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A Clariant Group Company
Pre Reformer Catalyst ReforMax ® 100
Parallel Reformer CatalystReforMax ® PRC-T
Catalyst Seminar 2016
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group CompanyPre-Reforming : • Feed stock flexibility like Naphtha/ LPG/Natural Gas & off gases
• Capacity enhancement up to 20% in existing units depending upon feedstock.
• Absence of C2+ → Allows higher inlet temperature (~650°C) at Reformer Inlet → Reduction in Radiant Heat → Improved Net Thermal Efficiency up to 4%
• Quick Start Up of Pre Reformer→ Pre Reduced State → Zero Startup time
• No special start up for downstream Reformer Catalyst (like reduction) & ease of overall plant operation and eliminating associated problems of Potash Leaching
• Enhanced lifetime of Steam Reformer catalyst, MT/LT Shift Catalysts & Reformer Tubeas sulphur and other poisons are arrested by pre-reforming catalyst
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group Company
Challenges Faced by Pre Reformer Catalyst Catalyst Poisoning
Activity at High LHSV
Temperature Window
Minimum S/C Ratio
Thermal Stability at Higher Temperatures
Structural Integrity
Steaming of Catalyst for Carbon/Sulphur removal
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group CompanyReforMax® 100The 3rd Generation Pre-Reforming Catalyst
To overcome the challenges…
Catalyst Poisoning
Activity at High LHSV Temperature Window Minimum S/C Ratio Thermal Stability at Higher Temperatures Structural Integrity Steaming of Catalyst for Carbon/Sulphur removal
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group CompanyCase Study 1 :World’s Highest LHSV’s (6.3 & 5.5 hr )
• Location: India• Plant type/capacity: Hydrogen, 28,000 Nm³/h• Reactor design: Linde• LHSV : 6.3 hr• Start-up of ReforMax® 100: July 2016• Feed : SR Naphtha
SITUATION BENEFIT OF INSTALLING REFORMAX® 100
SPECIFIC CUSTOMER NEED
• Stable plant operation and a catalyst lifetime of more than 12 months • Results: Design Life, months 12
Süd-Chemie, months 21Competition, months 11
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• Other Reference, LHSV : 5.5 hr
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-1
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0 10 20 30 40 50 60 70 80 90
SOREORB
ed T
empe
ratu
res
Thermocouples
A Clariant Group CompanyCase Study 2 : Thermal Stability -High Temperature Operation
• Location: China• Plant type/capacity: MeOH, 2500 MTPD• Reactor design: Davy• Inlet Temperature : 575 °C• Start-up of ReforMax® 100: Apr 2015• Feed : Natural Gas
SITUATION BENEFIT OF INSTALLING REFORMAX® 100
SPECIFIC CUSTOMER NEED
• Stable plant operation at high inlet temp, allowing a catalyst lifetime >12 months
• Pre Reformer Temperature Profile
• Results: Design Life, months 12
Expected Life, months >16
A Clariant Group CompanyCase Study 3:Feed Flexibility with Mixed Feed (Naphtha + NG + Off Gas)
• Location: India• Plant type/capacity: Hydrogen, 98,000 Nm³/h• Reactor design: HTAS• Start-up of ReforMax® 100: May 2013• Reaction conditions:
SITUATION BENEFIT OF INSTALLING REFORMAX® 100
SPECIFIC CUSTOMER NEED• Stable and flexible plant operation at
different feeds feeds allowing lifetime of more than 24 months
• Pre Reformer Temperature Profile
• Results: Design Life, months 24
Expected Life, months > 48
Mixed feed operation
A Clariant Group CompanyCase Study 4:World’s Lowest Steam-to-Carbon Ratio
• Location: Malaysia• Plant type/capacity: MeOH, 5000 MTPD • Reactor design: Air Liquide• S/C : 1.0• Start-up of ReforMax® 100: Oct 2015• Feed : Natural Gas (C2+ - 10.5 mol%)
SITUATION BENEFIT OF INSTALLING REFORMAX® 100
SPECIFIC CUSTOMER NEED
• Stable performance at low steam to carbon ratio with improved life cycle
• Pre Reformer Temperature Profile
• Results: Design Life, months 18
Süd-Chemie, months >36Competition, months 22
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Bed
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ture
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Thermocouples
A Clariant Group CompanyCase Study 5:Steam Starvation and Reactivation by Steaming
• Location: India• Plant type/capacity: Hydrogen, 50,400 Nm³/h• Reactor design: NTD• Feed: Naphtha• Start-up of ReforMax® 100: September 2014
SITUATION BENEFIT OF INSTALLING REFORMAX® 100
SPECIFIC CUSTOMER ISSUE• During start-up activities: Pre-Reformer bed
temp ~460°C under N2 circulation
