(336e) Innovative Syngas Production Catalyst for Utilization of CO2 (CT-CO2AR(TM) Catalyst)

Production of synthesis gas from natural gas and conversion of synthesis gas to fuels and chemicals has become increasingly attractive from the viewpoint of energy resource diversification. The technology of synthesis gas production by the reforming of natural gas with CO₂ (hereafter referred to as “CO₂-reforming”) is an effective solution for the issues of efficient energy resource utilization and environmental preservation.
The reforming reaction and the solid carbon deposition reaction occur at the same time, and the deposited carbon causes deactivation of the catalyst and obstruction of the reformer tubes. As a result, a stable operation cannot be achieved. To maintain a stable plant operation, the conventional Ni-based reforming catalyst requires two or three times more steam (Steam/Carbon ratio: S/C) and CO₂ (CO₂/Carbon ratio: CO₂/C) than the stoichiometric coefficient of the CO₂-reforming reaction.

 To produce synthesis gases with valuable H₂/CO ratios more efficiently, it is essential to develop a reforming catalyst which can generate synthesis gas by CO₂-reforming under lower S/C and CO₂/C in the feed gas compared with the conventional one. Operating lower S/C and CO₂/C compared to the conventional CO₂-reforming catalyst has the following competitive advantages; a reduced fired duty, and reduced steam and CO₂ in the raw synthesis gas at the reformer outlet.

First, the reduced reformer fired duty is achieved because the sensitive heat of excess steam and CO₂is reduced. The reduced fired duty leads to lower fuel consumption and a smaller reformer section. Lower fuel consumption leads to lower OPEX and a smaller reformer section leads to lower CAPEX.

Second, reduced steam and CO₂ in the raw synthesis gas at the reformer outlet compared to the conventional reforming catalyst is achieved because of reduced steam and CO₂ in the feed. Lower steam in the raw synthesis gas makes the waste heat recovery section smaller, and lower CO₂ in the raw synthesis gas makes the CO₂ removal and CO₂ recycling sections smaller. These smaller sections can reduce both OPEX by reducing utilities like steam and electricity and CAPEX.
In case of lower H₂/CO ratios (especially lower than 1.0), the benefits are more notable.

For example, in the case of an H₂/CO ratio of 1.0, compared to a conventional operation, the CAPEX and OPEX can be reduced by approximately 10%, and CO₂ emissions by approximately 20%.

In addition, in the case of an H₂/CO ratio of 0.5, reductions of approximately 30% in CAPEX and OPEX, and approximately 75% in CO₂ emissions can be achieved.

If a lower S/C and CO₂/C operation is achieved, it enables the monetization of low-calorie, CO₂-containing natural gas fields and can also be applied to efficient reuse of CO₂ emitted from various industrial processes.

Some companies have been trying to develop the new reforming catalyst or process, however, only a few catalysts with the above properties have been commercialized.

Chiyoda has developed and commercialized a new noble metal based reforming catalyst named CT-CO₂AR(TM) catalyst which has a higher resistance to carbon formation compared to the conventional reforming catalyst.
The CT-CO₂AR(TM) catalyst has been used in a commercial plant in Japan and a stable operation of more than 9,000 hours was achieved. During this operation, The CT-CO₂AR(TM) catalyst proved to be more economical than the conventional catalyst.

In this presentation, we will elaborate on the characteristics and the competitiveness of the CT-CO₂AR(TM) catalyst and the results of the operation of the commercial plant.