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KATALCOJM a commitment to excellence
For many years, methanol has been used primarily as a Within the methanol industry, Johnson Matthey is seen as the
chemical intermediate in manufacturing plastics and resins, world leader with the greatest depth and breadth of knowledge.
then more recently in the manufacture of methyl tertiary This position has been developed through a combination of its
butyl ether (MTBE). However, now methanol is being seen as own technology and catalyst development efforts alongside the
a product that can be introduced directly into the gasoline experience gained from the large number of plants that use
pool by blending. This allows indigenous resources to be used them. It has been further underpinned by operating experience
and provides a diversity of supply that can help to reduce in the methanol plants formerly operated by ICI, which ensures
dependence on crude oil. that Johnson Matthey understands your needs as a plant
operator better than any other catalyst or technology provider.
The methanol industry as we know it today is based almost
entirely around the technology and catalysts developed and Our focus is on delivering the best plant performance in
commercialized by ICI in the late 1960s. Since that time, the world. We have on-going development programmes
Johnson Matthey (having acquired the ICI catalyst business and producing new and better catalysts and improving the process
then Davy Process Technology now known as Johnson Matthey technology for the methanol industry. Our applications
Davy Technologies (JM Davy)) has invested enormous resources know-how and services enable the best performance to be
in R&D to ensure that the technology has adapted to meet our achieved from these products. The overall impact of Johnson
customers’ needs. KATALCOJMTM methanol catalysts are more Matthey’s new catalysts and technology can be to improve
active, more selective and more robust, to give you the highest methanol plant costs by millions of dollars every year.
plant rates, longest run time and the best value for money.
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Purification feed and syngas
Mercury removal
PURASPEC JM 1156
absorbent
Organic sulphur
KATALCOJM 61-1T
removal - HDS
Johnson Matthey offers our range of KATALCOJM For methanol plants using a coal feedstock and gasification
purification absorbents and catalysts, which ensures technology, we can again offer KATALCOJM and
optimized systems for meeting individual plant PURASPEC JM purification solutions to remove impurities
requirements. In addition through our range of such as chloride and sulphur after the RECTISOLTM
PURASPEC JMTM catalysts and absorbents we can provide or SELEXOLTM acid gas removal system, upstream of
mercury removal down to ppb levels, low temperature methanol synthesis.
H2S removal absorbents and ultrapurification down to
ppb levels of sulphur to protect even the most sensitive KATALCOJM 33-1 is the latest addition to our purification
of downstream catalysts, including pre-reforming and range. It is a 3-in-1 total sulphur removal product, which
methanol synthesis catalysts. combines the functionality of organic sulphur conversion,
high capacity sulphur removal, and low level sulphur
polishing (ultrapurification) in a single product. The
versatility of KATALCOJM 33-1 allows it to be deployed in
methanol plants in numerous ways, as a single product or
in conjunction with conventional purification products.
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By using KATALCOJM 33-1, the total
catalyst volume can be reduced while still
achieving the required life. Further savings
are also realized from much easier loading
and discharge, and no requirement for
pre‑sulphiding of the HDS catalyst or
reduction of the ultrapurification catalyst.
5
Pre-reforming
catalysts
CRG LHR
CRG LHCR
Johnson Matthey has been associated with CRG LHR is available in two distinctive shapes.
pre-reforming catalysts since the 1960s and together The exceptionally high geometric surface area that
with JM Davy offers the CRG series of catalysts which is produced by the small standard cylindrical pellet
have been demonstrated to be the most active and delivers outstanding catalytic activity and allows
robust commercially available products. In methanol the construction of relatively small pre-reforming
plants, operating on natural gas feeds, the use of high reactors. However, where pressure drop must be
pre-reformer inlet temperatures allows the maximum minimized, the unique microcloverleaf shape, CRG
amount of heat recovery from the steam reformer flue LHCR provides low pressure drop characteristics
duct giving an economic benefit through improved in combination with high pre-reforming activity.
thermal efficiency of the process. In addition, by
transferring the maximum amount of reforming duty
into the pre-reformer, the size of the primary reformer
is reduced which results in a lower capital cost.
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CRG pre-reforming
technology delivered
increased production and
lower energy consumption
on a syngas plant.
