-Chemie delivers specialised catalysts for innumerable applications and with the most widely varying performance features. But that is not all. On request, we can develop and produce customised solutions individually tailored to your needs. Well then: which catalyst would you like?

Custom Catalysts

À la carte Catalysts As a customised catalyst group, Süd-Chemie has a long histor y of manufacturing quality catalysts à la carte. Indeed, customised catalyst manufacture accounts for a significant proportion of our business. Since the 1960s, customers have come to us both to manufacture new catalysts for commercialisation and to improve the catalysts they already use. Whether a petrochemical, refining, chemical, or engineering company approaches us for manufacturing or developing a catalyst from concept to completion, we have the resources, systems, and people to provide the level of service and confidentiality that any custom project may entail.

116

Custom Catalysts

Three types of customer relationships are generally identified:

Toll Manufacture Catalysts are produced exclusively for the customer in line with the customer’s expertise.

Licensed Manufacture Catalysts are produced relying on the customer’s expertise, but marketed and sold by Süd-Chemie (either freely or with specific restrictions). The customer receives royalty payments on sales.

Custom Manufacture Catalysts are developed on the basis of Süd-Chemie’s expertise, but produced exclusively for the customer in question.

Although Süd-Chemie does not sell process design services per se, customers can benefit from the expertise and services of Süd-Chemie’s entire technical staff whether in the context of investigating and establishing operating conditions, or for recommendations on a specific catalyst in answer to any requirement or problem.

117

Fuel Cell Technologies Energy in tight spaces There are works of art that burst with energy. Whoever wants to see them like this in colour, form and imagery, needs high tech without compromises. That is why Süd-Chemie develops catalysts for hydrogen extraction for laptops, cameras and mobile phones.

Fuel Cell Technologies

Süd-Chemie also applies its core competence in the field of hydrogen technology to the business area of Fuel Cell Technologies. Hydrogen is the feed for all fuel cell types, including PEMFC, MCFC and SOFC. In tandem with our partners, we work at a global level to develop all possible applications for fuel cells, whether mobile or stationary.

120

Fuel Cell Technologies

Süd-Chemie’s fuel-processing catalysts can handle virtually all hydrocarbon feedstocks, such as:

• Natural gas • LPG • Petrol • Kerosine • Diesel • Heating oil

The conversion of these feeds to hydrogen involves the use of several key steps, for which Süd-Chemie supplies the catalysts. These are:

• Desulphurisation • Reforming • Prereforming • Steam reforming • Autothermal reforming • Catalytic partial oxidation • CO shift • Selective CO oxidation • Selective CO methanation • Combustion of fuel cell off-gases

121

Research and Development Continually discover something new Whether nature, a painting, or simple every-day things: when you look closely and let yourself be inspired, you will discover surprising details and unending possibilities. And that is exactly what sets the experts in Süd-Chemie’s Research and Development apart. Researchers, engineers, and developers who are as tenacious as they are determined to work on new technologies.


Süd-Chemie has eight catalyst R&D laboratories located in Germany, the USA, Japan, India and Italy. Our catalyst R&D is particularly oriented towards applied research in the development of new products and the study of reaction mechanisms. In order to perform these activities, our R&D laboratories are fully equipped for laboratory-scale and pilot-plant-scale catalyst preparation and catalyst testing facilities.

124


Since thorough knowledge of their physical and chemical properties is the key to understanding the behaviour of catalysts, advanced physical measurement capability is vital to our R&D laboratories. Süd-Chemie’s testing facilities allow for the catalytic testing and evaluation of all catalysts under both standard and individual operating conditions (i.e. process conditions specified by our customers) in conventional, continuous flow or batch reactors under isothermal or adiabatic conditions. Should you have any specific or unusual requirements that are not highlighted above, please don’t hesitate to contact us. We would be only too glad to assist you.

125

Service and Performance Guarantees The art of straightening things out True perfection lasts longer than a glance. That is the insight that defines a quality enterprise like Süd-Chemie. What does that mean for you as a customer? Simply this: we offer you first class service, even on location, and guarantee the functionality of our products without any ifs ands or buts. That is partnership that pays for itself.

