KATALCOJM PERFORMANCE Services

Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. Johnson Matthey plc (JM) gives no warranty as the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. JM accepts no liability for loss or damage (other than that arising from death or personal injury caused by JM’s negligence or by a defective Product, if proved), resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed.

© 2015 Johnson Matthey Group

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More than a catalyst business...

At Johnson Matthey, our customers have often told us that catalysts alone are not sufficient to ensure the best possible performance from a synthesis gas (syngas) plant. As a business with an operating heritage in the industry and people on our team who have designed, built, operated, monitored and maintained syngas plants over a period of more than 30 years, we know this to be true. As a result, Johnson Matthey manufactures catalysts, licenses process technology and delivers services to our customers in order to extract maximum value for our customers from their processes.

The right loading techniques, operation and process optimization of catalysts can give world-beating performance. However, there are many areas away from the catalyst envelope that affect the plant performance.

Through a combination of working closely with our customers, strategic partnerships and our background in the industry, we are able to offer advice and solutions that are a direct benefit to our customers. This is the essence of KATALCOJM

TM PERFORMANCE.

KATALCOJM PERFORMANCE concentrates on issues that are important to you with the aim of improving your plant performance and profitability.

KATALCOJM PERFORMANCE focuses this experience and knowledge in five key areas of:

∆ Efficiency

∆ Throughput

∆ Integrity and Reliability

∆ Environment

∆ Safety

Our range of services and know-how will allow you to make more product, at higher rates, to tighter specifications, at reduced cost, while improving safety, reliability and reducing environmental impact.

To achieve this, KATALCOJM PERFORMANCE offers process technology, proprietary equipment sales, process optimization, revamps and CATALYST CARESM services. We believe that our people are uniquely qualified to provide value-adding services to our customers. Our skills have been inherited from our history and we draw on many years of experience in syngas plant operation, process technology licensing, catalyst technology development and catalyst manufacture. It is this combination of Johnson Matthey’s personnel and skills, and those which our alliance partners bring, that enables us to offer a customized solution to address key issues on your plant.

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Our services

While excellent catalysis is crucially important to our customers, there are activities outside the catalyst envelope that can have a profound effect on the overall plant performance. As a consequence, we have developed a portfolio of industry leading consultancy and service products to help our customers achieve the best possible performance from their assets.

KATALCOJM PERFORMANCE services cover all stages of the improvement process:

∆ strategic review to identify business improvement opportunities

∆ assessment with a specific focus to identify the improvement scope

∆ development of improvement options and selection of an optimum solution

∆ implementation that delivers the business improvement

It is this focus on catalysts, licensing process technology and providing services that makes Johnson Matthey the ideal partner for our customers.

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Reformer survey

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Efficiency

Legislation is becoming more stringent as the link between energy consumption, carbon dioxide emissions and environmental impact becomes clearer, leading to increased regulations incorporating energy efficiency. The financial incentives to decrease energy consumption therefore go beyond traditional energy costs, putting pressure on companies to reduce both energy consumption and emissions.

Johnson Matthey and our alliance partners offer a range of services to improve energy efficiency from preliminary energy studies to full plant modifications.

Our skills are varied and the deliverables and content of a KATALCOJM PERFORMANCE project or consultancy support are individually tailored to meet your needs. The following examples are by no means exhaustive and are designed to give an appreciation of the breadth of knowledge and support available to you.

Examples

∆ Revamp studies

∆ Pre-reformer scoping

∆ Gas heated reformer (GHR) design and supply

∆ Secondary reformer high intensity burner

∆ Energy management consulting

∆ Reformer surveys

Typical energy losses in an ammonia plant

Heatinput

System losses

Other losses

Overall energyrequirements of

reaction

Syngas compressorFiring losses

NH3 compressor

Process air compressor

Refridge condenserOverhead condenser

BFW pump

Energyrequirements

Throughput

Whether you are looking to optimize the current operation of your reformer or considering a full plant revamp, KATALCOJM PERFORMANCE can help you achieve your goals. Full plant simulation models are created rapidly using the Aspen Technology’s HYSYS modelling tool. Proprietary extensions, developed by Johnson Matthey, incorporate detailed kinetics of all syngas catalytic unit operations that enable a wide range of options to be reviewed in a short time frame.