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Steam reforming
Nickel oxide on
KATALCOJM 23-4 series
alpha alumina
Nickel oxide on
KATALCOJM 57-4 series
calcium aluminate
Johnson Matthey manufactures three main catalysts for Selecting the right catalyst for your application is
use in steam reformers using a natural gas feedstock: essential for good reformer performance. Johnson
Matthey will make detailed recommendations based
KATALCOJM 25-series, 23-series and 57-series
upon your individual operating conditions ensuring
catalysts. Johnson Matthey reforming catalysts
reliable optimal performance of your reformer.
are made in a range of sizes, allowing optimum
reformer loading for each individual plant. For naphtha feedstocks Johnson Matthey also
manufactures KATALCOJM 46-series.
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Reformer services
Through KATALCOJM PERFORMANCE we want you to get
the most from our catalysts. We optimize each application
using our world-leading modelling capability and support
the operation of your reformers with a wide range of
services including process consultancy, mechanical design
consultancy and other engineering services that are used
to help solve customer problems.
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Autothermal reforming
10
Autothermal
reformer services
100 The performance of an autothermal reformer is related
90
not just to the catalyst performance but also the burner
80
and the mixing space above the catalyst bed as well as the
Pressure drop, kPa
70
60 integrity of the refractory lining system of the reformer.
50
40
30
We have the right combination of expertise and practical
20 experience to help our customers determine the cause
10 of any under performance and develop reliable systems.
0
0 2 4 6 8 10 12
We have also combined our catalysis, CFD and
Months on line
mechanical design skills to resolve autothermal
KATALCOJM Previous
reformer and transfer main “hot spot” problems.
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Sour shift
KATALCOJM K8-11
KATALCOJM K8-11 HA
The production of syngas using gasification or partial Johnson Matthey’s experience in the application of
oxidation differs considerably from that using catalytic sour shift catalyst downstream of gasifiers puts us in an
steam reforming. Depending on the feed and process ideal position to provide advice on the optimum system
configuration, the raw syngas will have a high CO configuration, including the appropriate number of
content and, it is likely that it will also have high sulphur reaction stages, the use of bypasses, steam requirements
content. This gas needs to be shifted and the excess and heat recovery options. For instance, at large plant
CO2 removed to achieve the desired hydrogen to capacities, the use of radial flow reactors may allow
carbon oxides ratio, and this requires the use of a the use of a single reactor instead of multiple parallel
sulphur tolerant shift catalyst. Johnson Matthey is the axial reactors, so reducing installed plant cost. Johnson
world’s leading supplier of sour shift catalysts with the Matthey is able to provide a sour shift catalyst customized
KATALCOJM K8-11 series of products. These catalysts are for radial flow applications (KATALCOJM K8-11R) along
particularly robust and can withstand sharp temperature with proven designs of internals for radial flow reactors.
changes, high steam partial pressures and the effect
of contamination from impurities in the raw gas.
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Johnson Matthey’s experience
in sour shift applications means
optimum system configurations
for our customers.
13
Methanol synthesis
catalysts
KATALCOJM 51-7
KATALCOJM 51-8
KATALCOJM 51-8PPT
KATALCOJM 51-9
KATALCOJM 51-9S
The KATALCOJM 51-series of catalysts is key to the The latest in this series, KATALCOJM 51-9S, is particularly
methanol technologies offered by Johnson Matthey suited to highly stressed duties with its activity, strength
and JM Davy. KATALCOJM 51-1 and the LPM and selectivity.
process revolutionized synthetic methanol production
in the 1960s and have provided the majority of The high activity and stability of KATALCOJM 51-series
the world’s production ever since that time. These catalysts means that typically a charge lasts between
technologies currently account for an annual production four and six years, but some charges have been in
capacity of over 30 million tonnes of methanol. operation for more than 8 years. Their strength enables
them to withstand the rigours of this extended operation
KATALCOJM 51-1 was the first three-component and as a result they show little change in pressure
methanol synthesis catalyst comprising zinc oxide and drop and are easily discharged at the end of life.
alumina as the support with copper as the active catalytic
component. Successive generations of KATALCOJM
51-series catalysts have been developed to give increasing
activity, selectivity and stability, so ensuring ever more
efficient operation whatever the source of syngas.