• Naphtha passed over Pre-Reformer in the absence of steam & bed temp went up to 700°C and remained there for >8 hours
• Corrective action and outcome: ReforMax® 100 steamed and re-reduced Carbon removal (CO2 Nil @exit) & unit start up
No activity loss & pressure drop issue Nil C2+ slip & excellent performance until today
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Normal OperationAfter IncidentB
ed T
empe
ratu
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Thermocouples
A Clariant Group Company
• Available also in highly active & low pressure drop Five Hole shape
ReforMax® 100 FHLower Differential Pressure Drop
Size, mm Shape Relative Delta P 4.7 x 4.7 Tablets 1.0011 x 5 x 2 5 hole 0.38
Operating Reference : Dakota Gasification Company, USAOn stream since September 2015
A Clariant Group CompanyReforMax® 100 Operating References (Ammonia)
Company Name Location Country Capacity Unit Onstream Date
CNOOC Fudao Hainan China 1,500 MTPD May 2010IFFCO-Kalol Kalol India 1,125 MTPD Apr 2008Jinxi Natural Gas Chemical Liaoning China 1,000 MTPD Sep 2006NFL-Vijaypur Vijaipur India 1,850 MTPD Apr 2010Petrochina Ningxia Petrochemical Ningxia China 1,000 MTPD Mar 2014Yara Belle Plaine Belle Plaine Canada 2,200 MTPD Sep 2015Yara Sluiskil Sluiskil D Netherlands 1,500 MTPD Nov 2014Yara Sluiskil Sluiskil Netherlands 1,500 MTPD Nov 2012Yara Sluiskil Sluiskil C Netherlands 1,000 Nm³/h Sep 2015Yara Tertre Tertre Belgium 1,150 MTPD May 2014
More than “125” ReforMax® 100 Pre-Reformer Charges supplied amongAmmonia, Hydrogen, Methanol & HYCO Plants Worldwide
A Clariant Group CompanyReforMax® 100 Operating References (India Region - Refineries )Technip / Linde/ Uhde Design
HTAS Design
Hydrogen Plant IOCLA
IOCLB
HPCLA
IOCLC
IOCLD
Capacity, TPA 25,000 75,000 36,000 20,000 75,000Feed Naphtha Naphtha Naphtha Naphtha Naphtha
LHSV 3.3 5.5 1.5 6.3 2.6
HydrogenPlant
BPCLA
IOCLE
IOCL F
IOCLG
IOCL H
IOCL I
IOCLJ
IOCLK
Capacity, TPA 49,500 11,000 15,000 38000 70,000 70,000 34000 72500
Feed Naphtha/NG
Naphtha Naphtha Naphtha/NG Naphtha/NG
Naphtha/NG
Naphtha NG
LHSV 2.1 1.8 1.8 2.3 2.4 2.4 2.2 2.6
ReforMax 100 is holding 59% of Market Share across Indian Refineries
A Clariant Group Company
• Operation with diverse feeds like Naphtha, Natural Gas & other off gases
• Can be steamed for carbon & sulphur removal and re-reduced for activation without any magnesia hydration Issue.
• Proven operating references with high LHSV due to higher Ni surface area
• Track Record with long life versus Design with better coke resistance
• Excess sacrificial nickel offers resistance to Sulphur Poisoning.
• Thermal stability at elevated temperature
• Robust tablet integrity for sustainable pressure drop & to withstand operational upsets
ReforMax® 100 - Unique FeaturesThe 3rd Generation Pre-Reforming Catalyst
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group Company
Typical Configurations :• Reforming Heat Exchanger - Shell and Tube• Tubes filled with tailor made customized catalyst• Driving heat duty from effluent of Secondary reformer• Low differential pressure drop
Parallel Reformer – More Ammonia by Energy Substitution
Source : http://jpkc.zzu.edu.cn/ehgrlx/109-thermodynamics/Square/
Süd-Chemie offering Parallel Reforming Catalyst “ReforMax PRC – T”
• KRES (KBR’s Reforming Exchanger System)• TPR (Technip Parallel Reformer)
TM
Key features of ReforMax PRC – T :
• Alkalized/ Non-Alkalized to minimize the potential of carbon formation.
• Customized in size ranging from 8 mm to 20 mm with Multi – Hole Rings
• Calcium Aluminate as carrier material to ensure efficient Heat Transfer Properties
®
A Clariant Group CompanyTable of Contents PRE-REFORMING
CHALLENGES TO PRE-REFORMING
REFORMAX® 100 - THE 3RD GENERATION PRE REFORMING CATALYST
USER’S INTERFACE / CASE STUDIES
PARALLEL REFORMING
CATALYST ARRAY & CONFIGURATIONS
A Clariant Group Company
Operating Conditions with “ReforMax PRC-T” Series• Feed : Natural Gas, Light Hydrocarbons & Naphtha• Operating Temperatures, °C : Thermodynamically Optimized• Steam To Carbon (mol/mol) : Thermodynamically Optimized• CH4 Slip, % mol dry : Thermodynamically Optimized• Operating Pressure, Kg/cm2 : As designed
• Expected Life, Years : 6+
Global Operating References :
• Kitimat, Canada : Start Up on 1994 (Replaced - May 2000)• Liaohe, China : Start Up on 2003• CFCL Ammonia-1, India : Start Up on 2009• PCS Lima, USA : Start Up on 2015• Petronor, Spain : Start Up on 2016
Typical Parallel Reformer Conditions
A Clariant Group Company