KATALCOJM PERFORMANCE can assist in every stage of project delivery from conceptual ideas through to detailed design and implementation.

Examples

∆ Revamp studies

∆ Pre-reformer scoping

∆ STREAMLINE pressure drop reduction

∆ Secondary reformer high intensity burner

∆ Converter internals design and supply

∆ Reformer surveys

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Reformer imager

purification

hydrogenator

H2

natural gas

ZnO absorbent steam air

primary reforming

secondary reforming

low temperature shift

methanation ammonia synthesis (dual pressure ammonia process)

once through converter (low pressure) high pressure loop

process condensate

process condensate

ammonia product

ammonia product

purgeCO2

refrigeration

Reliability

Benchmarking has shown that world-class petrochemical

plants typically achieve 98% occupacity. However,

many plants fall significantly short of this. Plant reliability

is not just asset related, as people and practices as

well as processes and systems may also contribute

to unreliability. KATALCOJM PERFORMANCE offers

a suite of products that can help you increase the

reliability and therefore availability of your plant.

The benefits of reliability improvement covers the

whole business; from operations, maintenance

and sales through to your customer. Our teams

of functional engineers from different specialities

are available to help. Our focus is to help you

achieve high plant occupacity and quality from

routine operations and maintenance activities.

Examples

∆ LOTISTM and MANTISTM inspection

∆ Enhanced reformer surveys

∆ Reduction and start-up assistance

∆ Process hazard review studies

∆ CatTrackerTM multipoint thermocouples

A CatTracker can be installed in a reformer tube using Johnson Matthey’s patented loading technique.

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High intensity ring burner

Environment

Acceptable environmental performance is

essential to maintain a license to operate, financial

performance and the standing of a company

within the business community and society. A

company’s responsible care image is important

and like quality, is an integral aspect of business.

Legislation changes with time and consequently

companies have to adapt to the often tightening

pressure on environmental performance.

KATALCOJM PERFORMANCE has significant

experience in helping customers focus on defining

and delivering a sustainable environmental

plan. Whether it is improving plant efficiency or

reducing emissions, we have a solution for you.

Examples

∆ Energy management consultancy

∆ Purge converter engineering studies

∆ Start-up assistance

∆ Reformer surveys

∆ Measurement of remnant catalyst bed life

∆ Selective catalytic reduction (SCR) designs

Safety

KATALCOJM PERFORMANCE is able to offer

consultancy in world leading safety practices from

advice on designing for safety, process hazard reviews,

and trip and alarm studies on existing and new assets,

through to incident investigations in the case where

things go wrong. We are also able to offer customers

world leading methodology to enable hazard and

operability studies (HAZOPS) or train your people

to become leaders in such studies themselves.

For example, a methanol producer with several sites

requested Johnson Matthey to act as an independent

consultant, conducting a process hazard review on

each site to provide a comparison of standards within

the same company. The output from the work gave

the customer’s senior management an unbiased

comparison and ideas where to focus the budget

for safety improvements in the following months.

Examples

∆ Process hazard reviews

∆ Catalyst reduction support

∆ Operator training

∆ LOTIS and MANTIS inspection

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“Johnson Matthey’s survey, using their Reformer Imager was second

to none. They helped us identify exactly what was going on in the

reformer, and provided operating conditions that have mitigated the

risk, allowing us to continue operating and avoid a costly shutdown.”

European customer

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“We offer so much to customers who invite us in. Our experts have intimate experience gained from working every day of the week with the most challenging plants in the world. Not only do our staff pass on the benefits of this experience, they are also able to introduce and work alongside a range of partners.

These alliances offer you a quality of advice which is not available elsewhere.”

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Our partners

Johnson Matthey work in partnership with ABB Consulting to identify and implement pragmatic solutions based on technical excellence and industry expertise.

Together we provide the full solution, from the identification of potential issues, right through to implementation to ensure benefits are realized through:

∆ reduced risk

∆ optimized costs

∆ improved efficiency

Daily Thermetrics provides the process industries with precise temperature measurement instrumentation. Renowned for quality, engineering and delivering to demanding needs, with patents on CatTracker technology Daily Instruments provide temperature measurement devices worldwide.

