Parallel Reformer Catalyst ReforMax - sud-chemie …. PRE_PAR… · Parallel Reformer Catalyst...

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





PARALLEL REFORMING


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





PARALLEL REFORMING



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





PARALLEL REFORMING


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





PARALLEL REFORMING


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

-1

• Other Reference, LHSV : 5.5 hr

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SOREORB

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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



• 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:


SPECIFIC CUSTOMER NEED• Stable and flexible plant operation at

different feeds feeds allowing lifetime of more than 24 months



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%)



• Stable performance at low steam to carbon ratio with improved life cycle



Süd-Chemie, months >36Competition, months 22

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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


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

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• 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


• 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





PARALLEL REFORMING



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

®





PARALLEL REFORMING



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


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