Catalysts for - CLARIANT/media/Files/Solutions/Products/Brochures/A/19/... · The LTS catalysts ShiftMax 230 and ShiftMax 240 are state-of-the-art products featuring excellent copper

SyngaSCatalysts for

Catalysts for syngas2

CatalystsClariant 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.

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Prereforming A prereformer is an adiabatic fixed-bed reactor up-stream of the primary reformer. It allows increased flexibility in the choice of feedstock, increased lifetime of the steam reforming catalyst and tubes, and the option of increasing the overall plant capacity. Further-more it allows operation at lower steam/carbon ratios.

ReforMax 100 is a prereforming catalyst designed to handle the entire range of hydrocarbon feedstocks from natural gas up to and including LPGs and naphthas.

Steam Reforming Selection of the optimum catalyst depends on several factors, in-cluding furnace design, severity of service, and the type of hydro-carbon processed. Our recommended catalysts are shown in the table below.

RefoRMax 330 LDP

RefoRMax 210 LDP

RefoRMax 250

Nominal Content [wt.%]

Typical feed NG NG/LPG Naphtha

NiO 14 18 23

K2O - 1.5 6

Carrier CaAl12O19 CaK2Al22O34 Magnesium, Aluminate

Shape 10 Hole Rings 10 Hole Rings Multihole Rings

Size [mm] 19 x 16 19 x 12 16 x 16

RefoRMax 100


NiO 56.5

Support and Promoter Balance

Shape Tablets

Size [mm] 4.7 x 4.7

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


Secondary Reforming The optimum catalyst for an air-fed secondary reformer depends on the design of the burner and the distance between burner tip and top catalyst layer. If hexagonal target bricks are not used, we recommend installation of a top layer of ReforMax 400 GG to serve as an active heat shield. This material is also ideal for a bottom active support layer where extreme short loadings are required and/or where high purity inert supports can be replaced with an active catalyst. ReforMax 410 LDP catalyst is used for the bulk of the reactor loading.

autothermal Reforming Oxygen-fed autothermal reformers require a mixed loading of catalysts, comprising an active heat shield and a reforming catalyst of excellent physical stability and thermoshock resistance. The standard catalyst loading is approx. 5 - 10% of ReforMax 420 on top of ReforMax 330 LDP catalyst.

RefoRMax 420 RefoRMax 330 LDP


NiO 7.4 14

Carrier α-Al2O3 CaAl12O19

Shape Extrusions 10 Hole Rings

Size [mm] 30 19 x 16

RefoRMax 400 gg

RefoRMax 410 LDP


NiO 11.5 11.5

Carrier α-Al2O3 CaAl12O19

Shape 6 Hole Rings 10 Hole Rings

Size [mm] 33 x 18 19 x 16

Catalysts for Syngas RefoRMax® ShiftMax®

5

Co Conversion Most ammonia plants convert CO to CO2 by high-tem-perature water-gas shift followed by low-temperature water-gas shift. For special process design, it can be advantageous to combine these two steps to form one isothermal or adiabatic step called medium tempera-ture CO conversion (MTS).

High-temperature CO Conversion The HTS catalyst ShiftMax 120 combines high activity with extremely good physical robustness. In addition, this catalyst is very effective in preventing Fischer- Tropsch by-product formation when operating at low steam to gas conditions.

Low-temperature CO ConversionThe LTS catalysts ShiftMax 230 and ShiftMax 240 are state-of-the-art products featuring excellent copper dispersion leading to unparalleled activity for water-gas shift. These catalysts feature higher CO conversion for longer life, enhanced resistance to poisons, and superior physical strength. The promoter in ShiftMax 240 suppresses the formation of methanol by more than 95% compared to standard LTS catalysts without decreasing activity.

ShiftMax 120


Fe2O3 80

Cr2O3 8.5

CuO 2

Shape Tablets

Size [mm] 6 x 6 other sizes on request

ShiftMax 230 ShiftMax 240


CuO 58 58

ZnO 31 31

Al2O3 11 11

Promoter - 1

Shape Tablets Tablets

Size [mm] 5 x 3 5 x 3


Methanation 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.

ammonia Synthesis 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.

aMoMax-10


Fe -

FeO 92

Promoter Balance

Shape Granules

Size [mm] 1.5 - 3 other sizes on request

Meth 134 Meth 150


NiO 25 -

Ru - 0.3

Support Balance Balance

Shape Spheres Tablets

Size [mm] 3 - 6 4.5 x 4.5

Catalysts for Syngas Meth® aMoMax® MegaMax® RefoRMax®

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Methanol Synthesis For the synthesis of methanol from carbon oxides and hydrogen, Clariant produces the MegaMax 800 cata-lyst, which is used in isothermal reactors (Lurgi-type) and all other plant designs, such as adiabatic quench type reactors. MegaMax 800 has extremely good low-temperature activity, which allows it to be operated at more thermodynamically favorable conditions. This catalyst also has excellent selectivity, even with high CO-content feed gas.

Methanol Reforming Hydrogen and carbon monoxide can be produced by means of steam reforming of methanol, which is per-formed with ReforMax M.