Johnson Matthey has an exclusive partnership for the supply and installation of the CatTracker into reformer tubes. This brings together a unique temperature measurement and a patented loading technique. The collaboration also extends to fixed bed applications.

Jacobs provide engineering, fabrication, construction and maintenance management technology to primary process industries.

Recognising that to enable full execution of projects Johnson Matthey has partnered with Jacobs to provide detailed engineering and project delivery expertise.

LAND specialize in the design and manufacture of infrared temperature measurement, process and thermal imaging, combustion efficiency and environmental emissions monitoring and are the world leader in the design and application of infrared temperature measurement for industry.

As both innovators and manufacturers of high quality precision radiation thermometers and thermometer systems, LAND’s position is unrivalled with over 60 years’ experience in temperature measurement.

Johnson Matthey works with a wide variety of expert partners who have specialist skills that complement our own. It is this combination of Johnson Matthey’s knowledge and expertise with that of our specific partners which makes this service so unique.

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Quest Integrity Group LLC, provides highly accurate, technology-enabled inspection and assessment solutions that help companies in the process, pipeline and power industries increase profitability, reduce operational and safety risks and improve operational planning. The company is built on a foundation of leading-edge science that has innovated and shaped industries for nearly forty years.

Services include LOTISTM and MANTISTM (internal and external) steam reformer tube inspection services and remaining life analysis using their LifeQuest Reformer software. It is in this area that Johnson Matthey and Quest have an alliance.

Schmidt + Clemens is a privately owned German group that is truly global. The group of companies are leading international specialists in the supply of high-alloy centrifugal castings for plant components. This exceptional position is the result of years of experience and collaborative research and development, as well as the most stringent quality requirements in melting, casting, machining and fabrication of special alloys.

The close partnership between ThyssenKrupp Industrial Solutions GmbH and Johnson Matthey builds on the traditional strengths of the two companies. It takes advantage of ThyssenKrupp’s experience in design, engineering and project execution together with our know-how in catalysis, operating syngas plants and related services. This strong collaboration ensures that the Uhde ammonia process is optimized to take best advantage of the latest high performance KATALCOJM catalysts, thus improving efficiency and lowering costs. The most recent development in ammonia synthesis loop design has come as a direct result of this partnership. The Uhde Dual Pressure Process allows a step change in new plant build capacity to be achieved.

The UNIDENSETM technology is a catalyst loading method for primary reformer tubes which is less complex and faster than the traditional “sock” loading method. Johnson Matthey has an operating license and works closely with UNIDENSE to deliver professional catalyst handling services for reformer loadings using both the UNIDENSE and the automated UNILOADERTM technique.

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Examples of services that can be accessed to address your plant requirements

KATALCOJM PERFORMANCE services Energy

efficiencyThroughput Reliability Environment Safety

Reformer loading using UNIDENSE technology ✓ ✓ ✓ ✓ ✓

LTS, ITS and MTS catalyst reductions: Provision of expert and experienced supervision with bespoke portable analyser kit for controlled shift catalyst reduction

✓ ✓ ✓ ✓ ✓

Ammonia synthesis or methanol synthesis reductions: provision of expert and experienced supervision on site to advise during reduction

✓ ✓ ✓ ✓ ✓

Start-ups: provide paid expert and experienced supervision on site to advise during start-up

✓ ✓ ✓ ✓ ✓

Operator training available on a wide variety of catalytic and non catalytic subjects relating to syngas plants. Improved catalytic understanding, up to date knowledge of new products, advice on plant and operational issues

✓ ✓ ✓ ✓ ✓

Measurement of remnant catalyst bed life, improve catalyst change-out planning, reduce catalyst cost

✓ ✓ ✓ ✓

Bespoke software tools for catalyst and equipment performance monitoring including benchmarking, process optimization and troubleshooting

✓ ✓ ✓

STREAMLINE proprietary pressure drop reduction devices providing low pressure drop options for converters

✓ ✓ ✓

CatTracker® multipoint thermocouples with multiple sensing points to allow accurate bed temperature monitoring including reformer tubes

✓ ✓ ✓ ✓

Health check reformer survey including visual inspection and tube shoot

✓ ✓ ✓ ✓

Standard reformer survey including all elements of the health check survey plus catalyst predictions and reformer benchmarking