Service

Technical Service Süd-Chemie firmly believes that even an outstanding catalyst may not provide the best performance without the appropriate level of assistance during the phases of selection, installation, start-up and operation. Our technical services has specific expertise in the areas of catalyst characterisation, catalyst installation, start-up assistance, plant operation and performance evaluations. This depth of knowledge allows us to provide the following services:

• Review of reactor system design • Selection of proper catalyst • Technical reviews of start-up and shutdown procedures • Technical assistance for loading • Technical assistance during catalyst start-up • Routine performance evaluations • Immediate troubleshooting • Catalyst life projections • Technical assistance during catalyst shut-down • On-site training seminars for engineering and operations personnel • Chemical and physical analyses of spent catalyst Süd-Chemie also has an extensive list of portable analytical and computer systems to further add to our list of resources.

128

Performance Guarantees

Handling of Spent Catalysts Süd-Chemie is not active in the field of catalyst recycling, but works closely with several specialised companies who are committed to taking back spent Süd-Chemie catalysts on favourable terms. Cooperation of this type guarantees that users of Süd-Chemie’s catalysts will always have the option of having their catalyst recycled in an eco-friendly way and at a competitive price. Please don‘t hesitate to contact us for an up-to-date list of catalyst disposal companies.

Quality Management Süd-Chemie is committed to quality and responsible care of the environment. Both Süd-Chemie AG and most of the Süd-Chemie Group companies have a quality and/or environmental management system in line with ISO 9001/ISO 1400.

Performance Guarantees Süd-Chemie grants users of our catalysts performance guarantees covering the key process parameters, such as yield, selectivity and pick-up capacities. Before such guarantees are granted, the design conditions and/or the anticipated operating conditions must be evaluated. Please contact our technical service for details of any application.

129

Catalyst Index and Contact Details At a glance Where can you find the catalyst you are looking for in this catalogue? The following pages will answer that question, showing you how to quickly target the fastest way to the right section. Enjoy!

