Effect of the shape of catalyst on hydrogen production by steam methane reforming process

Steam methane reforming (SMR) is probably the most common method for producing hydrogen in the chemical process industry. In this process hydrocarbon feedstock and steam are converted in an endothermic reaction over a nickel catalyst. The SMR reaction is endothermic and requires external heat input that is often provided by the combustion of a fraction of the incoming natural gas feedstock. Because of bad operation the reformer’s tubes bent and created hot areas and applied thermal stresses to the catalyst.As a result, increasing unit production over 50% of capacity was not possible. This problem was a bottleneck for the program of increasing HDPE production.The only possible solution for this problem was replacment of the catalyst.Since due to limited time,preparing of the original catalyst (Sud Chemi catalyst) was not possible, Sarv-111 as an Iranian catalyst was considered to replace the catalyst.Both of catalysts were nickel based but the major difference was in the shape of catalysts. Sud Chemie catalyst was made in form of 10-hole tablet and was produced in 1916mm size. While the Size of Sarv catalyst was16.520mm and was produced in shape of 4 hole cylinder with 4 flutes and domed ends. It was found that Methane conversion value was 88.9%. Coming to this conclusion, by using of the new catalyst, a favorable conversion was achieved for methane. Production of H2unit increased up to 70% of capacity. But due to the high pressure drop caused by the catalyst shape, further increase was not possible.