Catalysts for

Syngas
 Catalysts
Clariant is a leading supplier of catalysts used in synthesis gas processes. These
processes include those for the production of ammonia, methanol, hydrogen,
HyCo (hydrogen/CO mixtures), and direct-reduced iron. Additionally, Clariant
offers several catalysts and adsorbents for the purification of feedstocks used in
these processes.

Our strength in syngas technology grows from our roots in Süd-Chemie, a lead-
ing company in the development of process catalysts for chemicals markets.
The broad portfolio of highly innovative catalyst products is now part of the
Catalysts business unit of Clariant.

The Catalysts business unit is headquartered in Munich, Germany, and has 16

catalyst production sites and 11 R&D centers around the world. Our catalysts
contribute significantly to value creation in our customers’ operations, ensuring
that finite raw materials and energy are used efficiently in the production of
industrial chemicals, plastics, and fuels. Our products enable the use of alter-
native raw materials – such as natural gas, coal and biomass – as chemical and
energy feedstocks, and are used to clean emissions from industrial processes
and combustion engines to limit the impact on the environment.

We are committed to R&D and customer service to ensure that our products are
well positioned to meet the global challenges of raw material scarcity, energy
efficiency and responsible care for our environment.

2 Catalysts for Syngas

Catalysts for Syngas
Reformax®

Production of Ammonia and Methanol

The production of ammonia and methanol involves the
use of several key unit operations, including:
· Prereforming
· Steam reforming
· Secondary or autothermal reforming
· High and low temperature conversion of CO to CO2
· Methanation
· Ammonia synthesis
· Methanol synthesis Steam Reforming
Selection of the optimum catalyst depends on several factors, in-
Prereforming cluding furnace design, severity of service, and the type of hydro-
A prereformer is an adiabatic fixed-bed reactor up- carbon processed. Our recommended catalysts are shown in the
stream of the primary reformer. It allows increased table below.
flexibility in the choice of feedstock, increased lifetime
of the steam reforming catalyst and tubes, and the ReforMax 330 ReforMax 210 ReforMax 250
option of increasing the overall plant capacity. Further- LDP LDP

more it allows operation at lower steam/carbon ratios. Nominal Content [wt.%]

Typical feed NG NG/LPG Naphtha
ReforMax 100 is a prereforming catalyst designed to NiO 14 18 23
handle the entire range of hydrocarbon feedstocks from
K2O - 1.5 6
natural gas up to and including LPGs and naphthas.
Carrier CaAl12O19 CaK2Al22O34 Magnesium,
Aluminate
ReforMax 100
Shape 10 Hole Rings 10 Hole Rings Multihole Rings
Nominal Content [wt.%] Size [mm] 19 x 16 19 x 12 16 x 16
NiO 56.5
Support and Promoter Balance
Shape Tablets
Size [mm] 4.7 x 4.7

3
Catalysts for Syngas
Reformax® Shiftmax®

Secondary Reforming Autothermal Reforming

The optimum catalyst for an air-fed secondary reformer Oxygen-fed autothermal reformers require a mixed
depends on the design of the burner and the distance loading of catalysts, comprising an active heat shield
between burner tip and top catalyst layer. If hexagonal and a reforming catalyst of excellent physical stability
target bricks are not used, we recommend installation and thermoshock resistance. The standard catalyst
of a top layer of ReforMax 400 GG to serve as an active loading is approx. 5 - 10% of ReforMax 420 on top of
heat shield. This material is also ideal for a bottom ReforMax 330 LDP catalyst.
active support layer where extreme short loadings are
required and/or where high purity inert supports can ReforMax 420 ReforMax 330
be replaced with an active catalyst. ReforMax 410 LDP LDP
catalyst is used for the bulk of the reactor loading. Nominal Content [wt.%]
NiO 7.4 14
ReforMax 400 ReforMax 410 Carrier α-Al2O3 CaAl12O19
GG LDP
Shape Extrusions 10 Hole Rings
Nominal Content [wt.%]
Size [mm] 30 19 x 16
NiO 11.5 11.5
Carrier α-Al2O3 CaAl12O19
Shape 6 Hole Rings 10 Hole Rings
Size [mm] 33 x 18 19 x 16

