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Delivering world class catalysts for Gas to Liquids

22843 JM Gas to Liquids Brochure ML.indd 1 02/09/2014 16:51

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 the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent 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. Freedom under Patent, Copyright and Designs cannot be assumed.

© 2014 Johnson Matthey Group

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A world leader in catalyst science and technology

Johnson Matthey is a world leader in catalyst science and

technology. Every day, customers around the world rely on our

catalysts, our technical expertise and our operational knowledge

to operate their processes and give them a competitive edge.

Having the best catalysts and technologies is key to the success of any process but especially so in Gas to Liquids (GTL) where reliability and even small gains in efficiency and output have a major impact on plant performance and profitability.

Since our foundation in 1817 the Johnson Matthey name has been synonymous with quality and integrity and for almost a century Johnson Matthey has been a reliable and proven supplier of catalysts and technology for synthesis gas processes. We manufacture the widest range of sulphur removal products for natural gas purification; we offer an unrivalled range of reforming catalysts and for almost fifty years we have led the world in methanol technology culminating in the development of the KATALCOJM APICOTM range of synthesis catalysts in 2009.

Manufacture of Fischer-Tropsch catalysts is a core Johnson Matthey capability which we have developed over the past ten years. In that time we have developed the formulation or manufacture of a large number of Fischer-Tropsch catalysts, many in partnership with customers. This, together with the advanced characterization techniques and manufacturing processes we employ gives Johnson Matthey an unrivalled capability in the understanding of Fischer-Tropsch catalysis.

Johnson Matthey Davy Technologies (JM Davy) develops and licenses process technologies to the synthesis gas and other industries. JM Davy has for many years been the leading licensee of the Johnson Matthey Low Pressure Methanol (LPM) process and also develops and licenses technology for GTL and other processes.

The emergence of Coal to Liquids (CTL) and Biomass to Liquids (BTL) technologies presents additional challenges. While non-catalytic gasification or pyrolysis processes replace reforming these processes produce a synthesis gas deficient in hydrogen. This must be accommodated by use of an appropriate iron based Fischer-Tropsch catalyst, by adjustment of the H2:CO ratio with a shift catalyst or by addition of hydrogen from a separate steam reforming unit. Johnson Matthey provides products for each of these options. Gasification and pyrolysis processes also produce synthesis gases laden with impurities which must be removed before further processing and Johnson Matthey can provide catalysts and absorbents for this important part of the process.

Shell Photographic Services, Shell International Limited.


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Leading the world in GTL catalyst capability


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About Johnson Matthey

Johnson Matthey is a speciality chemicals company and a world-leader in advanced materials

technology. The group focuses on its core skills in catalysts, precious metals and process

technology, developing products that enhance the quality of life for millions around the world.

Since its foundations in London as a precious metals assayer in 1817, Johnson Matthey has continued to develop new technology, demonstrating its ability to maintain world leadership by adapting constantly to the ever-changing needs of customers. Today the company employs around 11,000 people in over 30 countries across the globe and its principal activities reflect its core skills.

Johnson Matthey is synonymous with precious metals and is the world’s largest fabricator and distributor of platinum group metals (PGM) and the market leader in the refining of gold and silver. For the global pharmaceutical industry, Johnson Matthey works in partnership with its customers to develop and supply active pharmaceutical ingredients such as the world-leading platinum based anti-cancer drugs, cisplatin and carboplatin. Johnson Matthey also applies its expertise in precious metals and materials technology, supplying coatings and surface treatments for glass and other applications.

In catalysts, Johnson Matthey is a world-leader in the manufacture of catalysts for vehicle exhaust emissions control and a leader in catalyst systems for the reduction of volatile organic compound (VOC) emissions from industrial processes. It supplies high performance base metal and precious metal process catalysts into a diverse range of global markets and is world-leader in catalysts and components for the emerging fuel cells market. These combined catalyst interests - Johnson Matthey – have an unrivalled breadth and depth of technology and experience.

Today, Johnson Matthey’s long-term commitment to investment in research and development, as well as in new manufacturing technologies and production facilities, enables the company to exploit the potential for growth in many of its key product areas.

Johnson Matthey has committed to a long-term development of fuel cells, which are highly efficient and clean technology for mobile and stationary power generation. Johnson Matthey is the world’s leading supplier of the platinum catalysts and catalysed electrodes at the heart of the fuel cell and continues to make significant investments in the fuel cell business.

And in GTL, Johnson Matthey continues to demonstrate its long-term commitment to the development of catalysts and technology. Our work in reforming and materials technology continues to set industry standards, our scientists lead the world in catalyst characterisation and our developments in Fischer-Tropsch catalyst manufacture are used by an increasing number of leading GTL companies.

