recommended to provide carbon resistance and conversion efficiency. • Middle to outlet section : This hotter region requires thermally stable catalysts. As the reaction becomes more diffusion-limited, this section benefits most from surface-enriched catalysts like Katalco 57-6Q, which reduce methane slip and lower tube wall temperatures by improving approach to equilibrium. Additionally, as the molar flow of gas increases along the tube, plants constrained by pressure drop can benefit from using larger-sized pellets in this section to reduce resistance. This zonal strategy ensures that each part of the tube contains a catalyst tailored to the specific operating challenges; this maximises reliability and minimises the Ni inventory for the overall catalyst charge. A growing range of catalyst grades, combined with improved modelling capabilities, now allows for better customisation of specific catalyst loading solutions to meet the unique requirements of each plant. Sustainability, scalability, and the road ahead Hydrogen production must scale rapidly to support global decarbonisation goals. Further catalyst optimisation plays a pivotal role in this expansion. Efficient Ni utilisation, extended catalyst lifetimes, and reduced energy consumption all contribute to lowering both the carbon intensity and the cost per unit of hydrogen. Process intensification through steam reforming catalysts with optimised Ni distribution will help drive growth in a more sustainable manner. Utilisation of highly active, low Ni-containing complex shaped catalysts will support growth. Another emerging catalyst technology is the use of structured catalysts, such as Catacel SSR. A structured catalyst is a system in which the fundamental characteristics of a catalyst- coated metal foil are used to design a precision-engineered reaction medium. The inherent and repeating structure of such systems ensures that reacting gases within a tubular SMR are guided through a highly controlled flow path. This provides consistent behaviour from tube to tube and allows
designers to engineer unique features into the structure. Structured catalysts can deliver better performance than randomly packed pellets due to higher voidage, higher geometric surface area, and better controlled gas flow patterns. Summary As the hydrogen economy accelerates and pressure mounts to reduce emissions and operating costs, catalyst innovation in steam methane reforming is proving to be a powerful enabler. Advances in catalyst shape, material stability, and Ni distribution are extending catalyst lifetimes, improving heat and mass transfer, and reducing pressure drop, all while lowering the raw material resource utilisation, carbon impact, and financial cost of syngas production. “ Structured catalysts can deliver better performance than randomly packed pellets due to higher voidage, higher geometric surface area, and better controlled gas flow patterns ” Precision engineering of Ni deposition, as demonstrated in catalysts like Katalco 57- 6Q, allows operators to achieve equivalent or superior performance with significantly less metal. Zonal catalyst strategies further optimise SMR performance by tailoring catalyst properties to the specific demands of each section of the tube. Emerging technologies, such as structured catalysts, offer even greater control and scalability for future plant designs. Together, these innovations deliver environmental benefits in reducing raw material resource consumption, enhancing cost- effectiveness, and enabling a scalable syngas production process, thereby supporting the industry in meeting its measurable economic and environmental targets. QUADRALOBE, KATALCO, and CATACEL SSR are registered trademarks of the Johnson Matthey group of companies.
Jumal Shah Jumal.Shah@matthey.com
Refining India
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