✓ ✓ ✓ ✓

Enhanced reformer survey including everything from our standard reformer survey plus the application of either the gold cup or reformer imager for unparalled information about the reformer

✓ ✓ ✓ ✓ ✓

LOTIS and MANTIS inspection providing accurate measurement of inside or outside reformer tube wall diameters

✓ ✓ ✓

Day to day technical support for KATALCOJM customers ✓ ✓ ✓ ✓ ✓

Methanol synthesis reductions: provision of experienced supervision on site to advise during reduction

✓ ✓ ✓ ✓ ✓

KATALCOJM PERFORMANCE servicesEnergy

efficiencyThroughput Reliability Environment Safety

Revamp studies ✓ ✓ ✓ ✓

Pre-reformer scoping and design for a revamp ✓ ✓ ✓ ✓

Gas heated reformer design and supply ✓ ✓ ✓ ✓

Secondary reformer high intensity burner technology packages ✓ ✓ ✓

Oxygen burner and autothermal reformer technology packages ✓ ✓ ✓

Purge converter engineering studies ✓ ✓ ✓

Computational Fluid Dynamic capability used for detailed modelling and process diagnosis

✓ ✓ ✓

Asset life and reliability studies ✓ ✓

Process hazard review studies including HAZOP ✓ ✓ ✓

Selective catalytic reduction (SCR) designs for NOx removal from reformer flue gases

✓

Energy management consultancy ✓ ✓ ✓

Converter internals design and supply ✓ ✓

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Should you be interested in any of these services, please contact us.

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Achieve a zero ‘greater than three day accidents’ safety target

The elements of sustainability

Sustainability is a core part of our business strategy. It is about the way we do business – using natural resources efficiently to make products that improve the environmental performance of our customers’ products and processes.

But our view of sustainability extends beyond this. It’s also about the health, safety and wellbeing of the people who work for us, our customers and our communities. It means using resources efficiently, innovatively and effectively, striving to achieve the highest environmental standards in our own operations. At the same time sustainability is about delivering value to our shareholders and our customers in the most responsible way, making sustainable long-term decisions to build a company and

plan its third century of business. Sustainability is about making the right decisions for our people, our communities, our shareholders and, most significant of all, for the planet.

As we progress towards 2017, we are managing sustainability according to five elements:

∆ Social

∆ Environment

∆ Health and Safety

∆ Governance

∆ Financial

Find out how we are progressing towards Sustainability 2017 – www.matthey.com/sustainability

Halve our carbon intensity

At least double earnings per share

Achieve zero waste to landfill

Halve key resources consumed per unit of output

Achieve zero occupational illness cases

SocialEmployment, development, wellbeing, recruitment Safeguard reputation

Health and SafetyEmployees, customers, communities Beneficial Products

FinancialMust be profitable to be sustainable Align financial and sustainability targets

GovernanceWell run business Transparent reporting

Environment Responsitive operations Beneficial products

SUSTAINABLE BUSINESS

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Designed and produced by www.houseoftype.co.uk

For further information on Johnson Matthey, please contact your local sales representative or visit our website. KATALCO, PURASPEC, STREAMLINE and TRACERCO Diagnostics are all trademarks of the Johnson Matthey group of companies. CATALYST CARE is a service mark of the Johnson Matthey group of companies.

Headquarters: Other offices worldwide:Billingham, UK for contact details please visitTel +44 (0) 1642 553601 www.jmprotech.com/locations

www.jmprotech.com© 2015 Johnson Matthey group

1088JM/0315/4/syn

Designed and produced by www.houseoftype.co.uk

For further information on Johnson Matthey, please contact your local sales representative or visit our website. KATALCO, PURASPEC, STREAMLINE and TRACERCO Diagnostics are all trademarks of the Johnson Matthey group of companies. CATALYST CARE is a service mark of the Johnson Matthey group of companies. CatTracker is a trademark of Daily Instruments. LOTIS and MANTIS are trademarks of Quest Integrity Group LLC.

Headquarters: Other offices worldwide:Billingham, UK for contact details please visitTel +44 (0) 1642 553601 www.jmprotech.com/locations