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2014 Johnson Matthey Group
Mercury removal
absorbent
KATALCOJM 61-1T
Organic sulphur
removal - HDS
KATALCOJM 33-1
KATALCOJM 59-3
Chloride removal
KATALCOJM 32-4/
32-5
PURASPEC JM 2084
Ultrapurification
PURASPEC JM 2020
Syngas purification
Conventional purification
catalyst loading
Pre-reforming
catalysts
CRG LHR
CRG LHCR
CRG pre-reforming
technology delivered
increased production and
lower energy consumption
on a syngas plant.
Johnson Matthey 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 fluegas duct.
Johnson Matthey CFD modelling quickly showed
that the coil would work as designed.
Contours of Velocity
Magnitude (m/s)
Steam reforming
KATALCOJM 23-4 series
Nickel oxide on
alpha alumina
Nickel oxide on
calcium aluminate
KATALCOJM 25-series:
This is a lightly alkalized nickel oxide on a calcium
aluminate support. The alkali prevents carbon formation
in the upper part of highly stressed reformers where
the heat fluxes are high and especially when the
feedstock contains heavier hydrocarbons, while
retaining the high activity of gas reforming catalysts.
KATALCOJM 23-series:
This catalyst is nickel oxide on an alpha alumina support.
KATALCOJM 57-series:
This catalyst is nickel oxide on a calcium aluminate support.
Selecting the right catalyst for your application is
essential for good reformer performance. Johnson
Matthey will make detailed recommendations based
upon your individual operating conditions ensuring
reliable optimal performance of your reformer.
For naphtha feedstocks Johnson Matthey also
manufactures KATALCOJM 46-series.
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 Aspen HYSYSTM, which includes our PRIMARY
reformer model, we can determine the full impact of
changing reformer conditions within a complete plant
flowsheet. This is typically used for:
retube studies
reformer surveys
operational audits.
reformer consultancy
Autothermal reforming
KATALCOJM 23-8 series
KATALCOJM 28-4 series
KATALCOJM 54-8 series
10
Ruby formation
Autothermal
reformer services
The performance of an autothermal reformer is related
not just to the catalyst performance but also the burner
and the mixing space above the catalyst bed as well as the
integrity of the refractory lining system of the reformer.
100
90
Pressure drop, kPa
80
70
60
50
40
30
20
10
0
0
6
Months on line
KATALCOJM
Previous
10
12
11
Sour shift
KATALCOJM K8-11
KATALCOJM K8-11 HA
12
13
Methanol synthesis
catalysts
KATALCOJM 51-7
KATALCOJM 51-8
KATALCOJM 51-8PPT
KATALCOJM 51-9
KATALCOJM 51-9S
14
KATALCOJM APICO
methanol synthesis
methanol production
Most
em
or
M
a
eth
an
nol
fp
res
ha
n
Slowest
deactivation
ta
lys
tc
Strongest
product available
ges
Highest
activity
te
roved efficiency
d imp
Pre-reduced
catalyst
ra
est
Low
Fastest
start
-up
Least by-products
su
re
d
rop
in
creas
e
tl
Longes
ives
an
tc
es
ew
f
d
15
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.
M5000 reformer
16
Compact
reformer
in Alaska
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 significantly 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 difficult.
Coal gasification
Coal gasification is an established technology which, in
combination with sour shift, acid gas removal and syngas
purification, can be readily used to generate syngas for
methanol synthesis. Johnson Matthey has catalysts and
technologies in sour shift, purification and, of course,
methanol synthesis and distillation, and can work with
the licensors of the gasification technologies to deliver
an integrated coal to methanol production facility.
17
18
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 by-products. To produce refined methanol
for chemical or fuel usage, for example Federal AA
and IMPCA grade methanol, a two or three column
refining system is used. The three-column system uses
the least heat so is preferred where energy costs are
high or the heat for distillation is not readily available.
Shenhua methanol
synthesis
19
Further development
We continue to drive the improvement of our processes and
to develop new ones that will continue to lower the installed
cost, improve efficiency 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 efficiency and
maintain or increase the time between plant turnarounds.
China Blue
Chemical Company
20
Product realization:
From the laboratory to the plant
Catalysts and processes are developed in laboratory
reactors, semi-technical units and side-stream reactors
specifically designed to simulate accurately the important
features of operation in full scale plants. The catalysts
are then finally proven at commercial scale before being
incorporated into the Johnson Matthey KATALCOJM
and PURASPEC JM sales range.
New catalysts continue to deliver significant plant
improvements. Every catalyst activity improvement
enables a corresponding potential increase in plant rate,
and can also deliver a longer life before current end
of run conditions are achieved. Lower pressure drop
options enable plant rate and efficiency improvements.
For steam reforming catalysts, improved heat transfer
reduces the temperature of reformer tubes, extending
the time between costly renewal. Better poison pick-ups
extend absorbent lives and improve the performance of
downstream catalysts.
21
Social
Environment
Governance
Financial
Social
Environment
Responsitive operations
Beneficial products
SUSTAINABLE
BUSINESS
Governance
Financial
Must be profitable to be sustainable
Align financial and sustainability targets
22
23
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