Introduction
1 Background
The main uses of hydrogen product is hydrogen source for many kinds of downstream hydroprocessing units. With the shortage of crude oil resources and the escalating pressure of environmental protection standards, the development of the petrochemical industry must take the road of deep hydroprocessing for many kinds of distillation and heavy oil, environmental friendliness and product cleanliness. So, the demand for hydrogen sources is huge and growing. Chempack’s making hydrogen product catalysts have high activity and excellent stability.
2 Feed and Product
The making hydrogen production unit’s feed is natural gas, or refinery dry gas, or liquid petroleum gas (LPG) or naphtha. The main target product is hydrogen product with hydrogen purity over 99.9 vol% and CO content (CO <10 ppmv) and CO₂ content (CO₂ <10 ppmv) meeting specification.
3 Catalyst Function and Loading
Purification Section Catalysts
PuriCat S-103E is a high activity NiCoMo type hydrotreating catalyst. PuriCat S-103E has excellent desulfurization and denitrification activity. It also provides excellent activity to saturate olefin and to remove organic oxygenates and metals. PuriCat S-103E is delivered under oxide form. It can be sulfided in situ by injection of a sulfur agent or sulfur in feed. PuriCat S-103E is available with a diameter of 1.3 mm, 1.6 mm or 2.5 mm.
PuriSorb CCR-400 is designed to efficiently remove chloride from both vapour and liquid streams, i.e. hydrogen net gas, recycle hydrogen, natural gas, syngas, and liquid hydrocarbons. PuriSorb CCR-400 can also be used in chemical production of ethylene oxide, propionic aldehyde and linear alpha-olefins (LAO). Its excellent performance is due to a sophisticated manufacturing process that protects the ethylene matrix while removing a broad variety of omnipresent impurities. PuriSorb CCR-400 is a metal oxide type chloride adsorbent, operating from ambient temperature to 400°C.
PuriSorb T-90E Zinc Oxide Catalyst is widely applicable to feedstock purification processes in production of hydrogen, ammonia, alcohols and organic chemicals. It can remove hydrogen sulfide from various feed gases (oils) to less than 0.1 ppm. PuriSorb T-90E can work in severe conditions with high sulfur absorption capacity, high activity, high strength, and good sustainability of activity and sulfur absorption capacity. It can obtain satisfactory operation results both at higher (around 400°C) and lower (around 200°C) temperatures. PuriSorb T-90E is also capable of converting and absorbing organic sulfur such as COS and CS₂.
Pre Reforming Section Catalyst
HyKat SPR-50R Pre-reforming Catalyst, with nickel as its active ingredient, is applicable to pre-reforming using natural gas, refinery gas, LPG or naphtha as feed. HyKat SPR-50R offers excellent activity, stability, anti-carbon ability and mechanical strength. It can be used at high space velocity with operational flexibility. HyKat SPR-50R can be provided in oxidized or reduced and stabilized form upon request.
Steam Reforming Section Catalysts
HyKat SR-212/213 are non-alkali-promoted, unreduced nickel catalysts for steam reforming. They are designed for tubular reformers downstream of a pre-reformer or for steam reforming using light feedstocks such as natural gas and LPG. HyKat SR-213 is typically installed at the bottom of the reformer tubes in combination with HyKat SR-212. Their formulation and processing technology support high activity during long-term operation while reducing carbon formation.
Medium and High Temperature CO Shift Section Catalysts
HyKat ST-213 is a promoted iron/chromium-based CO shift catalyst with ultra-low hexavalent chromium levels. It is designed for mild or high temperature CO shift reactors to convert carbon monoxide in various applications, particularly hydrogen and ammonia plants.
4 Process Flow
The hydrodesulfurization section includes a sulfur hydrogenation reactor and hydrogen sulfide removal adsorbers, where natural gas treatment and hydrogen sulfide adsorption take place.
In the pre-reforming section, purified feed is mixed with superheated steam and sent to the pre-reforming reactor. It is converted into syngas containing H₂, CO, CO₂, CH₄ and unreacted steam, while most heavy hydrocarbons are converted.
The steam reforming section includes a steam reforming heater and a high-pressure steam generation system. Feed is mixed with superheated steam and sent to the heater, where an endothermic reaction converts it into syngas containing H₂, CO, CO₂, CH₄ and unreacted steam.
In the carbon oxide shift section, cooled steam reforming products enter the shift reactor. The shift reaction with steam forms carbon dioxide and additional hydrogen.
The pressure swing adsorption (PSA) section removes impurities to produce high-purity hydrogen (99.9 vol%). Tail gas is used as fuel for the steam reforming heater. The process flow is shown below.
5 Production Specification
The main target product is hydrogen with purity over 99 vol%, CO content below 10 ppmv, and CO₂ content below 10 ppmv, meeting specification.
6 Reference
So far, the technology has been used in over 40 commercial units.
Conclusion
A dependable hydrogen supply is essential for downstream hydroprocessing, especially when treating heavier feedstocks and meeting increasingly demanding product requirements. Natural gas, refinery dry gas, LPG, and naphtha can all serve as feedstocks, but each requires suitable preparation before hydrogen production and purification.
CHEMPACK offers catalysts and adsorbents for the key stages of this process: feed purification, pre-reforming, steam reforming, and CO shift conversion. Pressure swing adsorption (PSA) then removes remaining impurities, while its tail gas can be used as fuel for the reforming heater. Together, these stages support efficient hydrogen production and consistent product quality.
With the technology used in more than 40 commercial units, CHEMPACK understands that reliable performance depends on how well each stage works with the next. We help customers select materials suited to their feedstock and operating conditions, supporting stable operation and a dependable hydrogen supply for downstream units.