Johnson Matthey sustainability objectives

Johnson Matthey is a world leader in environmental technologies and with more than half our profits generated from products that directly benefit the environment, sustainability is a key element of our strategy for the future growth of our business. For Johnson Matthey there are two main sustainability thrusts. The first is to use more efficiently the resources that we use as a business and the second is about designing new and improved products that will help our customers to be more sustainable and competitive.

In GTL, these include advanced reforming systems to maximise efficiency and minimise carbon emissions, highly efficient and robust Fischer-Tropsch catalysts that improve plant efficiency and can be recycled at end of life, and treatment processes to recover energy from and reduce the environmental burden of co-produced Fischer-Tropsch water.


Product summary Our heritage in synthesis gas catalysts and technology

goes back almost a century. Today our products are

used to make ammonia, in oil refining and to process

and purify natural gas. Our leading capability in steam

reforming is well known and over half the world’s

methanol is produced using our licensed process.

Our catalyst range includes the proven KATALCOJM™

brand and PURASPECJM™ catalysts and absorbents

for purification. We offer our proprietary Gas Heated

Reforming (GHR) and Autothermal Reforming (ATR)

technologies and these are complemented by JM

Davy’s pre-reforming technology. With our in-depth

operating knowledge and our range of support service

packages we work with you to tailor a complete

package to optimize your plant performance.

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Gas Production

Feedstock purification

Catalystreprocessing Process and

system modelling

Reformingcatalysts andtechnology

Water gas shift catalysts

Synthesis gas purification

Catalyst handlingand management

Hydrogenplant catalysts

Trainingservices

Instrumentationand diagnostics Custom catalyst

manufacture

Fischer-Tropschcatalysts

Processtechnology

Metals supply andmanagement

Technicalservice and

projects

Syngas generation

Fischer-Tropschsynthesis

Hydrogenmanufacture

Hydroprocessing


In Fischer-Tropsch catalysis our characterization

capabilities are second to none and are an invaluable

tool in the understanding of the relationships between

catalyst design, manufacture and performance. You

can draw on our expertise and resources to custom

manufacture your own specific formulation or we can

work in partnership to develop a customized product

based on your own formulation or one of ours.

This distinctive range of catalysts, technologies and service

options is only one element of the solution. What further

differentiates Johnson Matthey is our depth and breadth

of expertise and the way we apply it. Throughout Johnson

Matthey, our working philosophy is strongly focused

on building strategic partnerships with our customers,

leading both to deeper mutual understanding and to the

protection of developing technology. Our dynamic groups

of scientific, commercial and service personnel are the

catalysts for your individual competitive advantage.

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Gas Production


Catalystreprocessing Process and

system modelling

Reformingcatalysts andtechnology



Catalyst handlingand management

Hydrogenplant catalysts

Trainingservices

Instrumentationand diagnostics Custom catalyst

manufacture

Fischer-Tropschcatalysts

Processtechnology

Metals supply andmanagement

Technicalservice and

projects

Syngas generation

Fischer-Tropschsynthesis

Hydrogenmanufacture

Hydroprocessing


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Johnson Matthey manufactures the widest range of

sulphur removal products on the market. These catalysts

and absorbents have been formulated to operate over

a wide range of temperatures and process conditions

and to be simple and reliable in operation. Our products

hydrodesulpurize organic sulphur compounds, hydrolyze

COS and absorb H2S. Our product range includes high

(350-400oC) and low (220-300oC) temperature

hydrodesulphurization, pre-sulphided catalysts where

required for ease of start up and a range of H2S

absorbents covering temperatures from sub-ambient

to over 400oC. According to your specific requirements

we can provide a tailored combination of catalysts

and absorbents combining maximum sulphur capacity

with minimum residual sulphur in the treated gas.

The Johnson Matthey range includes KATALCOJM products

for conventional process conditions and PURASPECJM

products for low temperature applications and special

duties. The PURASPECJM range also includes products for

the removal of less common impurities including mercury,

arsine, hydrogen chloride and organo-chloride compounds.

The removal of mercury has become increasingly

necessary in recent years as compounds of the metal have

been found to be present in many gas sources and its

removal for both environmental and process reasons can

be essential. Mercury is an environmental hazard if emitted

to atmosphere or into waste water and its corrosive effect

on cryogenic sections of plant, with potentially serious

consequences, are now well known. Johnson Matthey

makes a range of absorbents for removal of mercury alone

or in combination with sulphur which are simple to operate,

have extremely long lives and do not release mercury in

the event of process upsets or changing process conditions.

Natural gas purification

Almost all natural gas contains sulphur and many

gases contain other impurities such as mercury. These

impurities need to be removed to low levels in order

not to poison steam reforming and other catalysts and

it has long been established that the more complete

the removal the more efficient the plant operation

and the longer the catalyst lives that can be achieved.