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KATALCOJM APICO
methanol synthesis
methanol production
Most
KATALCOJM APICO 51-100
M
or
Least by-products
em
eth
a
-up
nol
Ever since ICI turned synthetic methanol manufacture on its
start
and imp
head with the introduction the first copper-based methanol
Fastest
Pre-reduced Highest
roved efficiency
catalyst activity
synthesis catalyst and the LPM process, catalysts have
continued to develop organically. Until now that is. Johnson
Matthey has introduced its new methanol synthesis
catalyst, the KATALCOJM APICOTM range, which represents
the biggest single leap forward; bigger than the sum of all
ges
Strongest Slowest
Low
n
ha
the incremental improvements over the last 40 years.
est
tc
ra
lys
te
fp a
ta
tc
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res
su es
Made on a new, state-of-the-art catalyst manufacturing re
d d few
rop an
plant at Clitheroe, Lancashire, the catalyst offers: in creas tl ives
e Longes
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Leading edge syngas
technologies
Since the acquisition of JM Davy by Johnson Matthey in 2006, Syngas generation technologies
we now have the most extensive portfolio of catalysts and
technologies for syngas preparation and methanol production. With the wide range of expertise available
Our complementary skills and capabilities allow us to provide: within Johnson Matthey, our portfolio of syngas
generation technologies is extensive.
∆ world-class technology
∆ Steam methane reformers (SMRs)
∆ high performance catalysts While this technology has been around for a long time,
∆ conceptual design and licensing conventional SMRs have been undergoing a continual
process of improvement. The largest methanol plant
∆ basic and detailed engineering in the world based on natural gas is the Methanol
∆ commissioning and start-up Holdings (Trinidad) Limited M5000 plant. Based on LPM
technology, this plant started up in 2005, produces 5,000
∆ on-going operational support.
tpd of methanol from a single SMR, and represents the
benchmark for future technology development in this field.
Johnson Matthey offers the technology most suited to
customer requirements. Whether a client wants large or small ∆ Autothermal reformers (ATR)
capacity in high or low cost gas areas, to build on a ship that Johnson Matthey’s 30+ years of experience was gained
will access gas from remote fields, or to use syngas generated on air and oxygen blown autothermal refomers (ATRs)
from coal as a feedstock, the technology exists within Johnson including the Coogee LCM plant in Australia. Our unique
Matthey and JM Davy to meet these requirements. design of ATR has proven its reliability and durability
over many years in both oxygen and air fired service.
Use of the Johnson Matthey LPM technology has increased All elements from the burner and distribution system,
steadily over the years and it is the preferred methanol production through to the refractory lining, catalyst and refractory
technology, with its unrivalled reliability and on-stream factor. support arch, deliver long term trouble-free performance.
∆ Combined reforming
Combined reforming incorporates the steam
methane reforming process and the ATR. The
technology is particularly applicable for use on large
capacity plants using light natural gas. Two versions
of this concept have quite different features.
M5000 reformer
16
Coogee LCM plant
Compact
in Australia
reformer
in Alaska
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Leading edge methanol
technologies
Methanol synthesis technologies ∆ Radial flow steam raising converter
This steam raising converter is a radial flow reactor with
A number of reactor designs and synthesis flowsheet
catalyst outside and steam inside the tubes. In the JM
arrangements for methanol production can be utilized.
Davy design, fresh feed gas enters at the bottom of the
reactor and into a central perforated-wall distributor pipe.
∆ Tube cooled converter
The gas then flows radially out through the catalyst bed.
The tube cooled converter is a simple reactor which uses
Water from a steam drum enters at the bottom of
the feed gas to the reactor to control the temperatures
the vessel, and flows upwards through the tubes where
in the catalyst bed. Fresh feed gas enters at the bottom
it is partially vaporized, removing the heat generated
of the reactor and is preheated as it flows upwards
by the reaction before returning to the steam drum.
through tubes in the catalyst bed. The heated feed gas
leaves the top of the tubes and flows down through The reaction temperature is controlled by varying the steam
the catalyst bed where the reaction takes place. pressure inside tubes embedded in the catalyst bed.
