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Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. Johnson Matthey plc (JM) gives no warranty as the tness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. JM accepts no liability for loss or damage (other than that arising from death or personal injury caused by JMs negligence or by a defective Product, if proved), resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.
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Johnson Matthey Catalysts offers our range of KATALCOJM purication absorbents and catalysts, which ensures optimized systems for meeting individual plant requirements. In addition through our range of PURASPECJMTM catalysts and absorbents we can provide mercury removal down to ppb levels, low temperature H2S removal absorbents and ultrapurication down to ppb levels of sulphur to protect even the most sensitive of downstream catalysts, including prereforming and methanol synthesis catalysts. For methanol plants using a coal feedstock and gasication technology, we can again offer KATALCOJM and PURAPECJM purication solutions to remove impurities such as chloride and sulphur after the RECTISOLTM or SELEXOLTM acid gas removal system, upstream of methanol synthesis.
KATALCOJM 33-1 is the latest addition to our purication range. It is a 3-in-1 total sulphur removal product, which combines the functionality of organic sulphur conversion, high capacity sulphur removal, and low level sulphur polishing (ultrapurication) in a single product. The versatility of KATALCOJM 33-1 allows it to be deployed in methanol plants in numerous ways, as a single product or in conjunction with conventional purication products.
Further savings are also realised from the much easier loading and discharging, no requirement for pre-sulphiding of the HDS catalyst or reduction of the ultrapurication catalyst.
Pre-forming catalysts
CRG LHR CRG LHCR
Johnson Matthey Catalysts has been associated with pre-reforming catalysts since the 1960s and together with Davy Process Technology offers the CRG series of catalysts which have been demonstrated to be the most active and robust commercially available products. In methanol plants, operating on natural gas feeds, the use of high pre-reformer inlet temperatures allows the maximum amount of heat recovery from the steam reformer ue duct giving an economic benet through improved thermal efciency of the process. In addition, by transferring the maximum amount of reforming duty into the pre-reformer, the size of the primary reformer is reduced which results in a lower capital cost. CRG LHR is a precipitated catalyst with nickel as the active component. The catalyst is supplied in the pre-reduced and stabilized form. The oxidized form, CRG LH, is available as a special order. CRG LHR pre-reforming catalyst is specially formulated to deliver good performance at high pre-reformer inlet temperatures (>500C), which cannot be attained with many other catalysts. This allows the maximum amount of heat recovery from the steam reformer ue duct and hence increases the economic benets that can be obtained from the pre-reformer.
CRG LHR is available in two distinctive shapes. The exceptionally high geometric surface area that is produced by the small standard cylindrical pellet delivers outstanding catalytic activity and allows the construction of relatively small pre-reforming reactors. However, where pressure drop must be minimized, the unique microcloverleaf shape, CRG LHCR provides low pressure drop characteristics in combination with high pre-reforming activity.
Johnson Matthey Catalysts offered the most effective combination of CRG LHCR catalyst supply and engineering capability to deliver a 15% increase in capacity and a 5% reduction in energy consumption. An element of engineering capability used was CFD, as the new pre-reformer reheat coil needed to be installed within an existing convection section, adjacent to a 90 bend in the uegas duct. Johnson Matthey CFD modelling quickly showed that the coil would work as designed.
Steam reforming
KATALCOJM 23-4 series KATALCOJM 57-4 series KATALCOJM 25-4 series
Nickel oxide on alpha alumina
In this critical operating unit in the methanol production train, the KATALCOJM combination of catalysts and services ensures optimal operation at all times. KATALCOJM catalysts are unique with the ability to reform efciently the full range of feedstocks from light natural gases and renery off-gases right up to naphthas. Our QUADRALOBE TM catalyst range employs a carefully designed shaped support offering high surface area and high voidage with excellent heat transfer performance. The resulting high activity, heat transfer and low pressure drop gives a combination of lower methane slip, high throughput and longer tube lives for methanol plant reformers. Johnson Matthey manufactures three main catalysts for use in steam reformers using a natural gas feedstock: KATALCOJM 25-series, 23-series and 57-series catalysts. Johnson Matthey reforming catalysts are made in a range of sizes, allowing optimum reformer loading for each individual plant.
Reformer services
Through KATALCOJM PERFORMANCE we want you to get the most from our catalysts. We optimize each application using our world-leading modelling capability and support the operation of your reformers with a wide range of services including process consultancy, mechanical design consultancy and other engineering services that are used to help solve customer problems. Reformer modelling expertise is one of our key skills. By using HYSYS, which includes our PRIMARY reformer model, we can determine the full impact of changing reformer conditions within a complete plant owsheet. This is typically used for: revamp studies and revamp implementation re-tube studies reformer surveys operational audits. Results are immediately available allowing rapid assessment of variations in conditions. Other reforming services from Johnson Matthey Catalysts include: UNIDENSETM reformer loading technique LOTIS TM laser optical tube inspection system reformer surveys and operational audits catalyst tube temperature measurement managing the life cycle of reformer catalyst tubes reformer consultancy pressure drop measurement combustion systems advice.