MegaMax 800


CuO Proprietary

ZnO Proprietary

Al2O3 Proprietary

Shape Tablets

Size [mm] 6 x 4

RefoRMax M


CuO 60

ZnO 30

Al2O3 Balance

Shape Tablets

Size [mm] 6 x 4


actiSorb Catalyst SeriesThe ActiSorb series of catalysts and adsorbents are used for the pu-rification of almost all hydrocarbon feedstocks. This purification is typically a combination of a reaction using a pre-treatment catalyst, i.e. hydrogenation, followed by adsorption with the ActiSorb adsor-bent. The following table gives a general overview of the different families of ActiSorb materials.

oR

ga

niC

Su

LPh

uR

thio

Ph

en

S

Co

S

h2S

oR

ga

niC

Ch

LoR

iDe

S

hC

l

oR

ga

niC

fLu

oR

ine

hf

he

av

y M

eta

LS

Ph

3

SiLi

Ca

Co

MP

ou

nD

S

o2

ActiSorb S • • • •

ActiSorb Cl • •

ActiSorb F • •

ActiSorb Hg 1 •

ActiSorb Hg 5 • •

ActiSorb 301 • •

ActiSorb 310 • • •

ActiSorb Si •

ActiSorb O •

Catalysts for Syngas aCtiSoRb® hDMax®

Sulphur RemovalSulphur in the form of organic compounds can be removed either as such or by hydrogenation to H2S followed by adsorption of the latter. The ActiSorb S 7 catalyst is recommended for the removal of H2S, mer-captans, disulphides and thiophenes in hydrocarbon feedstreams, ranging from naphtha to middle distillates. The achieved purity is less than 0.1 ppm wt. sulphur.

aCtiSoRb S 7


NiO 66

Binder Balance

Shape CDS Extrusions

Size [mm] 1.5

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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.

hDMax 200 hDMax 301


CoO 3 - 5 -

NiO - 3 - 6

MoO3 10 17

Al2O3 Balance Balance

Shape CDS Extrusions TRIAX Extrusions

CDS ExtrusionsTRIAX Extrusions

Size [mm] 2.5 2.5

h2S Removal The ActiSorb S series of ZnO-based adsorbents is used for the removal of sulphur components such as hydro gen 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.

aCtiSoRb S 1 aCtiSoRb S 2 aCtiSoRb S 3


ZnO 100 90 90

Al2O3 - Balance Balance

Shape Extrusions Extrusions Extrusions

Size [mm] 4.5 4.5 4.5

In some cases, it is necessary to remove the sulphur to a level below 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 remaining H2S to a value < 10 ppb H2S under a wide range of oper-ating conditions.


Purification of natural gas containing low concentra-tions of total sulphur can also be performed by ActiSorb G 1, a promoted ZnO catalyst. Simultaneous hydrodesulphurisation and H2S pick-up is a feature unique to ActiSorb G 1. Even when saturated, the ActiSorb G 1 catalyst fully retains its hydrogenation capabilities.

aCtiSoRb S 6


CuO Proprietary

ZnO Proprietary

Al2O3 Balance

Shape Tablets

Size [mm] 5 x 3

aCtiSoRb g 1


CuO 1.5

MoO3 1.8

ZnO + Binder Balance

Shape Extrusions

Size [mm] 4.5

CoS hydrolysis The ActiSorb 410 catalyst selectively promotes the simultaneous hydrolysis of COS and hydrogenation of CS2. HCN is also hydrolysed. The high selectivity of ActiSorb 410 means that process gases with very high CO concentrations can be treated.

The feed to the COS hydrolysis reactor usually contains nickel and iron carbonyls. These carbonyls decompose on the ActiSorb 410 catalyst into CO and the respective metals, leading to deactivation of the ActiSorb 410 cat-alyst. It is therefore necessary to install a guard reactor with ActiSorb 400 to selectively decompose any traces of metal carbonyls on the guard catalyst.

aCtiSoRb 400 aCtiSoRb 410


Cr2O3 - 11

K2O - 6

Al2O3 16 Balance

SiO2 Balance -


Size [mm] 5 4.5 x 4.5

Catalysts for Syngas aCtiSoRb®

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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.

aCtiSoRb 300 aCtiSoRb 301 aCtiSoRb 310


CuO 41 53 16

ZnO 41 27 -

MnO2 - - 25

Al2O3 Balance Balance Balance

Shape Tablets Extrusions CDS Extrusions

Size [mm] 4.8 x 3.2 3 1.5

Chlorine RemovalClariant 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 Ci 2 aCtiSoRb Ci 3 aCtiSoRb Ci 6

Content includes Na2O, ZnO, Al2O3 and Promoters.

