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Dry Reforming Catalysts

Dry reforming catalysts for advantageous plant operation - Regarding coking, opex, capex and carbon footprint

Syngas generation based on the conventional steam reforming process requires considerable amounts of process steam. Producing this steam has a major impact on the plant's energy bill. This industry is therefore looking for ways to reduce the steam-to-carbon (S/C) ratio of syngas generation. With conventional reforming catalysts, the reduction of steam can ultimately lead to or accelerate deactivation of the catalyst due to carbon accumulation and coke formation.

The stabilized crystal structure and tuned catalyst composition of BASF's SYNSPIRE G1-110 catalyst improves gasification activity and paves the way for coke-free operation under conditions with a low S/C ratio.

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With conventional reforming catalysts coking is initiated through deposition and insertion of a carbon species from the vapor phase into the metallic nickel (Ni) particles. Carbon accumulates at these weak points, forming carbon “whiskers“ and soft coke. This ultimately leads to deactivation of the catalyst. Self- cleaning mechanism Unique structure and composition of metal oxide carrierNo accumulation of C on catalyst surfaceNo deactivation in dryer conditions

BASF Catalysts | Synrise Catalyst Chart

BASF's SYNSPIRE Catalyst: Designed to Withstand Coke Formation

Catalysts SYNSPIRE G1-110
Main active component Ni-oxides
Shape and size Green tablets, 4-hole quadrilobes, 15 mm x 8 mm
Tapped density 0.9-1.1 kg/l
Packaging 200 l steel drums
Expected lifetime 5-8 years
Typical operating conditions S/C < 1.8 [mol]/[mol] , H2/CO: 1-3 [mol]/[mol]
Typical operating temperature (outlet gas temp) 800-950° C
Typical operating pressure 20 – 40 bar
BASF Catalysts | Synspire

*S/C: Steam/Carbon [mol] / [mol], with Carbon defined as C from hydrocarbons

Advantages for our Customers

Linde‘s DRYREF syngas generation plant capitalizes on the features of this new catalyst based on a tailored set of steam reforming parameters.

Benefits at a glance

  • New catalyst enabels coke-free operation
  • Low OPEX – energy savings and lower costs
  • CAPEX savings thanks to more compact equipment
  • CO2 utilization as feedstock
  • Smaller carbon footprint

Potential applications

  • All processes with CO2 source that require a H2 /CO ratio < 3
  • Various processes in the chemical industry
  • Downstream process in oil and gas (refining)

BASF and Linde: A Strategic Alliance to Push the Efficiency Boundaries.

2010-2014 (Phase I)

Catalyst screening test
Extensive catalyst screening @hte, identification of optimized catalyst material

Learn more about hte

2014-2016 (Phase II)

Catalyst development and laboratory test

Upscaling of G1-110 from grams to hundert of kg scale, thorough performance testing on lab-scale

2016-2017 (Phase III)

Pilot testing in Linde Pilot Reformer (LPR)

G1-110 fully transferred to BASF production lines, catalyst pellets operated under actual reformer tube conditions

2017 (Phase IV)

Commercial demonstration

G1-110 utilization in Linde‘s industrial-scale HyCo plant with full product utilization

*Image courtesy of Linde

2019 (Phase V)


Technology ready to contribute to customer success

For further information, please download our brochure below:

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