Johnson Matthey

Inspiring science, enhancing life

As a global leader in sustainable technologies, we apply our cutting edge science, creating solutions with our

customers that make a real difference to the world around us

Our vision is for a world that’s cleaner and healthier; today and for future generations

2

We create value from the efficient transformation and use of natural resources:

Demand for the world’s natural resources is increasing

Efficient Natural Resources enables our customers to use natural resources more efficiently

Using JM’s core chemistry and technology expertise to solve complex problems through close collaboration with customers

3

4

Demonstrating innovative Johnson Matthey catalyst solutions at G2X Energy Pampa Fuels facility

Introduction

G2X Energy Pampa Fuels is a wholly owned subsidiary of Consolidated energy, part of Proman Group

JM DAVYTM technology plant

Nominal 185 mtpd (22 million US gallons per year)

First operated in Cheyenne WY 1992-2003 by Coastal Chem. Inc.

Relocated to ex-Celanese Chemicals Pampa site

• Major ISBL items refurbished, new piperacks, I/E and Package boiler

• SMR steel work was relocated but tubes not replaced

• New suite of JM catalysts

Refurbished and recommissioned in 2013 and started up in April 2015

Methanol sidestream unit (MSU) refurbished and relocated to Pampa site in 2016

• Takes gas inlet the convertor and allows on-stream testing of JM catalysts in real operating conditions

• Operates 24/7 and has online data capture facilities

• Individual reactors can be isolated and returned to JM in active state

• Key to development of JM next generation of methanol synthesis catalysts

Demonstration opportunities for JM technology

Engineered metal support made frommetal strips, called “fans”. Fans aremade into stacks and loaded into thetubes

Uses proprietary coating process that has tough and long lasting catalyst coating

Contains promotors that allow reduction and start up on either NG or pre-reformed naphtha feeds with no special reduction process

Demonstrating new JM reformer catalyst offeringsCATACEL SSR

CATACEL SSR™ breaks the usual relationship that requires higher PD for improved thermal and catalytic performance

The combination presents Pampa Fuels with real opportunities:

• High HTC would reduce the TWT and improved thermal efficiency.

• The lower TWT would also increase the tube life.

• High activity would reduce the methane slip while further lowering the TWT, which together would reduce risk of carbon formation and improve catalyst life

• Low PD could yield benefits either through reduced load on the plant compressors or higher reformer (and therefore plant) throughput, the latter being the one of most interest.

Demonstrating new JM reformer catalyst offerings CATACEL SSR

QUADRALOBE™ comes in a wide range of pellet size options from XQ (20mm x 20mm) to MQ (13mm x 11mm)

Provides optimized pellet solution to activity, heat transfer and PD

Potash promoted: KATALCO 25 series

Alfa alumina: KATALCO 23 series

Calcium aluminate: KATALCO 57 series

New variant KATALCO 57-8Q

• Same ceramic QUADRALOBE shape

Demonstrating new JM reformer catalyst offerings KATALCO 57-8Q

Conventional catalyst have active Ni crystals impregnated evenly throughout pellet. Much of the Ni is in the core and is not used in the high temperature part of the tube

Unique patented technology applies Ni where needed on the geometric surface at the outer layer (

Upper 30% of tube catalyst needs high activity and carbon removal promotion to withstand potential for poisoning and carbon formation

Upper part is heat transfer limited but only mildly pore diffusion. Normally recommend KATALCO 25 series

Bottom 50-70% of tube low chance of poisoning and carbon formation

At higher temperatures, SMR reaction is highly diffusion limited an need of increased thermal stability of catalyst

Diffusion limit means reaction is effectively complete within thin outer layer so KATALCO 57-8Q ideally suited

Demonstrating new JM reformer catalyst offerings KATALCO 57-8Q

Simulations from base pellet to 100% CATACELand mixed loadings were reviewed

• Optimal economic performance loading was deemed to be split charge of CATACEL / KATALCO 57-8Q

• Demonstrated that increase to 120% of front end capacity was possible with min. CAPEX

Charge 1: KATALCO 51-101 proved high activity can be achieved

Charge 2: KATALCO 51-102, aims to demonstrate improved long term stability of the high activity

Uprate using JM catalyst solutions

Reformer

• New micro alloy tubes

• New inlet/outlet pigtails

• New inlet/outlet headers

• New demin. water heater to lower ID fan inlet temperature

New small parallel syngas compressor to handle additional throughput

• Existing syngas compressor VFD settings increased

• Existing circulator impellor size increased

2018 T/A

Stacks color coded to reflect position in tube

Small (10”) transition layer of KATALCO 25-4MQ on top of KATALCO 57-8Q,then single yellow, then multiple red stacks in the middle layers, then single green stack on top.

Loading of CATACEL SSR

20181018_174215 (loading) vertical.mp4

Delivering expected performance

• Front end peak at 123% of design

• Methane slip trending lower

• Normalised DP is significantly lower for similar time on-line in comparison to full pellet offering

Catalyst performance - reformer

Delivering expected performance

Higher front end rate matched by increase in methanol production

Initial high activity with KATALCO51-102

Performance is encouraging but higher activity will become apparent after 12-18 months

Catalyst performance – synthesis

Pampa Fuels post start-up comments:

Combination of JM catalyst developments and equipment upgrades allows Pampa to achieve a substantial increase in methanol capacity

Early performance is matching expectations and plant is operating >121% with combination of:

• CATACEL SSR / KATALCO 57-8Q in SMR

• KATALCO 51-102 in synthesis convertor

Post start-up and conclusions

Acknowledgments – paper first presented in June 2019 by

18

• Layne Clark, G2X Energy• Julian Morris, Johnson Matthey