1200
1.2
1000
1.0
800
0.8
600
K atalco 65-3XR
Previous catalyst
0.6
Pre-ag e ing Post-ag e ing 510˚C
Post-ag e ing 610˚C
Post-ag e ing 685˚C
heavier hydrocarbons. Alternatively, beds can be short-loaded to reduce the fill cost of a pre-reformer. The catalyst’s chromium-free formulation, means it has a lower environmental impact than many other pre-reforming catalysts. Non- hazardous classification simplifies shipping and handling and eliminates Cr(VI) disposal risks. The catalyst has also been successfully deployed in multiple hydrogen plants. Field data have confirmed reduced temperature profile movement and longer operating lives. Averaged data from several plants in America, Europe, and Asia show that installed charges of Katalco 65- 3XR have typically lasted 5% longer before the pre-reformer temperature profile has reached the same bed depth as the previous catalyst charge (see Figure 7 ). Katalco 65-3XR is a significant advancement in pre-reforming catalyst technology, offering excellent activity, thermal stability, and an environmentally friendly profile for modern syngas and hydrogen plants. As the demand for hydrogen plants evolves, it will deliver cleaner, more efficient, and more flexible operations. With proven performance in both laboratory and commercial settings, it is set to replace legacy CRG catalysts and help refiners tackle future challenges. Figure 7 The average number of days for the pre-reformer Z90 to reach 60% of the catalyst bed depth in a sample of plants
Figure 6 Sintering comparison of Katalco 65-3XR vs CRG-LHR
the catalyst has a nickel surface area of more than 15 m 2/g catalyst. Katalco 65-3XR benefits from a proprietary reduction and passivation manufacturing process that simplifies start- up and conditions the catalyst for peak performance. The customised reduction and passivation process during production ensures that the catalyst is activated under controlled conditions, minimising the risk of thermal or chemical stresses. As a result, the catalyst can be activated at lower temperatures, is optimised for activity, and provides better performance throughout its operational lifecycle. Activity tests show that it consistently performs better than CRG-LHR over a wide range of operating conditions. With Katalco 65-3XR, the nickel is dispersed on a metal aluminate-based support, which offers excellent chemical and thermal stability. This support also provides a structure to assist with the dispersion of the nickel crystallites, hence inhibiting the effects of sintering and providing sustained high activity. Through these features, Katalco 65-3XR has demonstrated a slower movement in the temperature profile due to sintering and higher activity than CRG-LHR, as shown in post-ageing trials (see Figure 6 ). With Katalco 65-3XR, pellet porosity has also been improved from the previous generation of pre-reforming catalysts through the manufacturing process. Better sustained activity, a sharper poison mass transfer profile, and a sharper reaction profile enable its beds to be operated longer without slipping unreacted
KATALCO is a registered trademark of the Johnson Matthey group of companies.
Jumal Shah Jumal.Shah@matthey.com
Refining India
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