Fischer-Tropsch synthesis takes the requirements for

purification to a new level; cobalt Fischer-Tropsch catalysts

are extremely sensitive to even part per billion (ppb)

levels of contaminants including sulphur compounds and

these must be removed, typically to levels below 5 ppb.

Gas production Syngas generation Fischer-Tropsch synthesis Hydroprocessing Hydrogen manufacture


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CTL and BTL processes

Coal and Biomass to Liquids processes

present new challenges in purification. High

temperature gasification of solid feedstocks

produces synthesis gases containing COS,

ammonia, HCN, metal compounds and other

contaminants which may be contained in the

feedstock such as arsenic and phosphorus

while lower temperature pyrolysis processes

produce gases contaminated with a wide

variety of organic and other substances.

Cleaning these gases generally requires a

series of processing steps including liquid

scrubbing, chemical conversions and the

use of solid absorbents. Johnson Matthey’s

PURASPECJM products can provide final

treatment to ppb levels in these situations.

Liquid treating

Separation of natural gas liquids (NGL) is a common

feature of feedstock processing upstream of GTL

plants and in many cases provides an important

revenue stream where these can be exported

or sold locally. These streams can be combined

with propane and butane LPG products from the

Fischer-Tropsch synthesis section and the NGLs may

require purification before the streams are combined.

Johnson Matthey supplies a range of high

efficiency PURASPECJM absorbents which

have been specifically designed for removal of

sulphur and mercury compounds from these

streams at low temperatures and in the liquid

phase. Impurities can be readily removed to ppb

levels and the PURASPECJM products provide

a reliable solution, robust to changes in feed

stream composition and process conditions.


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Reforming catalysts & technology

conventional steam reformers. The elimination of the

heavy hydrocarbons minimises carbon formation in the

downstream reformer, the presence of hydrogen ensures

maximum catalyst activity and the CRG pre-reformer

also deals with any fluctuations in the composition of

the feedstock gas supply. The CRG pre-reformer can

also be used to process olefinic hydrocarbons being

recycled from the tail gas of the Fischer-Tropsch system.

With a light feed gas the CRG pre-reforming process

is endothermic and it has become common practice to

reheat the pre-reformed gas before introducing it to the

downstream reformer. By this means lower grade heat can

be collected and introduced to the reforming system, so

improving efficiency; the absence of heavy hydrocarbons

and the presence of hydrogen in the pre-reformed gas

allows very high reheat temperatures to be used

without risk of coking in the high temperature

preheater or in the reformer itself.

Johnson Matthey has manufactured steam reforming

catalysts and operated reforming processes over many

decades and today produces catalysts for all types of

process. Many of these products have their origins in

our experience of plant operation while some have been

developed specifically to address problems arising from the

extension of reforming technology into GTL processes.

Our record in the development of steam reforming

technologies is well known. We developed the

fundamental engineering data for the design of the

reforming furnace, invented the naphtha steam reforming

process and continued to advance reforming technology

with the development of Gas Heated Reforming.

Pre-reforming

Pre-reforming has its origins in the developments

surrounding the manufacture of towns gas in the 1950s.

Originally developed and used by British Gas to produce

towns gas from petroleum sources rather than from

coal, the CRG process has been used in over 70 plants

around the world, processing a variety of feedstocks

from natural gas to naphthas. Johnson Matthey

Process Technologies manufactures the range of CRG

catalysts whilst the process is licensed by JM Davy.

The highly active CRG catalysts operate in adiabatic

reactors at low temperatures. The C2 and heavier

components of the feed are reformed to synthesis gas

and the process stream is equilibrated at the catalyst

temperature to produce a lean, hydrogen containing

gas free of C2 and higher hydrocarbons. As such it is

ideally suited to pre-process the feed to highly stressed

reforming units such as Autothermal Reformers

(ATR), Gas Heated reformers (GHR) and high heat flux



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catalyst and high pressure drop in the lower parts of

the bed and further downstream where the evaporated

catalyst subsequently condenses back to solid material.

Also, as the top catalyst loses material and therefore

activity, the endothermic reforming reactions slow

down, catalyst temperatures increase and the problem

worsens and moves further down the catalyst bed.

Johnson Matthey’s scientists have studied these effects

in detail and have developed an ultra-stable catalyst and

support combination which is not susceptible to these

high temperature effects. Used with our regular ATR

catalysts in the lower parts of the bed this combination

is providing robust and reliable ATR service.

ATR technology incorporating Johnson Matthey’s

catalysts is supplied by JM Davy.

Combined reforming

Combined reforming combines a conventional steam

reformer with an autothermal reformer, the ATR being fed

with a mixture of reformed gas and desulphurised natural

gas. In recent years combined reforming has become an

increasingly popular choice for large methanol plants and

may be considered a more established technical choice

for GTL when compared with ATR or GHR alternatives.