Catalyst Index

132

Catalyst

Main Metal Component

Normal Application

Page

ActiSorb® 300

Copper, Zinc

Sulphur Removal

14, 19

ActiSorb® 301

Copper, Zinc

Sulphur Removal

19

ActiSorb® 310

Copper, Manganese

Sulphur Removal

19

ActiSorb® 400

Alumina

COS Hydrolysis

18, 73

ActiSorb® 410

Chrome, Alumina

COS Hydrolysis

18

ActiSorb® Cl 2

Sodium Oxide

Chlorine Removal

14, 19

ActiSorb® Cl 3

Calcium, Zinc Oxide

Chlorine Removal

14, 19

ActiSorb® Cl 6

Calcium, Zinc Oxide

Chlorine Removal

14, 19

ActiSorb® F

Sodium Oxide

Fluorine Removal

14, 19

ActiSorb® G 1

Copper, Molybdenum

Sulphur Removal

17

AcitSorb® Hg 1

Sulphur

Metal Removal

14, 20

ActiSorb® Hg 2

Sulphur

Metal Removal

14, 20

ActiSorb® Hg 5

Silver

Metal Removal

14, 20

ActiSorb® N 1

Phosphoric Acid

Nitrogen Removal

14, 24

ActiSorb® O 1

Proprietary

Oxygen Removal

14, 23

ActiSorb® O 2

Palladium

Oxygen Removal

14, 23

ActiSorb® O 3

Palladium

Off Gas Purification

14

ActiSorb® O 4

Palladium


14

ActiSorb® O 6

Platinum, Nickel


14

ActiSorb® S 1

Zinc Oxide

Sulphur Removal

14, 16

ActiSorb® S 2

Zinc Oxide

Sulphur Removal

14, 16

ActiSorb® S 3

Zinc Oxide

Sulphur Removal

14, 16

ActiSorb® S 6

Copper Oxide

Sulphur Removal

14, 16

ActiSorb® S 7

Nickel

Sulphur Removal

14, 15

ActiSorb® Si

Sodium Oxide

Metal Removal

14, 21

AmoMax 10

Iron Oxide

Synthesis of Ammonia

55

ASAT ®

Zeolite

Hydrogenation

89

ASAT ® LS

Zeolite

Hydrogenation

89

Beta BEA

Zeolite

Aromatics Alkylation, Transalkylation

32

C116

Vanadium Oxide

Production of Sulphuric Acid

56

C116 CS

Vanadium Oxide


56

C116 HV

Vanadium Oxide


56

CMG-1

Zeolite MFI

Fuel Technology

82

COD-9

Zeolite MFI

Fuel Technology

83

CPA 100

Zeolite MFI

Fuel Technology

83

EBUF®

Zeolite MFI

BTX Chemistry

36

EnviCat® AKH

Metal Oxides

Indoor Air

109

Catalyst Index

Catalyst


Normal Application

EnviCat® CO

Precious Metal


EnviCat® DOC

Precious Metal


EnviCat DPF

Precious Metal


EnviCat® G133

Palladium

Purification of Industrial Gases

106

EnviCat® HHC

Precious Metal


106

EnviCat® KGC

Metal Oxides

Desulphurisation and Deodorisation

106

EnviCat® KN-44

Base Metal


106

EnviCat® N-140

Base Metal

Ozone Destruction

106

EnviCat® MN-280

Metal Oxides

Ozone Destruction

106

EnviCat® N-150

Base Metal


EnviCat® N-500

Base Metal


106, 107

EnviCat® N-600

Base Metal


107

EnviCat® N-IDS

Iron Oxide


106

EnviCat® NG

Precious Metal


107

EnviCat® NKH

Base Metal


106

EnviCat® NKH-2

Base Metal

Ozone Destruction

106

EnviCat® SCOSE

Precious Metal


109

EnviCat® TWC

Precious Metal


107, 108

EnviCat® VOC

Precious Metal


105, 107

FAMAX ® HS

Molybdenum, Iron

Production of Formaldehyde

77

FAMAX ® J5

Molybdenum, Iron


77

FAMAX ® MS

Molybdenum, Iron


77

FAMAX ® TH

Molybdenum, Iron


77

G-13

Copper Chromite

Dehydrogenation

75

G-103

Cobalt-Silicon Oxide

Hydrogenation

60

G-132A

Copper, Zinc

Hydrogenation

70, 73

G-134 A

Nickel

Hydrogenation

59

G-22

Copper, Chrome, Barium

Hydrogenation

G-32J

Carbon

Sulphur Removal

17

G-49 B

Nickel

Hydrogenation

59

G-62

Cobalt

Hydrogenation

67

G-67

Cobalt

Hydrogenation

67

G-67 A

Cobalt

Hydrogenation

60

G-69

Nickel, Zirconium

Hydrogenation

59

®

Page 107 105, 107, 108 107, 108

105, 106, 107

57, 63, 75

133

Catalyst Index

134

Catalyst


Normal Application

Page

G-92D

Proprietary

Water Removal

14, 25

G-95 C

Nickel

Hydrogenation

68

G-99B

Copper, Chrome, Manganese, Barium

Hydrogenation

G-99C

Copper, Chrome, Manganese, Barium

Hydrogenation

57

G-99D

Copper, Chrome, Manganese

Hydrogenation

64

H2Max 5

Palladium

Production of Hydrogenperoxide

77

H2Max 5/S

Palladium


77

H2Max 50

Palladium

Hydrogenation

H2Max HAR

Palladium


77

H2Max HD

Palladium

Purification of Terephthalic Acid (PTA)