Shape Spheres Extrusions CDS Extrusions

Size [mm] 3 - 5 2.5 1.6


fluorine Removal ActiSorb F adsorbs organic fluorine compounds and HF in hydrocarbon feedstocks.

aCtiSoRb f


Na2O 0.3

Al2O3 Balance

Shape Spheres

Size [mm] 3 - 5

Metal RemovalMercury Removal The catalysts of the ActiSorb Hg series absorb traces of mercury from all types of feed to non-detectable levels. ActiSorb Hg catalysts are used for Hg removal from: · Natural gas · LPG· Mercury – ore – furnace gas · Incinerator vent gas · Vent streams from laboratories · Off-gases in manufacture of electrical devices and

operation of power plants

aCtiSoRb hg 1 aCtiSoRb hg 2


S 10 15

Activated Carbon Balance Balance

Shape Granules Granules

Catalysts for Syngas aCtiSoRb®

13

aCtiSoRb hg 5


Ag 6

Al2O3 Balance

Shape Spheres

Size [mm] 2 - 4

The ActiSorb Hg 1 catalysts are extremely effective in removing Hg in chlorine plants, and purifying hydrogen given off as a by-product in sodium amalgam decompo-sition and cell room ventilation air.

Silica Removal ActiSorb Si is a specially promoted alumina that is designed to remove silicon-based antifoaming agents from hydrocarbon feeds.

aCtiSoRb Si


Na2O 0.3

Al2O3 Balance

Shape Spheres

Size [mm] 3 - 5

CO RemovalVarious feed-streams contain CO in concentrations of several ppm up to one percent that must be removed to levels below 10 ppb. The type of catalyst is chosen according to the feed, e.g. Ni catalysts to methanate CO in hydrogen streams, and CuO-catalysts to remove CO from ethylene and nitrogen by adsorption or by catalyt-ic reaction with addition of air/oxygen.


Purification of natural gasTo produce pipeline grade and LNG grade natural gas a combina-tion of different adsorbents is required. Depending on the impuri-ties and the required specifications H2S, COS, AsH3 and Hg have to be removed.

aCtiSoRb hg 1 aCtiSoRb 301 aCtiSoRb 310


CuO - 53 16

ZnO - 27 -

MnO2 - - 25

Al2O3 - Balance Balance

S 10 - -

Activated Carbon Balance - -

Shape Granules Extrusions CDS Extrusions

Size [mm] - 3 1.5

Catalysts for Syngas aCtiSoRb® Meth® RefoRMax® SuLfoMax®

Removal of CO from Hydrogen In steam cracker plants, the hydrogen typically contains 0.2 - 1% vol. CO, but no CO2. Ideally, CO-methanation should be carried out at the lowest possible tempera-ture. To accomplish this task, we provide a Ru-catalyst for operating temperatures of approximately 170 °C and Ni-catalysts, which must be operated above 200 °C to avoid Ni-carbonyl formation.

Meth 134 Meth 150


NiO 25 -

Ru - 0.3

Support Balance Balance


Size [mm] 3 - 6 4.5 x 4.5

15

ammonia DissociationNH3 is an undesirable component often present in off-gases. To reduce environmental emissions, it is typ-ically dissociated at high temperatures to yield N2 and H2. Due to the extreme temperatures, the application requires a very rugged catalyst.

The ReforMax 117 nickel on MgO carrier catalyst is supplied in an enhanced surface area ribbed ring for maximum activity.

RefoRMax 117 RR


NiO 6

Al2O3 Balance

Shape Ribbed Rings

Size [mm] 30 x 28 x 11

Production of Sulphuric acidThe conversion of sulphur dioxide to sulphur trioxide is the cata-lytic step in the production of sulphuric acid. The SulfoMax series of catalysts feature different formulations and innovative shapes, covering all operating conditions in the sulphuric acid process.

SuLfoMax SuLfoMax hv SuLfoMax CS


V2O5 6.5 - 7.5 7.5 - 8.5 6.5 - 7.5

K2O 9.5 - 11.0 10.0 - 11.5 Proprietary

Shape Ribbed Rings/ Extrusions

Ribbed Rings/ Extrusions

Ribbed Rings/ Extrusions

Size [mm] 9 9 9

C0

613

Clariant international ltd

Rothausstrasse 614132 MuttenzSwitzerland

Catalysts

[email protected]

www.Catalysts.Clariant.Com

This information corresponds to the present state of our knowledge and is intended as a general descrip-tion of our products and their possible applications. Clariant makes no warranties, express or implied, as to the information’s accuracy, adequacy, sufficiency or freedom from defect and assumes no liability in connection with any use of this information. Any user of this product is responsible for determining the suitability of Clariant’s products for its particular application.* Nothing included in this information waives any of Clariant’s General Terms and Conditions of Sale, which control unless it agrees otherwise in writing. Any existing intellectual/industrial property rights must be observed. Due to possible changes in our products and applicable national and international regulations and laws, the status of our products could change. Material Safety Data Sheets providing safety precautions, that should be observed when handling or storing Clariant products, are available upon request and are provided in compliance with applicable law. You should obtain and review the applicable Material Safety Data Sheet information before handling any of these products. For additional information, please contact Clariant.

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Catalysts for - CLARIANT/media/Files/Solutions/Products/Brochures/A/19/... · The LTS catalysts ShiftMax 230 and ShiftMax 240 are state-of-the-art products featuring excellent copper