naphtha brochure katalco

KATALCOJM 46-series catalysts

Steam reforming catalysts for

naphtha containing feeds

Katalco

JM_1073_982 aNaptha Brochure 4/5/06 10:42 am Page 2

Contents

Page

The naphtha steam reforming process 1

KATALCOJM™ 46-series steam reforming catalysts 2

Features, benefits and applications of KATALCOJM 46-series 3

Typical reformer loadings with KATALCOJM 46-series 4

Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of

going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the product for its own particular

purpose. Johnson Matthey plc (JM) gives no warranty as to the fitness of the Product for any particular purpose and any implied

warranty or condition (statutory or otherwise) is excluded except to the extend that exclusion is prevented by law. JM accepts no

liability for loss or damage (other than that arising from death or personal injury caused by JM’s negligence or by a defective

Product, if proved), resulting from reliance on this information. Nothing here in should be considered to provide freedom to

operate under any Patent.


Tube inlet

Thermal dissociation of the most easily cracked components

of heavy naphtha occurs on all hot surfaces within the

reformer. This process can produce the carbon on the

external surface of catalyst pellets and on the metal

surfaces of the reformer tube:

CXHY CX+ (y/2)H2

Catalytic induced cracking of naphtha produces a variety of

olefins together with methane and hydrogen:

CXHY CH4 + Cx-1 H2X-2 + H2

Polymerisation of these intermediate olefins can lead to the

formation of carbon rich deposits.

The most important feature of the naphtha steam reforming

process at the inlet of the reformer is the potential for

carbon deposition. With very heavy naphtha feeds this zone

of heavy carbon deposition can stretch down to the middle

of the reformer tube. With lighter naphtha feeds the

cracking reactions only occur near the inlet of the tube.

Catalysts for this zone of the reformer must be designed to

prevent carbon deposition. However, the catalysts must also

have great strength in order to resist the impact of a process

upset which could cause gross carbon deposition and to

allow the catalysts to be steamed for prolonged periods in

order to remove the carbon deposits.

Tube middle

With heavy naphtha feedstocks a small amount of thermal

cracking can still be found within the middle zone of the

reformer. This does not occur with lighter naphtha feeds.

Catalytic induced cracking of hydrocarbons is usually

completed within the middle zone of the reformer.

The naphtha steam reforming processThe middle zone of the reformer is dominated by the steam

reforming reactions, which transform the methane and

olefins produced at the inlet of the reformer into carbon

monoxide and hydrogen.

CH4 + H20 CO + 3H2

CX-1 H2X-2 + (x-1) H2O (x-1)CO + (2x-2) H2

It is important that these reactions occur rapidly since the

build up of high concentrations of olefins in the lower, higher

temperature, zones of the reformer can cause carbon

deposition.

Catalysts for this zone of the reformer must have a

propensity to resist carbon deposition, which matches the

carbon forming potential of the hydrocarbon feedstock.

That is, high levels of promoters will be required on duties

involving heavy naphthas while lower levels of such materials

will be required for lighter naphthas or mixed feeds.

Tube exit

At the exit of the reformer the methane and olefin steam

reforming reactions are carried out until the system reaches

close to equilibrium conversation.

CH4 + H20 CO + 3H2

The water-gas shift reaction is also brought to equilibrium in

this zone of the reformer tube:

CO + H20 C02 + H2

This zone of the reformer is generally at very low risk of carbon

deposition but high activity catalysts are required to bring

the system close to equilibrium. However, olefin slip from

the middle zone of the reformer, which is most likely during

process upsets, can provide the potential for carbon formation.


2

• The KATALCOJM 46-Series catalyst range consists of three

distinctive catalysts, which are used in different combinations

depending on the nature of the hydrocarbon feedstock.

