Catalyst Support Media for Gasification and Syngas Technologies 2017 SYNGAS TECHNOLOGIES CONFERENCE COLORADO SPRINGS, CO

Transcription

1 Catalyst Support Media for Gasification and Syngas Technologies 2017 SYNGAS TECHNOLOGIES CONFERENCE COLORADO SPRINGS, CO

2 Christy Catalytics, LLC Christy Catalytics is a global company which manufactures and distributes inert fixed bed media and industrial ceramic products to the global refining, petrochemical, chemical and metals industries, shipping its products to over 40 countries worldwide.

3 Support Media Overview 1 balls catalyst 1/4 balls 1/2 balls Fixed Bed Reactors: Improves flow distribution. Prevents particle movement. Filters out contaminants. Retains the small particles comprising the catalyst, desiccant or adsorbent bed. Heat Retention Media: Retains process heat to improve efficiency and maintain reaction kinetics. Evenly distributes process flow. Provides surface area for combustion and/or reactions to occur.

4 Ceramic Support Media Raw Materials and Manufacturing Process Naturally occurring aluminosilicate clays 18 38% Alumina depending on the specific grade Fired until fully or partially vitrified (glass bonded) Max Usage Temperature 1800 C (980 F) 1370 C (2500 F) for premium grade Desulfurizers Shift Units Methanators Driers/ Molecular Sieve Hydrotreaters PSA Applications Ammonia/Methanol/Hydrogen Gasification Shift Units Guard beds

5 Alumina Support Media Raw Materials and Manufacturing Process High purity tabular alumina and alumina powders Sintered alumina Chemically bonded alumina Max Usage Temperature 1800 C (3272 F) Applications Secondary Reformers Autothermal Reformers High Temperature Shift Why Alumina Silica and other metal oxides such as soda leach out/are corroded by high temperature steam and hydrogen Corrosion of metal oxides happens exponentially faster with increasing temperature and pressure Materials volatize downstream, increasing pressure drop

6 Christy CATA COGS Low pressure drop (dp) support and hold down media Increased void fraction (57% for 26 mm cog versus 42% for 25 mm alumina ball) Available in both 99% high purity alumina and silica alumina formulations Sizes: 16, 26, 38, 75& 85 mm High density, low water absorption (1%) Used in LTS and HTS units around the elephant stool collector and/or as hold down to reduce pressure drop Option for PSA units as well to reduce dp

7 Pressure Drop Data Cogs/Balls dp ("w.c. per foot of bed depth) Average Pressure Drop Per Foot of Bed Depth Pilot tests show ~20% reduction in dp using cogs over comparable size balls Air Flow (FT3/Hr/In^2) 11 mm Alumina Balls 19 mm Alumina Balls 16 mm Cat-A- Cogs 26 mm Cat A Cogs 25 mm Alumina Balls 38 mm Cat-A- Cogs 38 mm Alumina balls 50 mm Alumina Balls 76 mm Alumina Balls 80 mm Cat-A- Cogs

8 Hold Down for Secondary/Autothermal Reformer Hottest, most severe portion of the part of the unit Reducing atmosphere in the presence of steam promotes corrosion of metal oxides Prone to churning or uplifting of the media, causing erosion and catalyst exposure Three primary options for hold down media: 1. Large, high alumina, low silica balls 2. Hexagonal Target Tiles 3. Alumina Lumps

9 Hexagonal Target Tiles Specialty product for Secondary Reformers and ATRs Best option to prevent milling or churning in the vessel Reduced pressure drop when compared to a 12 thick layer of alumina balls Tile area footprints range from 18.3 in2 (118 cm2) to 177 in2 (1141 cm2) Weight up to 49 lbs (22 kg) to provide resistance against moving Hole patterns designed to minimize dp and maximize physical integrity. Customization available Universal circle brick shapes recommended around the perimeter underneath the tiles, form seal at vessel wall

10 Super Jumbo Tiles Newest size option offers advantages over smaller tiles Greater thickness (3.5 in/88.9 mm) reduces settling of tiles into the catalyst bed over time, and enhances durability. Greater weight (49 lb/22 kg) SJ tiles weight 13x more than original standard size tile; virtually immovable in service Greater Stability Larger footprint with fewer joints between tiles lateral movement is restricted Reduced installation time Fewer pieces (10 9 diameter unit has 55 SJ full shapes versus 313 Jumbo Full Shapes)

11 HT LC Hex Tiles Newest formulation minimizes corrosion of Al 2 O 3, K 2 O, Na 2 O & SiO 2 by the high temperature steam and hydrogen environment in some secondary reformers and ATRs. These materials deposit downstream causing the bed to clog resulting in reduced throughput, increased energy usage and premature shut down. HT LC both resist these corrosion mechanisms and provide superior hold down due to its 60% greater density than 99% alumina tiles but is more costly. Alumina balls manufactured with HT LC formula are also available for use as SR Hold Down media

12 Fused Alumina Lumps Specified by some ammonia and methanol licensors as support and/or topping 25 50, , mm irregular shapes Inexpensive Irregular size, aspect ratio and jagged edges cause it to be the least common bed topping

13 QUESTIONS?