Methanation Catalyst

CC-J105 type methanation catalyst is a Catalyst produced by coprecipitation process with nickel as its active component, rare earth as its promoter, and alumina and magnesium oxide as its support. It is a new type catalyst which is of advantages of several catalysts often used in present, so it is characterized by excellent reduction performance, very high activity and strong heat resistance. It is mainly applicable to methanation units of ammonia plants and hydrogen plants.

I. Physical property and chemical composition

1. Appearance： φ5×4～5mm dark cylinder tablet

2. Chemical composition： ％(m/m)

3. Mechanical crush strength： ≥180N/cm

4. Bulk density： 1.0～1.15kg/L

II. Operating conditions：

1. Loading of catalyst：

It is essential to pay high attention to the catalyst loading, because the catalyst is operated under high conversion rate. There are thousands of ppm inlet CO+CO₂, but only several ppm outlet CO+CO₂. Namely, it is almost 100% to convert. If the loading is uneven and a channel generated to make some feed gas shorten and penetrated, it would lead to a trace outlet rise and further cause a very bad consequence.

Cautions during the catalyst loading：

(1) A free fall height of catalyst must be less than 0.5m.

(2) It is necessary to make the catalyst distribute uniformly in the catalyst bed. Never dump all the catalysts into the converter from a certain position and stack in one mound and then level at the end; otherwise, the small granules and the power dusts would gather in the center of the mound and the larger granules roll to the edge, which would result in gas distribution uneven.

2. Heat-up and reduction of catalyst：

The heating medium of type CC-J105 methanation catalyst can be nitrogen or qualified process gas. The reduction reaction is as follows(The reduction reaction is ndothermic):

NiO+H₂O=Ni+H₂O ΔH^O₂₉₈=2.55KJ/mol

J105 methanation catalyst would normally start to reduce at about 250℃ and has better reduction level at 350℃. It is necessary to heat up to 400℃ to reach the thorough reduction. Generally, after heating up to 400℃ for 2~3 hours, the outlet trace could meet the requirements, and it’s essential to further maintain the constant temperature for 3 hours and reduction is now complete. If permit, the reduction temperature could be increased to 450℃ so that the catalyst could bring out its best performance. If permit during the reduction, it’d better to adopt high space velocity so as to timely discharge the water generated in the course of reduction and make the nickel surface larger.

Cautions during heat-up and reduction of catalyst：

(1) The heat-up from ambient temperature to 200℃ must be very quick to prevent carbonyl nickel from forming.

(2) It must strictly control the CO+CO₂ content in the process gas so as to avoid over heating.

(3) When the temperature approaches to 400℃, it is necessary to slow down the heat-up speed appropriately so that the catalysts bed temperature could be even distributed.

3. Normal operation condition：

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