- Heavy naphtha feedstocks require a combination of

KATALCOJM 46-3Q and KATALCOJM 46-6Q

- Light naphtha feedstocks permit the use of

KATALCOJM 46-3Q, KATALCOJM 46-5Q and

KATALCOJM 46-6Q

- Mixed feedstocks, which involve the occasional use of

light naphthas, also use KATALCOJM 46-3Q,

KATALCOJM 46-5Q and KATALCOJM 46-6Q

KATALCOJM 46-Series steam reforming catalysts• All of the catalysts are manufactured with a distinctive

QUADRALOBE™ design

• Two types of QUADRALOBE design are used in the

KATALCOJM 46-Series catalysts

- KATALCOJM 46-3Q is produced as a high strength

QUADRALOBE pellet

- KATALCOJM 46-5Q and KATALCOJM 46-6Q are

produced as high activity QUADRALOBE pellets

• The chemical composition of each catalyst is individually

tailored to meet the different demands of the inlet

(KATALCOJM 46-3Q), middle (KATALCOJM 46-5Q) and exit

zones (KATALCOJM 46-6Q) of a naphtha steam reformer.

46-3Q 46-5Q 46-6Q

Form High Strength QUADRALOBE High Activity QUADRALOBE High Activity QUADRALOBE

Pellet length (mm) 15.0 17.0 17.0

Pellet O.D. (mm) 16.5 13.0 13.0

Hole diameter (mm) 3.7 3.5 3.5

Typical loaded density (kg/l) 1.05 0.89 0.89

Typical average crush strength (kg) 100 60 60

(radial)

Summary of typical catalyst physical properties

Summary of typical catalyst chemical properties

46-3Q 46-5Q 46-6Q

Form High Strength QUADRALOBE High Activity QUADRALOBE High Activity QUADRALOBE

NiO% 23 20 16

K2O% 7 2 0

ZrO2% 0 0 Proprietary

Support Balance Balance Balance


3

Features, benefits and applications of

KATALCOJM 46-Series

Catalyst features

KATALCOJM 46-3Q

• Produced in a large, high strength (average

crush strength > 100kg), version of the

QUADRALOBE pellet shape.

• The catalyst contains 7wt% of a potash promoter

in the form of a complex mineral phase. This

unique ingredient provides a mobile form of potash,

which ensures that carbon removal reactions are

promoted across the catalyst surface, within pores

and on the internal walls of the reformer tube.

KATALCOJM 46-5Q

• Produced in a smaller, higher activity, version

of the QUADRALOBE pellet shape. This shape

ensures that a large catalyst surface area is made

available for reaction within the reformer tube.

• The catalyst contains 2wt% of a potash promoter

intimately bonded as a mineral within the

support material.

• The catalyst contains an elevated concentration

of nickel (20% NiO)

KATALCOJM 46-6Q

• Produced in the small, high activity, version of the

QUADRALOBE pellet shape. This shape ensures

that a large catalyst surface area is made

available for reaction within the reformer tube.

• The catalyst contains a small concentration of a

special zirconia promoter. However, olefin slip

from the middle zone of the reformer, which is

most likely during process upsets, can provide

the potential for carbon formation.

Operational benefits

KATALCOJM 46-3Q

• The high strength QUADRALOBE shape

provides an assurance of robust and durable

performance at the inlet of the reformer when

operating on naphtha feeds.

• Potash is the best available promoter to

ensure carbon free operation when naphtha

feedstocks are to be processed. The unique,

mobile potash promoter within

KATALCOJM 46-3Q ensures that carbon

deposition is prevented on every hot surface

within the reformer tube.

KATALCOJM 46-5Q

• With lighter naphtha feeds, where the potential

for carbon deposition is reduced,

KATALCOJM 46-5Q can be substituted for

KATALCOJM 46-3Q in the middle zone of the

reformer tube. The lower concentration of

potash in KATALCOJM 46-5 is sufficient to resist

carbon deposition from light naphthas while the

high activity QUADRALOBE shape provides a

higher catalytic activity than is achievable with

KATALCOJM 46-3Q. Higher plant through puts

are therefore achievable if KATALCOJM 46-5 can

be used in the middle of the reformer tube.

• In plants with variable feedstocks, in which

a heavy naphtha will never be processed,

KATALCOJM 46-5Q will often be substituted for

KATALCOJM 46-3Q in the middle zone of the

reformer tube. The high nickel and lower potash

concentrations within KATALCOJM 46-5Q ensure

high activity for gaseous feeds while maintaining

resistance to carbon deposition if light naphtha

feeds are processed.