79

HDMax PA

Palladium

Phenylacetylene Hydrogenation

40

HDMax 200

Cobalt, Molybdenum

Sulphur Removal

15

HDMax 213

Cobalt, Molybdenum

Tail Gas Treating

101

HDMax 214

Cobalt, Molybdenum

Tail Gas Treating

101

HDMax 220

Cobalt, Molybdenum

Hydrotreating

HDMax 310

Nickel, Molybdenum

Hydrotreating

HDMax 510

Nickel, Molybdenum

Hydrotreating

92

HDMax 520

Nickel, Tungsten

Hydrotreating

92

HDMax 800

Platinum

Selective Hydrogenation

94


Proprietary

Alkine Dehydrogenation and Dealkylation

41

HOUDRY ® CATOFIN®

Proprietary


41

HOUDRY ® CATOFIN® PS

Proprietary


41

HOUDRY ® CATOFIN® ES

Proprietary


41

HOUDRY ® CATOFIN® HY

Proprietary


41

HOUDRY ® DETOL®

Proprietary


41

HOUDRY ® LITOL®

Proprietary


41

HOUDRY ® PYROTOL®

Proprietary


41

HYDEX ®-C

Zeolite MFI

Dewaxing

90

HYDEX ®-G

Zeolite MFI

Dewaxing

90

HYDEX ®-L

Zeolite MFI

Dewaxing

91

HYSOPAR®

Zeolite MOR

Naphtha Isomerization

85

HYSOPAR® SA

Zirconium Oxide

Naphtha Isomerization

85

ISOXYL

Zeolite MFI

BTX Chemistry

35

57, 61, 69, 73

72, 79

84, 87 15, 84, 87, 92

Catalyst Index

Catalyst


Normal Application

K 10, K 20, K 30

Acid Activated Montmorillonite

Catalyst Support Material

29

K 20, K 30, KP10, KSF/O


Rearrangements / Isomerizations

29

K 5, K 40, K 10, K 2


Alk ylati on / Acy lation

29

KP 10, K 5, K 10


Polymerizations / Dimerizations

29

KSF, KP 10, KSF/O, K 10


Esterfication / Etherification

29

MAVC

Zinc Oxide

Production of Vinylacetatmonomer

78

MAVC/C

Zinc Oxide

Production of Vinylacetatmonomer

78

MegaMax® 700

Copper, Zinc

Synthesis of Methanol

55

METH 134

Nickel

Methanation

METH 150

Ruthenium

Methanation

MHC-100

Nickel, Molybdenum

Mild Hydrocracking

89

Mordenite MOR

Zeolite

Paraffin Isomerisation, Hydrocracking

32

MPT 10

Palladium

Hydrogenation

74

MPT 3

Palladium

Hydrogenation

72

MPT 5

Palladium

Hydrogenation

72

MRT

Ruthenium

Hydrogenation

74

MTPROP®

Zeolite MFI

Conversion of Methanol to Propylene

47

NiSAT ® 200

Nickel

Hydrogenation

Page

21, 54, 99 21, 54, 99

70, 86, 88, 93 67, 72, 73, 74

NiSAT ® 300

Nickel

Hydrogenation

NiSAT ® 310

Nickel

Hydrogenation

NiSAT ® 320

Nickel

Hydrogenation

NiSAT ® 330

Nickel

Hydrogenation

NiSAT ® 340

Nickel

Hydrogenation

73

NiSAT ® 350

Nickel, Wolfram

Hydrogenation

74

NiSAT ® 400

Nickel

Hydrogenation

86, 88, 93

OleMax 101 (C36-1-02)

Nickel


42, 95

OleMax 102 (C36-2-02)

Nickel


42, 95

OleMax 103 (C36-3-02)

Nickel


42, 95

OleMax 201 (G-58 C)

Palladium


43

OleMax 203 (G-58 D)

Palladium


43

OleMax 204 (G-58 E)

Palladium


43

OleMax 250 (G-83 A )

Palladi um


42

OleMax 251 (G-83 C)

Palladium


42

OleMax 301 (C31-1-01)

Palladium


43

OleMax 302 (G-55 B)

Palladi um


43

86, 88, 93 67, 68, 70, 72 68, 72, 74

135

Catalyst Index

136

Catalyst


Normal Application

Page

OleMax 350

Palladium


23, 44

OleMax 353 (G-68 HX)

Palladium


44, 45

OleMax 400 (G-68 G)

Palladium


45

OleMax 450 (G-68 C)

Palladium


46

OleMax 452 (T-2464 B)

Palladium

Selective Butadiene Hydrogenation

OleMax 600 (G-68 C)

Palladium


46

OleMax 601 (G-68 C-1)

Palladium


46

OleMax 806 (C20-6-04)

Cobalt-Molybdenum


47

OleMax 807 (C20-7-06)