Combined reforming incorporating Johnson Matthey’s

catalysts is supplied by JM Davy.

Autothermal reforming

Autothermal reforming (ATR) has become an important

synthesis gas generation process for GTL plants. Suitable

for light natural gas feedstocks, it can be configured

to produce a synthesis gas composition suitable for

cobalt Fischer-Tropsch catalysts and it can be scaled to

large capacity units. Autothermal reforming has been

used for many decades in the production of ammonia

(secondary reforming) and more recently in methanol

plants (combined reforming). The process has been

very successful but is technically challenging especially

in the combustion section of the reactor where both

equipment and catalyst experience a severe environment.

The severity of the conditions in an ATR for both the

burner and the catalyst cannot be overstated. The

Johnson Matthey burner unit is a proprietary design

first developed around 1970. Whereas burners in other

designs generally require frequent refurbishment or repair,

at intervals sometimes measured in months, the Johnson

Matthey units have operated for periods of over 20 years

with air and 14 years with oxygen without damage.

The catalyst in an ATR can be damaged by a poorly

designed, or damaged burner resulting in flame

impingement or local overheating of the catalyst in the

upper part of the catalyst bed. The reactor will only

perform well if the combusted gas is fully burnt and well

mixed as it enters the catalyst bed and the burner is

critical in this respect. However, conditions are so severe

in these reactors that even with a well designed system

and properly functioning burner the top catalyst can

experience problems. Specifically, at the high temperatures

involved, the nickel on alumina catalysts usually employed

are volatile and both the active nickel and the alumina

support evaporate. This results in wasting of the upper


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Hydrogen plant catalysts

Coal to Liquids (CTL) and Biomass to liquids (BTL)

plants produce, by gasification or pyrolysis, a synthesis

gas rich in carbon monoxide. The H2:CO ratio is lower

than that required for the stoichiometric conversion to

paraffinic hydrocarbons. CTL and BTL plants may elect

to use an iron based Fischer-Tropsch catalyst which

re-adjusts the equilibrium and effectively converts

part of the carbon monoxide to hydrogen, rejecting

carbon dioxide in the process. However, if a cobalt

Fischer-Tropsch catalyst is to be used the H2:CO

ratio must first be adjusted to approximately 2:1.

The H2:CO ratio can be adjusted by adding hydrogen

from a conventional steam reforming plant. However,

this requires a source of a suitable feedstock such

as natural gas which may not be available and,

in the case of a BTL plant, the addition of large

amounts of hydrogen produced from fossil fuels may

undermine the green credentials of the project.

The preferred way to adjust the stoichiometry

is to shift all or part of the synthesis gas using a

catalyst. Johnson Matthey makes a range of shift

catalysts and is the leading supplier of sulphided

or sour shift catalysts. This is the shift catalyst

of choice for CTL and BTL plants in which the

synthesis gases at this point are generally laden

with sulphur and other impurities. These catalysts

have been widely used in substitute natural gas

(SNG) and other coal based plants and have a long

track record of efficient and robust operation.

Hydrogen is an integral part of any GTL, CTL or BTL plant.

In plants based on partial oxidation of natural gas or on coal

or biomass feedstocks, large quantities of hydrogen may be

needed to blend with the CO rich synthesis gas from the

partial oxidation reactors or gasifiers. In almost all plants

hydrogen is also required for product finishing operations.

Johnson Matthey has extensive experience in hydrogen

manufacture and produces a comprehensive range of

KATALCOJM catalysts for use in the process. The range

includes catalysts for desulphurization and removal of other

impurities, pre-reforming, steam reforming and water gas

shift (high, medium and low temperature) catalysts. The

range is being constantly improved and updated as our

catalyst science develops and as customer requirements

change. Catalysts are also available for pre-shifting Fischer-

Tropsch tail gas where this is to be used as the feed to

the hydrogen manufacturing unit (HMU). In particular, our

range of reforming catalysts can successfully process the

heavy hydrocarbon components which may be present

in some natural gases and Fischer-Tropsch tail gases.

The latest KATALCOJM steam reforming catalysts

are produced in a QUADRALOBE™ shape,

specially designed to maximize activity and

heat transfer while limiting pressure

drop through the catalyst tube.

All these catalysts are fully

supported with technology

and services for both large

and small hydrogen units.



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It is usual practice in gas based plants to complete the purification upstream of the first catalytic reactors – usually the reformers. However, for a variety of reasons this may not be possible; new impurities such as COS may be introduced by partial oxidation units or contaminated gases may be blended into the synthesis gas stream. And in coal or biomass based plants the synthesis gas is usually heavily laden with impurities which must be removed to very low levels before the Fischer-Tropsch section.