Autothermal reforming
KATALCOJM 23-8 series KATALCOJM 28-4 series KATALCOJM 54-8 series
The mechanical and physical requirements of an oxygen blown secondary are the most arduous in the plant. Johnson Matthey Catalysts combines sophisticated Computational Fluid Dynamic techniques and process modelling, calibrated against data generated from its Syngas Generation (SGG) pilot plant, to ensure the best performance from its state of the art range of catalysts. Johnson Matthey Catalysts and Davy Process Technology offer reactor technology including a proven burner design. KATALCOJM 23-series and 28-series is nickel on alumina catalyst which gives you high stability and high activity, KATALCOJM 54-8 series is nickel on calcium aluminate. These catalysts give you high stability and high activity allowing Johnson Matthey to offer you the best mix of activity, pressure drop and high temperature stability for your application.
KATALCOJM 89-6 is a catalyst designed for use in the top of autothermal reformers where the temperature and steam partial pressure is high, a combination that can lead to unacceptably fast volatilisation of alumina and the problems associated with this and its subsequent condensation. This catalyst utilizes a refractory metal as the active component on a stabilized high temperature ceramic support.
Sour shift
KATALCOjm K8-1 1 KATALCOjm K81 1 HA
The production of syngas using gasication or partial oxidation differs considerably from that using catalytic steam reforming. Depending on the feed and process conguration, the raw syngas will have a high CO content and, it is likely that it will also have high sulphur content. This gas needs to be shifted and the excess CO2 removed to achieve the desired hydrogen to carbon oxides ratio, and it will require the use of a sulphur tolerant shift catalyst. Johnson Matthey Catalysts is the worlds leading supplier of sour shift catalysts with the KATALCOJM K8-1 1 series of products. These catalysts are particularly robust and can withstand sharp temperature changes, high steam partial pressure and the effect of contamination from impurities in the raw gas. The standard catalyst for sour shift is KATALCOJM K8-1 1, which has been well proven in methanol applications downstream of several different types of gasier. Other variants of this standard catalyst are available to meet specic client requirements which may place greater emphasis on pressure drop or low-temperature activity. An example of this is KATALCOJM K8-1 1HA which uses a geometric shape with higher external surface but which creates a higher packed voidage and thus a lower pressure drop.
Johnson Mattheys experience in the application of sour shift catalyst downstream of gasiers puts us in an ideal position to provide advice on the optimum system conguration, including the appropriate number of reaction stages, the use of bypasses, steam requirements and heat recovery options. For instance, at large plant capacities, the use of radial ow reactors may allow the use of a single reactor instead of multiple parallel axial reactors, so reducing installed plant cost. Johnson Matthey Catalysts is able to provide a sour shift catalyst customised for radial ow applications (KATALCOJM K8-1 1R) along with proven designs of internals for radial ow reactors.
The KATALCOJM 51-series of catalysts is key to the methanol technologies offered by Johnson Matthey and Davy Process Technology. KATALCOJM 51-1 and the LPM process revolutionised synthetic methanol production in the 1960s and have provided the majority of the worlds production ever since that time. These technologies currently account for an annual production capacity of over 30 million tonnes of methanol. KATALCOJM 51-1 was the rst three-component methanol synthesis catalyst comprising zinc oxide and alumina as the support with copper as the active catalytic component. Successive generations of KATALCOJM 51-series catalysts have been developed to give increasing activity, selectivity and stability, so ensuring ever more efcient operation whatever the source of syngas.
The latest in this series, KATALCOJM 51-9S, is particularly suited to highly stressed duties with its activity, strength and selectivity. The high activity and stability of KATALCOJM 51-series catalysts means that typically a charge lasts between four and six years, but some charges have been in operation for more than 8 years. Their strength enables them to withstand the rigors of this extended operation and as a result they show little change in pressure drop and are easily discharged at the end of life.