Nickel-Molybdenum


47

OXYMAX ® A

Copper

Oxychlorination

76

OXYMAX ® B

Copper

Oxychlorination

76

Pentasil MFI

Zeolite

Dewaxing

32

PHTHALIMAX ®

Vanadium Oxide

Production of Phthalic Anhydride

78

PolyMax 131

Phosphoric Acid

Cumene Synthesis

43

PolyMax 172

Zincoxide

Dehydrogenation & Oxidation

75

PolyMax 301

Copper, Zinc

CO + Oxygen Removal

PolyMax 843

Phosphoric Acid

Oligomerization

94

PolyMax 845

Phosphoric Acid

Oligomerization

94

PRO*AOD

Base Metal

Ozone Destruction

106

PRO*BROIL

Precious Metal


109

PRO*ECOLITH

Precious Metal


105

PRO*RCO

Precious Metal


105

PRO-ECO-CAT

Precious Metal


109

ReforMax® 100

Nickel

Steamreforming

ReforMax® 117

Nickel

Ammonia Dissociation

ReforMax® 210 LDP

Nickel, Potassium

Steamreforming

51, 97

ReforMax® 250

Nickel, Potassium

Steamreforming

51, 97

ReforMax® 330 LDP

Nickel

Steamreforming

ReforMax® 400 GG

Nickel

Steamreforming

52

ReforMax® 400 LDP

Nickel

Steamreforming

52

ReforMax® 420

Nickel

Steamreforming

52

ReforMax® 450 LDP

Nickel

Steamreforming

112

ReforMax® M

Copper, Zinc

Methanol Reforming

56, 100

SCIL-TWC

Precious Metal


108

ShiftMax® 120

Iron, Chrome, Copper

CO Conversion

ShiftMax® 230

Copper, Zinc

Low-temperature CO Conversion

54, 98

ShiftMax® 240

Copper, Zinc

CO Conversion

54, 98

45, 46

22, 71

51, 96 25

51, 52, 97

53, 97, 112

Catalyst Index

Catalyst


Normal Application

ShiftMax® 300

Copper, Zinc

CO Conversion

98

ShiftMax® 800

Cobalt, Molybdenum

CO Conversion

99

SHUMax 105

Palladium


85

STYROMAX ® 3

Iron Oxide

Styrene Production

39

STYROMAX ® 5

Iron Oxide

Styrene Production

39

STYROMAX ® 6

Iron Oxide

Styrene Production

39

STYROMAX ® 7

Iron Oxide

Styrene Production

39

STYROMAX ® PLUS 5

Iron Oxide

Styrene Production

39

Support 222

Alumina, Silica

Inert and Support Material

113

Support 346

Alumina, Silica

Inert and Support Material

113

SynMax® 100

Alumina

Claus Reaction

82

SynMax® 200

Alumina Oxide

Sulphur Recovery

101

T-2130

Copper, Zinc

Hydrogenation

Page

58, 62, 65, 66, 75

T-4004

Calcium, Zinc

Hydrogenation

70, 75

T-4322

Copper, Zinc

Hydrogenation

65

T-4361

Nickel, Copper

Hydrogenation

58

T-4405

Cobalt

Hydrogenation

60

T-4419

Copper, Chrome

Hydrogenation

62, 75

T-4421

Copper, Chrome

Hydrogenation

62, 75

T-4424

Cobalt, Manganese

Hydrogenation

71

T-4466

Copper, Chrome

Hydrogenation

65, 66

T-4489

Copper, Manganese

Hydrogenation

58, 62, 63, 64, 66

TDP-1

Zeolite MOR

BTX Chemistry

35

Tonsil® APT-BT

Alumosilicates

BTX Chemistry

38

Tonsil® APT-mX

Alumosilicates

BTX Chemistry

38

Tonsil® APT-N

Alumosilicates

Nitrogen Removal

Tonsil® APT-pX

Alumosilicates

BTX Chemistry

38

Tonsil® CO 6 x 0 G

Alumosilicates

BTX Chemistry

38

Tonsil® CO 6 x 6 G

Alumosilicates

BTX Chemistry

38

Tonsil® CO 6 x 6 GS

Alumosilicates

BTX Chemistry

38

Tonsil® CO-Jet

Alumosilicates

Clay Treater

91

Tonsil® CO-N

Alumosilicates

Nitrogen Removal

24

Tonsil® Optimum

Alumina Silicate

Clay Treater

93

Tonsil® Standard

Alumina Silicate

Clay Treater

93

14, 24

137

Contact Details

1

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2

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3

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1 5 4

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138

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9

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2

Contact Details

18

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16 18 17 10 15 9

15

14 11

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12

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13

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139

Liabilities Although these instructions have been prepared by experienced experts and have been based on the best available information derived from laboratory, pilot plant and commercial experience with these catalysts, Süd-Chemie does not have intimate knowledge of the customers plant and operation. Therefore, Süd-Chemie, in issuing these instructions, cannot assume any liability for upsets and damage to either the customers plant or personnel resulting from customer`s plant and operating conditions. The customer is urged to review these instructions carefully and to satisfy himself that their application will not be hazardous to his specific operation. Further, Süd-Chemie`s technical service representatives are present at plant start-ups in an advisory capacity only and cannot be charged with knowledge and responsibility for hazardous conditions at customers plant that might result from the application of the instructions at the specific customers site. The information presented herein is believed to be accurate but shall not be guaranteed within the meaning of § 444 BGB (German Civil Code). The above product data and properties may vary based on fluctuations in the production process. Any terms and conditions of delivery shall be agreed upon separately.

© 2005 Süd-Chemie AG, all rights reserved

140

Sud Chemie Catalysts

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