Gas separates quickly from the surface
Gas separates very late from the surface
Narrow low pressure wake = Less drag, improved ow + surface interaction
Swirling gas creates heavy drag
Turbulent boundary layer
Laminar boundary layer
Turbulent ow sucks gas to surface
Figure 3 Magcat ® enhanced heat transfer properties
Textured catalysts create more turbulent gas flow around the catalysts, disrupting the thin static gas layer inside the tube wall. This results in a higher heat transfer coefficient, reduced tube skin temperature, and accelerated mass transfer of reactants to the active catalyst site ( Figure 3 ). This innovative SMR catalyst technology has enhanced the heat transfer coefficient, provided high intrinsic strength, and reduced pressure drop across the process. These improvements deliver performance benefits at a constant plant rate, including lower tube skin temperatures and reduced firing, resulting in an overall increase in operational efficiency under given operating conditions. Magcat ® offers several operational advantages in addition to the efficiency improvements and increased unit capacity. Its high crush strength allows for easy sock loading by direct pour method into reformer tubes. This ease of loading can lead to a significant reduction in unit downtime, thereby boosting economic returns. The spherical shape of Magcat ® ensures uniform packing within the tubes, even without dense loading, promoting even flow distribution and a predictable, controlled lower pressure drop. This lower pressure drop has enabled some Magcat ® users to increase their throughput by more than 15%. Figure 4 summarises the benefits Magcat ® can bring to your site. In addition to its potential for boosting hydrogen and syngas production, Magcat ® can also be used to lower reformer fuel consumption through enhanced heat transfer. This is particularly important in areas with high incremental fuel costs and where there is a need to reduce CO₂ emissions. Reformer furnaces are among the largest CO₂ emitters in refineries and petrochemical plants. By significantly reducing fuel consumption, a corresponding decrease in CO₂ emissions is achieved. The Magcat ® catalyst is versatile, capable of saving fuel and reducing CO₂ emissions under normal conditions, while also increasing hydrogen or syngas production when needed. Summary UNICAT’s customers requested innovations in PSA and SMR plants, which have led to significant improvements in hydrogen purification. By utilizing advanced adsorbents and
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1. Increased hydrogen
2. Pressure drop reduction
6-in-1 bene ts
6. Lower potassium fouling
3. Increased tube life
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5. Fuel saving
4. CO reduction
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Figure 4 Benefits when using Magcat ® technology
optimizing control systems, hydrogen recovery and production have been significantly enhanced. These innovations stem from commitment to continuous improvement, addressing industry challenges, and reinvesting in catalyst and process technologies that support hydrocarbon processors. UNICAT’s strategic business aim is constant reinvestment in catalyst and process technologies, which allows UNICAT to support hydrocarbon processors in achieving their goals. They actively seek to understand customers’ problems and process limitations, ensuring that solutions are tailored to meet specific needs. UNICAT’s innovations are not only the result of internal expertise but also strategic partnerships with customers, working together to improve customer sustainability, efficiency and profitability. Through these partnerships UNICAT has been able to improve the operation of many PSA and SMR units, fulfilling customer needs and ultimately driving advancements in the industry.
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