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But the most signicant change is that the catalyst is pre-reduced and stabilised, all but eliminating the time-consuming reduction that is required for conventional methanol synthesis catalysts. An activation step is still required, but your plant will be manufacturing more methanol sooner, and for longer, by using KATALCOJM APICO 51-100.
ta lys tc ha n ge s
Slowest deactivation
Leading edge syngas technologies Johnson Matthey Catalysts and Davy Process Technology
Since the acquisition of Davy Process Technology by Johnson Matthey in 2006, we now have the most extensive portfolio of catalysts and technologies for syngas preparation and methanol production. Our complementary skills and capabilities allow us to provide: world-class technology high performance catalysts conceptual design and licensing basic and detailed engineering commissioning and start-up on-going operational support. Johnson Matthey Catalysts and Davy Process Technology offer the technology most suited to customer requirements. Whether a client wants large or small capacity in high or low cost gas areas, to build on a ship that will access gas from remote elds, or to use syngas generated from coal as a feedstock, the technology exists within Johnson Matthey Catalysts and Davy Process Technology to meet these requirements. Use of the Johnson Matthey Catalysts LPM technology has increased steadily over the years and is the preferred methanol production technology, with its unrivalled reliability and on-stream factor. Syngas generation technologies With the wide range of expertise available within Davy Process Technology and Johnson Matthey Catalysts, our portfolio of syngas generation technologies is extensive.
M5000 reformer
Steam methane reformers (SMRs) While this technology has been around for a long time, conventional SMRs have been undergoing a continual process of improvement. The largest methanol plant in the world based on natural gas is the Methanol Holdings (Trinidad) Limited M5000 plant. Based on LPM technology, this plant started up in 2005, produces 5,000 tpd of methanol from a single SMR, and represents the benchmark for future technology development in this eld. Autothermal reformers (ATR) Johnson Matthey Catalysts 30+ years of experience was gained on air and oxygen blown ATRs including the Coogee LCM plant in Australia. Our unique design of ATR has proven its reliability and durability over many years in both oxygen and air red service. All elements from the burner and distribution system, through to the refractory lining, catalyst and refractory support arch, deliver long term trouble-free performance.
Combined reforming Combined reforming incorporates the steam methane reforming process and the ATR. The technology is particularly applicable for use on large capacity plants using light natural gas. Two versions of this concept have quite different features. Combined reforming with SMR Combined reforming with an SMR is a way of getting beyond the limitations imposed on plant capacity by the SMR alone. Around 40% of the reforming duty is carried out by the SMR, while the balance is carried out in the ATR. This combination of steam and autothermal reforming can yield an ideal stoichiometric gas for methanol production. The technology stretches the maximum capacity upwards, with capacities in excess of 10,000 tpd being possible with a single SMR the size of the M5000 reformer and a single ATR.
in 1994 (the Coogee LCM plant). To date, there is over 50 operating years of experience in four industrial scale units.
Used in a combined reforming process the outlet from an ATR feeds the shell side of the GHR and is forced to ow counter-currently to the feed natural gas and steam owing inside the tubes. It is the most energy efcient process available with the lowest CO2 emissions and water make up rate.
Combined reforming with Gas heated reforming (GHR) The GHR is a heat exchanger with catalyst inside the tubes and was originally developed by ICI in the 1980s for use in the ammonia industry, with three units coming into operation followed by the rst methanol application
Like the Compact Reformer, the GHR generates little steam and decouples the power system from the process, so plant designers can choose something other than steam turbines to drive rotating equipment. The use of gas turbines, for example, can give further efciency benets, reducing gas consumption and CO2 emissions.
Compact Reformer The Compact Reformer is similar to a conventional reformer in that the chemistry is the same, but the primary heat transfer mechanism is by convection rather than radiation. However, this device signicantly increases the process intensity. The Compact Reformer is a preassemble modular device that is less than a quarter of the weight and size of a conventional reformer. The technology is particularly suited to offshore use or remote locations where transportation and/or site construction are difcult.
Coal gasication Coal gasication is an established technology which, in combination with sour shift, acid gas removal and syngas purication, can be readily used to generate syngas for methanol synthesis. Johnson Matthey Catalysts and Davy Process Technology have catalysts and technologies in sour shift, purication and, of course, methanol synthesis and distillation, and can work with the licensors of the gasication technologies to deliver an integrated coal to methanol production facility
Leading edge methanol technologies Johnson Matthey Catalysts and Davy Process Technology
Methanol synthesis technologies A number of reactor designs and synthesis owsheet arrangements for methanol production can be utilized. Tube cooled converter The tube cooled converter is a simple reactor which uses the feed gas to the reactor to control the temperatures in the catalyst bed. Fresh feed gas enters at the bottom of the reactor and is preheated as it ows upwards through tubes in the catalyst bed. The heated feed gas leaves the top of the tubes and ows down through the catalyst bed where the reaction takes place. The heat of reaction is removed by counter-current exchange with feed gas which results in a temperature prole that approximates to the maximum rate curve. Operated in this manner the reactor achieves good catalyst utilization. Radial ow steam raising converter This steam raising converter is a radial ow reactor with catalyst outside and steam inside the tubes. In the DPT design, fresh feed gas enters at the bottom of the reactor and into a central perforated-wall distributor pipe. The gas then ows radially out through the catalyst bed. Water from a steam drum enters at the bottom of the vessel, and ows upwards through the tubes where it is partially vaporized, removing the heat generated by the reaction before returning to the steam drum. The reaction temperature is controlled by varying the steam pressure inside tubes embedded in the catalyst bed.