KATALCOJM 46-6Q

• This high activity catalyst minimizes methane

slip from the reformer when operating on

heavy naphtha, light naphtha or on variable

feedstocks. The catalyst maximizes hydrogen

production from the reformer while making

certain that any threat of carbon deposition in

the lower zones of the reformer tube is

minimized.

Plant applications

KATALCOJM 46-3Q

• If carbon deposition occurs during a process

trip then KATALCOJM 46-3Q will remain

physically intact. A prolonged steaming process

can then be used to remove the carbon

deposits. At the end of this procedure the

KATALCOJM 46-3Q pellets will be physically

intact and the pressure drop through the

reformer will not have increased.

• The potash promoter will allow a heavy naphtha,

with a final boiling point of 180°C, to be

processed at a steam/carbon ratio of only

3.5 without risk of carbon formation.

• The potash promoter will allow a light naphtha,

such as a pentane rich feed, to be processed

at a steam ratio of only 2.6 without risk of

carbon formation.

KATALCOJM 46-5Q

• With a pentane rich feedstock, the use of

KATALCOJM 46-5Q in the middle section of a

reformer tube will provide a 20% increase in

throughput above that which is attainable by

using KATALCOJM 46-3Q throughout the inlet of

the reformer. The improved throughput will be

obtained with no increased risk of carbon

formation.

• When the lighter, gaseous, component of a mixed

hydrocarbon feedstock is being processed then

high tube wall temperatures can be encountered.

However, by using KATALCOJM 46-5Q in the

middle section of the reformer the high activity of

this product ensures that the high tube wall

temperatures are reduced to acceptably low

levels. The use of KATALCOJM 46-5Q therefore

prolongs tube life on plants which process mixed

hydrocarbon feeds.

KATALCOJM 46-6Q

• Any plant that processes naphtha-containing

feedstocks runs the risk of experiencing a trip

or process upset, which could force heavy

hydrocarbons towards the exit of the reformer.

By using KATALCOJM 46-6Q in this zone of the

reformer the risk of carbon deposition from

such an event is minimised.

Tube inlet Tube middle Tube exit


4

Tube

46-3Q

Tube

46-6Q

Tube Inlet

46-3Q

Tube Exit

46-6Q

Tube Middle

46-5Q

Catalysts for heavy naphtha duties

The catalyst combination which delivers premium

performance when heavy naphtha is the only plant

feedstock is a 50:50 loading of KATALCOJM 46-3Q and

KATALCOJM 46-6Q.

Catalysts for duties involving light naphthas

If a heavy naphtha will never be used as the process

feedstock then the risk of carbon formation in the middle

zone of the reformer tube is significantly reduced. Therefore,

if a light naphtha feedstock (such as a pentane rich

material) is to be processed then it is possible to substitute

KATALCOJM 46-5Q instead of KATALCOJM 46-3Q in the

middle section of the reformer tube. Hence, the catalysts

which deliver premium performance when a light naphtha is

the heaviest hydrocarbon feedstock is a ‘triple-decker’

loading of KATALCOJM 46-3Q, 46-5Q and 46-6Q.

KATALCOJM 46-series catalysts should be used whenever a

plant desires the flexibility to process a naphtha feedstock at

some time during its operations. This range of catalysts is

uniquely designed to provide the combination of carbon

resistance, strength and activity which is required for the

steam reforming of naphtha. No other catalysts will deliver

the benefits associated with KATALCOJM 46-series products

and, even if naphtha is no more than an occasional feed

material, then only the 46-Series catalysts should be

considered for these type of duties.

Typical reformer loadings with KATALCOJM 46-Series


PO Box 1

Belasis Avenue

Billingham

Cleveland

TS23 1LB

UK

Tel +44 (0)1642 553601

Fax +44 (0)1642 522542

Oakbrook Terrace

Two Transam Plaza Drive

Chicago

Illinois 60181

USA

Tel +1 630 268 6300

Fax +1 630 268 9797

For further information on Johnson Matthey Catalysts, contact your local sales office or visit our website at www.jmcatalysts.com

KATALCO and QUADRALOBE are trademarks of the Johnson Matthey group of companies..

www.jmcatalysts.com© 2006 Johnson Matthey Group

928JM/0406/1/AMOG


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