4 Catalysts for Syngas

 CO Conversion Low-temperature CO Conversion
Most ammonia plants convert CO to CO2 by high-tem- The LTS catalysts ShiftMax 230 and ShiftMax 240 are
perature water-gas shift followed by low-temperature state-of-the-art products featuring excellent copper
water-gas shift. For special process design, it can be dispersion leading to unparalleled activity for water-gas
advantageous to combine these two steps to form one shift. These catalysts feature higher CO conversion
isothermal or adiabatic step called medium tempera- for longer life, enhanced resistance to poisons, and
ture CO conversion (MTS). superior physical strength. The promoter in ShiftMax
240 suppresses the formation of methanol by more
High-temperature CO Conversion than 95% compared to standard LTS catalysts without
The HTS catalyst ShiftMax 120 combines high activity decreasing activity.
with extremely good physical robustness. In addition,
this catalyst is very effective in preventing Fischer- ShiftMax 230 ShiftMax 240
Tropsch by-product formation when operating at low Nominal Content [wt.%]
steam to gas conditions.
CuO 58 58
ZnO 31 31
ShiftMax 120
Al2O3 11 11
Nominal Content [wt.%]
Promoter - 1
Fe2O3 80
Shape Tablets Tablets
Cr2O3 8.5
Size [mm] 5x3 5x3
CuO 2
Shape Tablets
Size [mm] 6x6
other sizes on request

5
Catalysts for Syngas
Meth® Amomax®
Megamax® Reformax®

Methanation Ammonia Synthesis

Depending on the severity and product purity require-
ments of the application, Clariant supplies two different
types of methanation catalysts.
METH 134 consists of alumina supported NiO. For
extremely low temperature applications (T < 170 °C)
Clariant provides METH 150, which is comprised of
ruthenium on an alumina support.
METH 134 METH 150
Nominal Content [wt.%]
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 operating temperatures, allowing
improved conversion at thermodynamically more
favorable conditions. Wustite contains less oxygen
than magnetite which means that reduction times can
be significantly reduced. AmoMax-10 also features
excellent long-term stability and is stronger than mag-
netite-based catalysts. AmoMax-10 is available in oxidic
and pre-reduced, stabilized forms.

NiO 25 -
AmoMax-10
Ru - 0.3
Nominal Content [wt.%]
Support Balance Balance
Fe -
Shape Spheres Tablets
FeO 92
Size [mm] 3-6 4.5 x 4.5
Promoter Balance
Shape Granules
Size [mm] 1.5 - 3
other sizes on request

6 Catalysts for Syngas

 Methanol Synthesis Methanol Reforming
For the synthesis of methanol from carbon oxides and Hydrogen and carbon monoxide can be produced by
hydrogen, Clariant produces the MegaMax 800 cata- means of steam reforming of methanol, which is per-
lyst, which is used in isothermal reactors (Lurgi-type) formed with ReforMax M.
and all other plant designs, such as adiabatic quench
type reactors. MegaMax 800 has extremely good ReforMax M
low-temperature activity, which allows it to be operated Nominal Content [wt.%]
at more thermodynamically favorable conditions. This
CuO 60
catalyst also has excellent selectivity, even with high
ZnO 30
CO-content feed gas.
Al2O3 Balance
Shape Tablets
MegaMax 800
Size [mm] 6x4
Nominal Content [wt.%]
CuO Proprietary
ZnO Proprietary
Al2O3 Proprietary
Shape Tablets
Size [mm] 6x4

7
Catalysts for Syngas
Actisorb® HDMAX®

ActiSorb Catalyst Series Sulphur Removal

The ActiSorb series of catalysts and adsorbents are used for the pu- Sulphur in the form of organic compounds can be
rification of almost all hydrocarbon feedstocks. This purification is removed either as such or by hydrogenation to H2S
typically a combination of a reaction using a pre-treatment catalyst, followed by adsorption of the latter. The ActiSorb S 7
i.e. hydrogenation, followed by adsorption with the ActiSorb adsor- catalyst is recommended for the removal of H2S, mer-
bent. The following table gives a general overview of the different captans, disulphides and thiophenes in hydrocarbon
families of ActiSorb materials. feedstreams, ranging from naphtha to middle distillates.
The achieved purity is less than 0.1 ppm wt. sulphur.