Synthesis gas is more reactive than natural gas. This limits the options for removal of impurities and the process conditions that may be safely used. With CTL and BTL plants purification usually begins with liquid scrubbing processes to remove bulk levels of contaminants and specific impurities such as ammonia and hydrogen cyanide. The gas is then finally purified to the required ppb level using solid catalysts and absorbents in fixed bed reactors. In GTL plants any required synthesis gas purification would be confined to the use of solid catalysts and absorbents.

Johnson Matthey’s extensive range of sulphur absorbents are particularly suitable for synthesis gas duties since the range includes products which are active at low temperatures and can achieve extremely low levels of impurity in the treated gas. With the very large gas volumes to be treated it is important to avoid high pressure drops and this can be difficult with conventional fixed bed reactors. Johnson Matthey offers proprietary designs of radial flow reactors which achieve very low pressure drop while providing complete purification of the gas and enabling easy changeout of the catalyst or absorbent at the end of its life.

One particular class of troublesome contaminant is metal carbonyls, usually nickel and sometimes iron, which can arise from the reaction between CO rich synthesis gas and pipework or items of plant equipment. Johnson Matthey can provide products to guard against these contaminants entering the synthesis section.


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Fischer-Tropsch catalysts

Since their beginnings in the early decades of the twentieth century, Fischer-Tropsch catalysts based on both cobalt and iron have been used for producing hydrocarbon fuels from coal derived synthesis gas. The increases in oil prices in the 1970s spurred a further wave of development focused on natural gas feedstocks and this continued as large quantities of stranded gas became available. Fischer-Tropsch technology provides an effective way of converting large amounts of natural gas in remote locations into transportable liquid fuels. More recently, as the energy spectrum has changed, the technology is being further adapted to the production of fuels from biomass and, once again, from coal.

Since the turn of the century, the focus of Fischer-Tropsch developments has shifted towards the optimization of catalyst formulations and catalyst manufacture. New formulations have been developed to suit specific reactor technologies and an increased understanding of the linkages between catalyst manufacture and performance is enabling us to tailor manufacturing processes towards maximizing the performance of the catalyst in the plant. This understanding has been made possible by the development and use of advanced techniques for studying catalyst structure and Johnson Matthey’s scientists are at the forefront of these developments.

During the last ten years Johnson Matthey has worked closely with a number of leading companies, developing and optimizing the manufacture of Fischer-Tropsch catalysts on a commercial scale. With our extensive laboratory scale and pilot scale preparation facilities we can rapidly develop the manufacture of your catalyst formulation and can produce demonstration quantities for evaluation and testing. Our new, flexible, state of the art manufacturing facility can produce hundreds of tonnes of Fischer-Tropsch catalysts for large scale demonstration or for small to medium scale commercial plants. Catalysts can be supplied in oxide form or reduced, encapsulated and ready to go.

We work in close co-operation with our customers, using our skills and facilities to develop the efficient manufacturing processes necessary for cost effective manufacture of the highest performance catalysts. Our target is always to match or exceed the performance of your laboratory prepared samples and to contribute to still further improvements in the longer term.

Cobalt Fischer-Tropsch catalysts for slurry bubble reactors

Slurry bubble reactors can be an attractive technology choice for large commercial projects. Cost effective and with the potential to scale to very large capacities, these relatively novel reactors nevertheless place a considerable strain on the catalyst. To operate successfully, the Fischer-Tropsch catalyst must achieve high activity and selectivity with exceptional



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robustness and stability to the gruelling physical and chemical regimes in these reactors. These properties are determined by both the formulation and the manufacturing processes for the catalysts.

Johnson Matthey will work with you to scale up the manufacture of your catalyst and to develop this further as your requirements change. We have developed an extensive collection of processes and characterization techniques that we apply to manufacture your catalyst and to predict its behaviour in your plant. Catalysts for slurry bubble processes are normally supplied pre-reduced and encapsulated in wax and we draw on our many years of experience in reduction and encapsulation to supply these products as clean, free-flowing pastilles which are easy to handle and load into the Fischer-Tropsch reactor.

As an alternative to your own formulation we can offer a proprietary Johnson Matthey catalyst which offers exceptional physical and chemical stability under Fischer-Tropsch conditions. Our patented manufacturing procedures underpin this unique and highly robust formulation.

Cobalt Fischer-Tropsch catalysts for fixed bed reactors

Fixed bed, tubular Fischer-Tropsch reactors can be the right choice for both smaller plants and for large multiple train facilities where the minimization of technical risk is attractive. These reactors present different challenges to the catalyst. In addition to the usual requirement for high activity and selectivity, fixed bed catalysts must possess excellent heat transfer and pressure drop characteristics, have high tolerance to thermal gradients and be strong and robust to simplify loading into the reactor and to ensure a long life.

