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    Methanol Synthesis Catalyst
    RK-04 High Pressure Methanol Synthesis Catalyst
    RK-04 High Pressure Methanol Synthesis Catalyst

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    1. Application

    RK-04 high pressure methanol synthesis catalyst is applicable for high pressure methanol synthesis process based on synthesis gas made from natural gas, coal gasification gas, coke-oven gas, refinery tail gas as raw materials.

    2. Chemical composition and Physical properties

    Catalyst : RK-04

    Composition : CuO 49~54wt%, ZnO 26~31wt%, Al2O3 6~9wt%.

    Appearance : Tablet (Small black cylinder)

    Dimension : Ф 5 X (4-5) mm, or depend on buyer

    Bulk density  : 1.2-1.4KG/L

    Specific area : 90~100 m2/g

    Crushing strength : ≥220N/cm

    Shrinkage after reduction : ≤3.0%

    3. Catalyst quality testing

    RK-04 methanol synthesis catalyst activity laboratory testing conditions:

    ITEMS :Testing conditions 

    Catalyst loading volume :4 ml

    Size :0.425~1.180 mm

    Pressure:10.0MPa

    Temperature:250℃

    Space velocity:2x104 h-1

    Feed gas composition CO: 3-15%, CO2: 2-5%, H2:55-70%; inert gas

    Catalyst initiation activity, CO conversion rate based on above testing conditions: 

    CO conversion rate before catalyst deactivation: ≥81%, methanol space time yield ≥1.0g/ml.h)

    CO conversion rate after catalyst deactivation: ≥60%, methanol space time yield ≥0.8g/ml.h (Holding the catalyst at 400℃ constant temperature under inert gas flow for 4 hours).


    4. Catalyst operation condition and feed gas requirements

    Operation conditions
    Operation pressure : 120 ~ 300 Bar
    Reaction temperature : 210 ~ 300℃
    Space velocity : 6000 ~ 20000 h-1
    Impurities requirements in 
    Feed gas  : Total sulfur: ≤ 0.1ppm
                      Total chlorine: ≤ 0.01ppm
                      Hydroxy : ≤ 0.01ppm
                      NH3: ≤ 50ppm
                      Oxygen : ≤ 0.2%

    5. Catalyst loading

    Works of preparation
    Finished system feed pressure, gas leakage, sweeping according to designed requirements. Be sure to eliminate system leakage points.
    Facilities, instruments, analytical measurements are completed debugging, utility system meets start-up requirements.
    Choose dry weather condition without rain (snow, hailstone), wind and fog to handle catalyst loading.
    Well provided all kinds of labor protective equipments and tools required during catalyst loading, such as work cloths, dust mask, goggles, respirator, gloves, safety lamp, galoshes, copper rod, hop-pocket, plump, funnel, planks, crane, etc.
    To be sure internal parts of reactor absolutely corrected and fixed again.
    Completely remove rust, greasy dirty and impurity in reactor.
    Prepare lifting tools well.
    Alumina support ball loading
    Firstly, load alumina balls as a base at the bottom well according to designed requirements. Alumina balls loading required uniformly, smoothly and also checked by plumb to confirm meet the designed requirements. When enter in reactor, loading workers are required wear protection equipments and load alumina balls based upon designed reactor drawing. 
    Make a measurement with a marked plumb line to ensure the depths of 50~100 mm at different points.
    Catalyst loading
    Two loading workers wear protective equipments and long tube breathing apparatus, then enter reactor through upper head manhole.
    Another two loading operators are responsible for communication, supervision and catalyst transmission at the manhole place.
    Catalyst was carried into reactor by canvas hoses, loading workers hold the canvas hose head, and then load catalyst into reactor in bulk evenly. Along with loading of catalyst, using copper hammer knocking on tubes loaded catalyst frequently and controlling loading speed carefully to avoid catalyst crosslink. Try to ensure equivalent catalyst loading volume of each tube as much as possible (Firstly, load reactor tubes with thermo-wells to prevent operation error affecting thermo-wells loading).
    When total tubes are loaded full of catalyst, then continuously loading heat-insulating layer according to designed requirements. Loading workers are required to stand on planks, not allowed to tread on catalyst directly. Use copper hammer knocking on tubes when catalyst loading height of each tube is 50mm distance to the upper nozzle, and then proceed next step to fully load total tubes and exceed upper tube board 200mm~400mm.
    Based upon on catalyst loading finished, spread 5X5mm stainless steel mesh on proof layer of catalyst. And load alumina balls with the height of 200mm.
    Well load heat insulating layer and test the temperature thermocouple.
    After the end of catalyst loading, check out whether any tools left or not, organize relative workers to carry out inspection and acceptance, restore the disassembled equipments. Prevent the catalyst from moisture and poison gas pollution. 
    Dust sweeping of catalyst bed layers
    Take reactor outlet apart as sweeping gas outlet, mounting baffle in front of flange at outlet pipe.
    Utilize compressor blow nitrogen so as to operate sweeping, follow the principle of low pressure (~1Mpa) and large-capacity N2 gas flow during sweeping progress. The sweeping deemed qualified based on no dust in blown gas.
    Forbidden to stand at gas outlet during whole process of sweeping.
    Restore reactor outlet after sweeping qualified.
    Catalyst reduction operation based upon on whole synthesis system qualified through N2 leakage and displacement inspection. 
    If plant doesn’t plan to start-up for the time being, then kept reactor sealed off in positive pressure condition to prevent catalyst from moisture and poison gas pollution. 
    Loading workers members 
    Loading workers and checking acceptance workers are mainly from technical dept., production dept., engineering dept., equipments maintenance dept., etc.

    6. Catalyst reduction

    Note: RK-04 high pressure methanol catalyst reduction procedure should be provided based on cooperation.

    7. Low production ratio running parameters

    After catalyst reduction, gradually increase system circulation volume, and slow bring feeding gas, enhance synthesis pressure. Start low production ratio running at low system pressure and low concentration of CO and CO2. Then gradually control to 100% production ratio in regular production.
    Feed gas requirements
    CO : 2~5%
    CO2 : 0.3~3%
    Total sulfur : ≤ 0.1ppm
    Total chlorine : ≤ 0.01ppm
    Oxygen content : ≤ 0.2%
    Running parameters
    Pressure: 120-180 Bar
    CO content in inlet gas: 0.3%±2.5%
    Hot spot temperature : 230±5℃

    8. Shut-down

    Shut down
    Ensure normal operation so as to guarantee catalyst kept running at level of high activity and long lifetime. Minimize frequency of start-up and shut down.
    In case of short-term shut down, then turn off MUG, keep system recycle and system pressure to wait restart-up.
    In case of long-term shut down, then decrease system temperature, unload system pressure and handle N2 gas displacement. When plant operated start-up or shut-down, increase or decrease pressure is not allowed too fast. 
    Catalyst must handle oxidation procedure before replacement of catalyst.

    9. Catalyst storage and transportation

    Prevent catalyst from falling, rolling shaking in process of storage, transportation and loading. If not, will cause partial catalyst smashed. 
    Packing catalyst in airtight drum, prevent catalyst from moisture and poison impurities during transportation.
    Hold catalyst in dry condition and anti-proof warehouse, strictly forbidden storage with goods will harm on catalyst.

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