ActiSorb S 7
Organic Chlorides

Organic Fluorine

Silica Compounds
Organic Sulphur

Nominal Content [wt.%]

Heavy Metals

NiO 66
Thiophens

Binder Balance
Shape CDS Extrusions
COS

HCl

PH3
H2S

HF

O2

Size [mm] 1.5

ActiSorb S • • • •
ActiSorb Cl • •
ActiSorb F • •
ActiSorb Hg 1 •
ActiSorb Hg 5 • •
ActiSorb 301 • •
ActiSorb 310 • • •
ActiSorb Si •
ActiSorb O •

8 Catalysts for Syngas

 Hydrodesulphurisation
The standard catalysts for the hydrogenation of organic
sulphur com-pounds in hydrocarbon feedstocks are the
cobalt-molybdenum-type catalysts from the HDMax
200 series. These catalysts are used in both liquid and
gas phase for all types of hydrocarbons, such as naph-
tha, LPG, natural gas and off-gases. For the hydroge-
nation of organic nitrogen compounds and/or olefin
saturation, our nickel-molybdenum-based HDMax 301
catalyst is recommended.
H2S Removal
The ActiSorb S series of ZnO-based adsorbents is used for the
removal of sulphur components such as hydro­gen sulphide, mer-
captans 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 applica-
tions where the feed contains high inlet sulphur concentrations, and
where maximum sulphur pick-up per loaded unit volume is required.

HDMax 200 HDMax 301 In some cases, it is necessary to remove the sulphur to a level below
Nominal Content [wt.%]
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
CoO 3-5 -
remaining H2S to a value < 10 ppb H2S under a wide range of oper-
NiO - 3-6
ating conditions.
MoO3 10 17
Al2O3 Balance Balance
ActiSorb S 1 ActiSorb S 2 ActiSorb S 3
Shape CDS Extrusions CDS Extrusions
Nominal Content [wt.%]
TRIAX Extrusions TRIAX Extrusions
ZnO 100 90 90
Size [mm] 2.5 2.5
Al2O3 - Balance Balance
Shape Extrusions Extrusions Extrusions
Size [mm] 4.5 4.5 4.5

9
Catalysts for Syngas
Actisorb®

ActiSorb S 6
COS Hydrolysis
The ActiSorb 410 catalyst selectively promotes the
Nominal Content [wt.%]
simultaneous hydrolysis of COS and hydrogenation of
CuO Proprietary
CS2. HCN is also hydrolysed. The high selectivity of
ZnO Proprietary
ActiSorb 410 means that process gases with very high
Al2O3 Balance CO concentrations can be treated.
Shape Tablets
Size [mm] 5x3 The feed to the COS hydrolysis reactor usually contains
nickel and iron carbonyls. These carbonyls decompose
Purification of natural gas containing low concentra- on the ActiSorb 410 catalyst into CO and the respective
tions of total sulphur can also be performed by metals, leading to deactivation of the ActiSorb 410 cat-
ActiSorb G 1, a promoted ZnO catalyst. Simultaneous alyst. It is therefore necessary to install a guard reactor
hydrodesulphurisation and H2S pick-up is a feature with ActiSorb 400 to selectively decompose any traces
unique to ActiSorb G 1. Even when saturated, the of metal carbonyls on the guard catalyst.
ActiSorb G 1 catalyst fully retains its hydrogenation
capabilities.
ActiSorb 400 ActiSorb 410

ActiSorb G 1 Nominal Content [wt.%]

Nominal Content [wt.%] Cr2O3 - 11
CuO 1.5 K2O - 6
MoO3 1.8 Al2O3 16 Balance
ZnO + Binder Balance SiO2 Balance -
Shape Extrusions Shape Spheres Tablets
Size [mm] 4.5 Size [mm] 5 4.5 x 4.5

10 Catalysts for Syngas

COS and Arsine Removal
Refinery feeds and C3 streams from steam crackers often contain
both COS and AsH3, and sometimes trace PH3. 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.
The consumption of polymerisation catalysts is drastically reduced
with a poison guard. Feed polishing prior to polymerisation is
therefore extremely valuable for downstream operations.
Chlorine Removal
Clariant offers a range of adsorbents for the removal of HCl, ammo-
nium 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 applica-
tions, while ActiSorb Cl 2 and ActiSorb Cl 3 adsorbents are recom-
mended in the gas phase.
ActiSorb Cl 3 and ActiSorb Cl 6 are developed as traps for HCl and
organic chloride for Continuous Catalytic Reforming (CCR) outlet
streams to avoid chloride corrosion, polymer deposit and green oil
formation on downstream equipment.