Shenhua methanol synthesis
Axial ow steam raising converter The axial ow steam raising converter is a different design in which the catalyst is contained within the tubes with boiling water on the outside. As for the radial reactor, the reaction temperature is controlled by varying the steam pressure. This arrangement gives excellent cooling of the catalyst bed and allows steam to be generated at the maximum possible pressure without overheating the catalyst. The reactor does however require thick tube sheets that limits the maximum capacity of the reactor to around 1,500 tpd and requires a large number of tubes to accommodate that catalyst. This tends to limit the use of this type of reactor to those applications where its high heat transfer performance is required, e.g., in certain coal gasication based owsheets.
Distillation technologies Dependent on the grade of methanol required, there are different options for methanol distillation. To produce DME or MTO-grade methanol, only a single column is required to remove the dissolved gases and some of the light byproducts. To produce rened methanol for chemical or fuel usage, for example Federal AA and IMPCA grade methanol, a two or three column rening system is used. The threecolumn system uses the least heat so is preferred where energy costs are high or the heat for distillation is not readily available.
Further development The acquisition of Davy Process Technology by Johnson Matthey has created a unique environment in which it has been possible enhance the intimate interaction of catalysts and technology development. We continue to drive the improvement of our processes and to develop new ones that will continue to lower the installed cost, improve efciency to make better use of the natural resources and minimize the impact on the environment. It is also important that catalyst and new technology developments keep pace with one another to ensure that the process can operate at its optimum efciency and maintain or increase the time between plant turnarounds.
New catalysts continue to deliver signicant plant improvements. Every catalyst activity improvement enables a corresponding potential increase in plant rate, and can also deliver a longer life before current end of run conditions are achieved. Lower pressure drop options enable plant rate and efciency improvements. For steam reforming catalysts, improved heat transfer reduces the temperature of reformer tubes, extending the time between costly renewal. Better poison pick-ups extend absorbent lives and improve the performance of downstream catalysts. Johnson Matthey Catalysts has teams focusing on the catalysts for each plant reactor and targeting performance improvements driven by customers requirements. Each area has a dedicated team of experienced scientists. Research and development activities in Johnson Mattheys catalysis
The Elements of Sustainability Sustainability is a core part of our business strategy. It is about the way we do business using natural resources efficiently to make products that improve the environmental performance of our customers products and processes. But our view of sustainability extends beyond this. Its also about the health, safety and wellbeing of the people who work for us, our customers and our communities. It means using resources efficiently, innovatively and effectively, striving to achieve the highest environmental standards in our own operations. At the same time sustainability is about delivering value to our shareholders and our Social
customers in the most responsible way, making sustainable long-term decisions to build a company and plan its third century of business. Sustainability is about making the right decisions for our people, our communities, our shareholders and, most significant of all, for the planet. As we progress towards 2017, we are managing sustainability according to five elements: Social Environment Health and Safety Governance Financial Environment
Financial
Achieve carbon neutrality. More than double our earnings per share by 2017. Achieve zero waste to landfill by 2017. Halve the key resources we consume per unit of output by 2017. Achieve a zero greater than three day accidents safety target.
Find out how we are progressing towards Sustainability 2017 www.matthey.com
Reduce incidence of occupational illness cases by at least 30% by 2013/14. Johnson Matthey has developed a number of key performance indicators (KPIs) to monitor progress towards the Sustainability 2017 targets. Our performance against them is presented each year in our Sustainability Report.
The paper used in this report is 9lives 80 Silk, which contains 80% recycled bre content, produced with 100% ECF (Elemental Chlorine Free) ecological pulp which is fully recyclable biodegradable, pH Neutral, heavy metal absence and acid-free. It is manufactured within a mill which complies with the international environmental ISO 14001 standard. This report has been printed using a 50% reduced alcohol process, with a water based coating and vegetable based inks, which are non-hazardous and are from renewable sources. The printing plates used to produce this brochure were made in a chemical-free process. The printers are FSC and ISO 14001 certied with strict procedures in place to safeguard the environment through all processes. Designed and produced by Fat Frog Printed by Potts For further information on Johnson Matthey Catalysts, contact your local sales ofce or visit our website at www.jmcatalysts.com KATALCO, APICO, QUADRALOBE and PURASPEC are trademarks of the Johnson Matthey group of companies. RECTISOL is a trademark of Lurgi GmbH. SELEXOL is a trademark of UOP. UNIDENSE is a trademark of Unidense Technology GmbH. Headquarters: Billingham, UK Tel +44 (0) 1642 553601 Other offices worldwide: for contact details please visit www.jmcatalysts.com/offices
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