Johnson Matthey has developed and adapted a range of technologies for the manufacture of fixed bed catalysts and our long experience in forming processes ensures that your formulation is produced with the characteristics required to ensure an efficient and trouble-free life.

Iron Fischer-Tropsch catalysts

While cobalt catalysts have become the preferred choice for natural gas based Fischer-Tropsch plants, the special characteristics of iron catalysts can be suited to coal or biomass feedstocks. The water gas shift reaction is promoted by iron and the catalyst compensates for the low hydrogen content of the synthesis gas by converting excess carbon monoxide to additional hydrogen and carbon dioxide. Iron catalysts typically produce very low levels of methane and, although thorough clean up of the synthesis gas is still necessary, the catalysts are less affected by low level residual traces of impurities.

Johnson Matthey has a long heritage in Fischer-Tropsch catalysts and these were first made in our factory at Oberhausen many years ago. Our proprietary iron catalyst has been optimised for fixed bed duties and is well suited to processes requiring this type of catalyst.

Special catalysts for special situations

While slurry bubble and fixed bed reactors will be used for the majority of Fischer-Tropsch plants, a number of other proprietary reactor designs have been developed to suit particular situations and special Fischer-Tropsch reactors may be matched with novel synthesis gas generation systems. While these use the same basic chemistry as more conventional plants the catalysts may be required in very different physical forms or may have to be specially adapted in other ways to suit a particular reactor technology.

Within the Johnson Matthey group we have expertise

in almost every aspect of catalyst manufacture

and our corporate research centres are continually

extending our understanding and capabilities. We

can work with you to develop and produce special

catalyst products to suit almost any situation based on

your knowledge and requirements and our catalysis,

characterization and manufacturing expertise.

We welcome long term cooperation on projects

but we are often able to adapt products from our

existing programmes on a shorter timescale.


16 Gas production Syngas generation Fischer-Tropsch synthesis Hydroprocessing Hydrogen manufacture

Process technology

Fischer-Tropsch water treatment

JM Davy has an impressive track record

in the development of advanced process

technologies. Developed in collaboration

with BP, JM Davy’s GTL process combines

compact reforming and other reforming

technologies with fixed bed Fischer-Tropsch

technologies in a cost effective process.

In the case of compact reforming the units

are factory built and easily transported and

the fixed bed Fischer-Tropsch reactors,

also suitable for BTL and CTL plants, are

reliably scaled from existing units with years

of operational experience behind them.

A 300 barrel per day demonstration plant

began operation in Alaska in 2002 and has

provided a wealth of operational data at

effectively a commercial scale (since tubular

reactors are used), thus virtually eliminating

the scale up risk in the design of commercial

units. Development work also continues on

alternative reactor and process configurations.

The Fischer-Tropsch process generates

considerable quantities of co-produced water

which must be used within the plant or treated

efficiently for use elsewhere or disposal. The cost

of treatment, which may include secondary and

tertiary biotreatment and other capital intensive

processes is considerable in any GTL plant.

From our long experience in methanol technology

and licensing, Johnson Matthey provides natural

gas saturator technology which efficiently removes

oxygenates and other organic contaminants from the

co-produced water. The organics are stripped from

the water in the saturator by contact with hot natural

gas and returned to the reformers as feedstock

where their recovery contributes to the

overall efficiency of the plant. The

saturator generates the process

steam for the reformers using

low grade heat and surplus

water is cleaned of 99% of

its organic contaminants,

thus rendering it

suitable for other uses

or greatly reducing the

need for subsequent

effluent treatment.


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Process and system modelling

Technical service and projects

Johnson Matthey has developed and maintains extensive expertise in the modelling of reactors and catalytic processes. We have particular strength in reforming and a detailed capability in the modelling of autothermal and other reformers by computational fluid dynamics (CFD) and other techniques. In addition to the catalytic systems themselves we model related parts of the plant such as flue gas ducts and other systems.

This expertise leads to the improved design and enhanced performance of our catalyst products and the systems in which they are used. We can also offer this expertise for the troubleshooting and improvement of our customers’ proprietary reactors and plant systems.

Customers often tell us that catalysts alone are not sufficient to ensure the best possible performance from a plant. As a business with an operating heritage in the industry and people on our team who have designed, built, operated, monitored and maintained plants over a period of more than 30 years, we know this to be true.

Through KATALCOJM PERFORMANCE we offer a wide range of services, from loading and start-up assistance through to detailed plant modeling and optimization advice. However, our abilities and expertise go far beyond this. By working in close co-operation with a number of partners, we can deliver a wide range of studies and services covering the key areas of concern to plant operators: Efficiency, Reliability, Throughput, Safety and the Environment. Examples of these include reformer surveys, revamp studies, measuring exact reformer tube temperatures and energy efficiency studies.