ActiSorb 300 ActiSorb 301 ActiSorb 310 ActiSorb CI 2 ActiSorb CI 3 ActiSorb CI 6

Nominal Content [wt.%]

CuO 41 53 16 Content includes Na2O, ZnO, Al2O3 and Promoters.
ZnO 41 27 - Shape Spheres Extrusions CDS Extrusions
MnO2 - - 25 Size [mm] 3-5 2.5 1.6
Al2O3 Balance Balance Balance

Shape Tablets Extrusions CDS Extrusions

Size [mm] 4.8 x 3.2 3 1.5

11
Catalysts for Syngas
Actisorb®

Fluorine Removal Metal Removal

ActiSorb F adsorbs organic fluorine compounds and HF Mercury Removal
in hydrocarbon feedstocks. The catalysts of the ActiSorb Hg series absorb traces of
mercury from all types of feed to non-detectable levels.
ActiSorb F ActiSorb Hg catalysts are used for Hg removal from:
Nominal Content [wt.%]
· Natural gas
· LPG
Na2O 0.3
· Mercury – ore – furnace gas
Al2O3 Balance
· Incinerator vent gas
Shape Spheres · Vent streams from laboratories
Size [mm] 3-5 · Off-gases in manufacture of electrical devices and
operation of power plants

ActiSorb Hg 1 ActiSorb Hg 2

Nominal Content [wt.%]

S 10 15
Activated Carbon Balance Balance
Shape Granules Granules

12 Catalysts for Syngas

 The ActiSorb Hg 1 catalysts are extremely effective in Silica Removal
removing Hg in chlorine plants, and purifying hydrogen ActiSorb Si is a specially promoted alumina that is
given off as a by-product in sodium amalgam decompo- designed to remove silicon-based antifoaming agents
sition and cell room ventilation air. from hydrocarbon feeds.

ActiSorb Hg 5 CO Removal
Nominal Content [wt.%]
Various feed-streams contain CO in concentrations of
several ppm up to one percent that must be removed
Ag 6
to levels below 10 ppb. The type of catalyst is chosen
Al2O3 Balance
according to the feed, e.g. Ni catalysts to methanate CO
Shape Spheres in hydrogen streams, and CuO-catalysts to remove CO
Size [mm] 2-4 from ethylene and nitrogen by adsorption or by catalyt-
ic reaction with addition of air/oxygen.

ActiSorb Si

Nominal Content [wt.%]

Na2O 0.3
Al2O3 Balance
Shape Spheres
Size [mm] 3-5

13
Catalysts for Syngas
Actisorb® Meth®
Reformax® Sulfomax®

Purification of Natural Gas Removal of CO from Hydrogen

To produce pipeline grade and LNG grade natural gas a combina- In steam cracker plants, the hydrogen typically contains
tion of different adsorbents is required. Depending on the impuri- 0.2 - 1% vol. CO, but no CO2. Ideally, CO-methanation
ties and the required specifications H2S, COS, AsH3 and Hg have to should be carried out at the lowest possible tempera-
be removed. ture. To accomplish this task, we provide a Ru-catalyst
for operating temperatures of approximately 170 °C and
ActiSorb Hg 1 ActiSorb 301 ActiSorb 310 Ni-catalysts, which must be operated above 200 °C to
Nominal Content [wt.%]
avoid Ni-carbonyl formation.

CuO - 53 16
ZnO - 27 - METH 134 METH 150

MnO2 - - 25 Nominal Content [wt.%]

Al2O3 - Balance Balance NiO 25 -

S 10 - - Ru - 0.3

Activated Carbon Balance - - Support Balance Balance

Shape Granules Extrusions CDS Extrusions Shape Spheres Tablets

Size [mm] - 3 1.5 Size [mm] 3-6 4.5 x 4.5

14 Catalysts for Syngas

 Ammonia Dissociation Production of Sulphuric Acid
NH3 is an undesirable component often present in The conversion of sulphur dioxide to sulphur trioxide is the cata-
off-gases. To reduce environmental emissions, it is typ- lytic step in the production of sulphuric acid. The SulfoMax series
ically dissociated at high temperatures to yield N2 and of catalysts feature different formulations and innovative shapes,
H2. Due to the extreme temperatures, the application covering all operating conditions in the sulphuric acid process.
requires a very rugged catalyst.
SulfoMax SulfoMax HV SulfoMax CS
The ReforMax 117 nickel on MgO carrier catalyst is Nominal Content [wt.%]
supplied in an enhanced surface area ribbed ring for
V2O5 6.5 - 7.5 7.5 - 8.5 6.5 - 7.5
maximum activity.
K2O 9.5 - 11.0 10.0 - 11.5 Proprietary
Shape Ribbed Rings/ Ribbed Rings/ Ribbed Rings/
ReforMax 117 RR
Extrusions Extrusions Extrusions
Nominal Content [wt.%] Size [mm] 9 9 9
NiO 6
Al2O3 Balance
Shape Ribbed Rings
Size [mm] 30 x 28 x 11

15
Clariant International Ltd
Rothausstrasse 61
4132 Muttenz
Switzerland

Catalysts
syngas@clariant.com

www.catalysts.clariant.com

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