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∆ Axial flow steam raising converter Distillation technologies
The axial flow steam raising converter is a different
design in which the catalyst is contained within the Dependent on the grade of methanol required, there
tubes with boiling water on the outside. As for the are different options for methanol distillation. To produce
radial reactor, the reaction temperature is controlled DME or MTO-grade methanol, only a single column
by varying the steam pressure. This arrangement is required to remove the dissolved gases and some
gives excellent cooling of the catalyst bed and allows of the light by-products. To produce refined methanol
steam to be generated at the maximum possible for chemical or fuel usage, for example Federal AA
pressure without overheating the catalyst. and IMPCA grade methanol, a two or three column
refining system is used. The three-column system uses
The reactor does however require thick tube sheets the least heat so is preferred where energy costs are
that limits the maximum capacity of the reactor to high or the heat for distillation is not readily available.
around 1,500 tpd and requires a large number of
tubes to accommodate the catalyst. This tends to limit
the use of this type of reactor to those applications
where its high heat transfer performance is required,
e.g., in certain coal gasification based flowsheets.
Shenhua methanol
synthesis
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Further development
We continue to drive the improvement of our processes and
to develop new ones that will continue to lower the installed
cost, improve efficiency to make better use of the natural
resources and minimize the impact on the environment.
It is also important that catalyst and new technology
developments keep pace with one another to ensure that
the process can operate at its optimum efficiency and
maintain or increase the time between plant turnarounds.
China Blue
Chemical Company
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Product realization:
From the laboratory to the plant
Catalysts and processes are developed in laboratory Johnson Matthey has teams focusing on the catalysts for
reactors, semi-technical units and side-stream reactors each plant reactor and targeting performance
specifically designed to simulate accurately the important improvements driven by customers’
features of operation in full scale plants. The catalysts requirements. Each area
are then finally proven at commercial scale before being has a dedicated team of
incorporated into the Johnson Matthey KATALCOJM experienced scientists.
and PURASPEC JM sales range. Research and
development activities
New catalysts continue to deliver significant plant
in Johnson Matthey’s
improvements. Every catalyst activity improvement
catalysis research,
enables a corresponding potential increase in plant rate,
technology and
and can also deliver a longer life before current end
engineering centre
of run conditions are achieved. Lower pressure drop
at Billingham, UK,
options enable plant rate and efficiency improvements.
benefit directly from
For steam reforming catalysts, improved heat transfer
the close interaction of
reduces the temperature of reformer tubes, extending
chemists and physicists
the time between costly renewal. Better poison pick-ups
with engineers who have
extend absorbent lives and improve the performance of
plant operations experience.
downstream catalysts.
There is close co-operation between the
teams involved in fundamental research, catalyst
development, catalyst manufacture, and synthesis gas
production. Catalyst development is supported by the
most modern techniques in applied surface science.
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The elements of sustainability
Sustainability is a core part of our business strategy. It is about the plan its third century of business. Sustainability is about making
way we do business – using natural resources efficiently to make the right decisions for our people, our communities,
products that improve the environmental performance of our our shareholders and, most significant of all, for the planet.
customers’ products and processes.
As we progress towards 2017, we are managing sustainability
But our view of sustainability extends beyond this. It’s also about according to five elements:
the health, safety and wellbeing of the people who work for us,
our customers and our communities. It means using resources
∆ Social
efficiently, innovatively and effectively, striving to achieve the ∆ Environment
highest environmental standards in our own operations. At ∆ Health and Safety
the same time sustainability is about delivering value to our ∆ Governance
shareholders and our customers in the most responsible way,
making sustainable long-term decisions to build a company and
∆ Financial
Social Environment
Employment, development, wellbeing, recruitment Responsitive operations
Safeguard reputation Beneficial products
SUSTAINABLE
BUSINESS
Achieve zero waste to landfill Reduce annual incidence of occupational illness cases
by at least 30% over the five years to 2013/14
22
23
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is a trademark of Questare all trademarks
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of companies. CATALYST CARE is a service mark of the Johnson Matthey group of companies.
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Headquarters: Other offices
Other offices worldwide:
worldwide:
Billingham, UK
Billingham, UK for contact
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details please
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