These services can be provided on a case by case basis or as part of a more comprehensive long term service agreement to accompany the use of Johnson Matthey.


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Training services

Catalyst handling and management

Johnson Matthey has long been committed to

working with our most important customers

to provide technical training. We are proud of

the unrivalled reputation of our catalysts and

services in our chosen field and the economic

benefits these bring our customers worldwide.

We offer training packages tailored to each

customers’ needs depending on exactly what is

required, whom the target audience is (including

existing levels of expertise), and what the customer’s

objectives are. Overall, the training material is carefully

chosen to reflect site requirements but incorporating

the richness of Johnson Matthey’s experience.

These training programmes offer

a number of benefits:

∆ Sharing of best practice

∆ Opportunities for routine operating questions to be raised and addressed for team benefit

∆ Knowledge updating

Recent experiences

New products

New techniques

Johnson Matthey offers a full support package from

loading the catalysts, to plant start up and catalyst

reductions through to catalyst monitoring throughout

its life. For large contracts, we offer a full plant loading

guidance and advice package that ensures that

catalysts are loaded correctly, started up

correctly and that technical support and other

services are available when required.



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Metals supply and management

Catalyst reprocessing

Johnson Matthey is acknowledged to be the leading refiner and supplier of precious metals. As the world authority on platinum group metals our annual publication Platinum provides extensive and in-depth reviews of the supply

and demand situation from year to year and is the authoritative reference work

on the subject. Platinum is available on www.platinum.matthey.com

Johnson Matthey provides a discreet service for purchasing the metals required for your project. Our extensive knowledge and position in these markets enables us to meet

your requirements efficiently in both the supply and recovery of

these valuable materials and we can provide a variety of plans to suit

both immediate and long term needs.

In base markets such as nickel and cobalt, our contacts, relationships and knowledge of the markets enable us to secure supplies of these essential raw materials in accordance with the requirements of your projects and within the constraints of these markets. We will develop purchasing strategies with you to ensure that the significant quantities of these metals required for your commercial GTL plants can be obtained at competitive prices.

Johnson Matthey provides a full range of catalyst reprocessing services which ensures that spent catalysts are transported and reprocessed in efficient and environmentally acceptable ways. The valuable metals are recovered and credited to customer accounts as quickly as possible while other components are generally put to use as secondary raw materials.

We provide this service for our full range of both precious metal and base metal catalysts. For precious metals the Johnson Matthey name is synonymous with the production, marketing, reprocessing and handling of the whole range of platinum group metals, rhenium, silver and gold.

Fischer-Tropsch catalysts present particular challenges for the reprocessor since the latest catalysts have complex formulations and quantities are large. Recovering all the valuable components can be difficult and Johnson Matthey is developing new recovery technologies to ensure that efficient recovery processes are available as the market for these catalysts develops. The recovery of spent catalysts will be an integral part of the supply of catalysts to large GTL plants and will provide plant operators with the assurance of best environmental compliance as well as maximum cost effectiveness.


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Instrumentation and diagnostics

Fischer-Tropsch reactors

Slurry bubble reactors are an attractive technology

choice for Fischer-Tropsch synthesis. Combining

high productivity with economies of scale for large

plants, these reactors effectively solve the heat

management problems associated with

fixed bed reactors and provide the uniform

reaction conditions necessary for efficient

operation with either cobalt or iron catalysts.

Fischer-Tropsch synthesis is the first large-scale

application of this type of reactor and units are

being built and operated on a scale not before

seen. The reactor environment is complex with

liquid product, catalyst particles and reactant

gases all interacting in a complex set of physical

and chemical processes. These must be well

understood and closely controlled to achieve

maximum productivity and efficiency.

The performance of slurry bubble reactors

depends on a number of critical parameters

including catalyst distribution and attrition rates,

gas distribution, bubble characteristics and back

mixing, and heat transfer parameters. These

parameters are generally difficult to measure

or to infer from other data and yet are crucial

to the successful operation of these units.

Modern GTL plants incorporate many

large and complex systems that must

work reliably and efficiently together for a

successful project. Accurate measurement

plays a key part in monitoring, controlling

and understanding these systems.

As part of Johnson Matthey Process Technologies,

Tracerco offers GTL operators a wide range of

established and developing measurement and

diagnostics techniques which are ideally suited

to improving the monitoring, troubleshooting

and understanding of these complex systems.

Tracerco’s bespoke solutions can be applied to

gas production, Fischer-Tropsch reactors and

many other process systems within GTL plants.


