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High and Low Temperature Shift Catalysts

High Temperature Shift Catalysts

SmartHTS is an iron-chromium based catalyst promoted with copper used for the conversion of carbon monoxide via the water-gas shift reaction in hydrogen and ammonia plants.

CO + H2O ↔ CO2 + H2

The chromium oxide in the catalyst reverses the thermal degradation of the magnetite and prevents the catalyst contact surface at low temperatures. Generally, the existence of chromium increases the life of the catalyst and acts as a stabilizer. The combination of iron oxide and chromium oxide also changes based on the kind of manufacturer. The incorporation of copper into the catalyst structure, providing good dispersion as well as small crystallite size, significantly increases the intrinsic catalytic activity and brings the reaction closer to the thermodynamic equilibrium (low approach to equilibrium).

Physical Properties
Code SmartHTS1 SmartHTS2
Form Tablet Pellets
Size, mm 6 x 6 4.5 x (4-12)
Bulk Density, kg/l 1.12 ± 0.1 1.12 ± 0.1
Radial crush strength, Min.Average, kgf 10 10

Chemical Analysis (Nominal, wt%)
Fe2O3 > 85
Cr2O3 8 ± 1
CuO 1.8 ± 0.3
Sulphur, ppm < 250

high and low temperature shift catalyst

Low Temperature Shift Catalysts

SmartLTS are used for Conversion in synthesis and hydrogen production processes Using coal, naphtha, natural gas and oil field gas as feedstocks, especially for axial-radial low temperature shift converters. Low temperature shift catalysts are commonly made on the basis of ceramic phases filled with copper or copper oxide, while the most common bases involve alumina or alumina with zinc oxide. The role of ZnO oxide is as a catalyst base and also to inhibit copper poisoning by sulfur and chlorine compounds. Aluminum oxide or alumina Al2O3 also prevents dispersion and shrinkage. The catalyst has the advantages of activity at lower temperature. The lower bulk density, higher Copper and Zinc surface and better mechanical strength. The maximum temperature is in terms of the sensitivity of copper to thermal degradation. This low temperature also decreases side effects.

Physical and chemical properties
Type SmartLTS10 SmartLTS20 SmartLTS22
Appearance Tablet Pellet Pellet
Size, mm 5 x 3 5 x 3 5 x 3
Bulk density, kg/l Balance Balance Balance
Radial crushing strength, N/cm ＞160 ＞200 ＞200

Chemical Composition (Nominal, wt. %)
CuO 42 ± 2 42 ± 2 42 ± 2
ZnO 47 ± 2 47 ± 2 47 ± 2
Promoter – – < 1
Al2O3 Balance Balance Balance
Sulfur, ppm < 300 < 300 < 300

Nowadays, industrial hydrogen, in addition to its significance in various catalytic synthesis processes, is the most significant selection as a carrier of clean energy. For instance, high purity hydrogen is needed for the operation of low temperature polymer electrolyte membrane fuel cells. Thus, hydrogen production and refining has a dominant position in industrial technology which is also a necessary component of many industrial processes. Because industrial hydrogen can be produced from renewable energy sources (biodegradable organic waste), it is likely to decrease the negative impacts of civilization on the environment, like the greenhouse effect and air pollution. Hydrogen is produced in large quantities from hydrocarbon fuels (e.g. methane or alcohol) by process modification.

The product of the reforming process commonly consists of a mixture of hydrogen, carbon monoxide, carbon dioxide and steam. Industrial removal of carbon monoxide in the reforming process, which is necessary for several downstream processes, such as ammonia synthesis, involves several large and complex processing units. Hence, the gas-vapor shift reaction increases the hydrogen concentration because water decreases in the process of oxidizing carbon monoxide to carbon dioxide to hydrogen.

Steam-gas shift process

WGS process was discovered by an Italian physicist in 1780. The industrial value of this reaction was then considered. WGS process is one of the oldest heterogeneous catalytic reactions applied in industry to produce high-purity hydrogen and decrease carbon monoxide from synthesized gas.

CO + H2O → CO2 + H2

This process is commonly done in two steps in terms of the limitations of thermodynamic equilibrium. The initial step consists of a high temperature stage which operates at 310-450 °C and reduces the CO content to 2-3%. Expanded by German researchers at BASF in 1911 as section of a program to develop ammonia synthesis, iron / chromium oxide catalysts are now applied as the basis for high-temperature shift catalysts, which over the years have become highly popular. The title is the primary basis of research and has hardly changed.

The second step applies a Cu-based low temperature shift catalyst which operates at 210-240 °C.

Microstructure of HTS catalysts
Chromium element issues in HTS high temperature shift catalysts

FAQ

WGS reaction involves the reaction between CO and water on a suitable catalyst to enrich the gas mixture with H2. Iron-chromium and copper-zinc catalysts are usually applied to facilitate the reaction at high and low temperatures, respectively.

CO conversion at high temperatures reduces by about 300 to 450 °C, meaning that approximately 2.5% of CO remains dry at the reactor outlet. This change in CO or so-called heat shift conversion at an average temperature is decreased to 220 to 270 ° C, i.e. about 0.5% CO.

Low temperature catalysts commonly contain copper and zinc and operate in the temperature range from about 350 to 650 degrees. Because this reaction is an exothermic reaction, it reacts with CO2 as the gas passes via the bed and the temperature rises significantly.

Initially, a high temperature change catalyst is applied as the initial step, converting more than 80% of CO. HTS catalyst is composed of iron oxide and with a stabilizing agent of chromium oxide reduces the sintering rate of active iron crystals at high temperatures.

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