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Tracerco with over 50 years’ experience in

advanced process plant monitoring and diagnostics

analysis, offers a collection of intrusive and

non-intrusive measurement techniques enabling

real time characterization of conditions in the

industrial process for both routine monitoring

and troubleshooting on this type of reactor. A key

element of Tracerco’s technology is the ability to

diagnose a wide range of production problems using

sophisticated tracer and advanced measurement

technology. Techniques are normally carried out

online by highly trained and experienced Tracerco

engineers, require minimal site preparation and

provide immediate, onsite results for the customer.

These methods can verify conventional

instruments, give highly reliable non-intrusive

measurements for process control in hostile

environments, and provide unique measurements

not possible by other techniques. Taken together,

the measurements made possible by Tracerco’s

process diagnostics and specialist measurement

teams provide an unparalleled capability for

monitoring, process control, troubleshooting and

design development of slurry bubble reactors.

Our portfolio of services for Fischer-Tropsch

slurry bubble reactors includes:

∆ Residence time distribution of the synthesis gas or liquid wax phases

∆ Gas distribution across the cross section of the reactor

∆ Gas hold up profiles from top to bottom of the reactor

∆ Computer aided tomography to give a detailed picture of the contents of the vessel

∆ Liquid level measurement and foam detection

Services for other systems in GTL facilities

In addition to Fischer-Tropsch reactors, GTL

plants contain numerous other systems to

produce and purify the feedstock, generate the

synthesis gas, make hydrogen and to separate

and refine the products. Tracerco has established

measurement and diagnostics systems to give

benefits throughout these parts of the plant.

∆ Monitoring of sulphur absorbers for the prediction of the remaining life of the absorbent

∆ Leak detection in heat exchangers, control and bypass valves, relief valves and boilers

∆ Steam reformer tube temperature measurement using contact thermocouple and gold cup pyrometer techniques to give more accurate data than is normally available from optical pyrometers

∆ Measurement of reformer tube diameter to assess remaining tube life and develop tube replacement programmes

∆ Column and reactor scanning to identify internal mechanical damage, solid/liquid interfaces, foaming and liquid entrainment

∆ Gas/oil/water separator instrumentation including the TRACERCO ProfilerTM

∆ Flowmeter calibration

∆ Detection of entrainment and carryover

∆ Identification of catalyst distribution, settling, build-up and blockages

∆ Measurement of phase distribution

∆ Fluid distribution and channelling in fixed bed reactors


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Leading the world in GTL capability

∆ Johnson Matthey – world leader in catalysis science and technology, committed to the long term development of catalysts and technology for GTL

∆ A comprehensive range of high performance catalyst products, services and capability for every part of the GTL flowsheet

∆ A flexible working approach focused on building strategic partnerships with customers

∆ A strong and proven supplier of reforming catalysts and technology for synthesis gas production with over 80 years’ experience in the industry

∆ The widest range of desulphurisation and purification products for gas and liquid streams

∆ Unrivalled expertise in the development, manufacture and characterisation of Fischer-Tropsch catalysts

∆ A full range of catalysts for hydrogen manufacture, supported with technology and services for both large and small hydrogen units

∆ Efficient and responsible catalyst reprocessing services for base metal and precious metal catalysts

∆ About 200 years’ expertise and heritage in precious metal supply and management to meet your supply and recovery requirements efficiently

∆ A wide range of specialist measurement and diagnostic techniques and services to optimise your GTL assets

∆ JM Davy – a distinctive range of advanced process technologies including synthesis gas, methanol and Gas to Liquids


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How to find out more

If you would like to find out more about working with Johnson Matthey Process Technologies please contact your local representative or office.

We will be pleased to discuss in more detail our portfolio of products and services for GTL in relation to your individual requirements.


Designed and produced by www.houseoftype.co.uk

For further information on Johnson Matthey, please contact your local sales representative or visit our website. KATALCO, PURASPEC, STREAMLINE and TRACERCO Diagnostics are all trademarks of the Johnson Matthey group of companies. CATALYST CARE is a service mark of the Johnson Matthey group of companies.

Headquarters: Other offices worldwide:Billingham, UK for contact details please visitTel +44 (0) 1642 553601 www.jmprotech.com/locations

www.jmprotech.com© 2014 Johnson Matthey group

633/JM/0114/6/Ref

Designed and produced by www.houseoftype.co.uk

For further information on Johnson Matthey, please contact your local sales representative or visit our website. KATALCO, PURASPEC, STREAMLINE, QUADRALOBE and TRACERCO are all trademarks of the Johnson Matthey group of companies. CATALYST CARE is a service mark of the Johnson Matthey group of companies. MANTIS and LOTIS are trademarks of Quest Integrity Inc. UNIDENSE is a trademark of Unidense GmbH. Plant images courtesy of Air Products Inc and Linde GmbH

Headquarters: Other offices worldwide:Billingham, UK for contact details please visitTel +44 (0) 1642 553601 www.jmprotech.com/locations


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