Contact Section - Catalysts - SMART CATALYST
January 18, 2021

Introduction Catalyst Types         SC38         SC48         SC69         Dust Protection	Associated Links Catalyst Unloading Catalyst Loading

---

Introduction

Sulfur burning, metallurgical, spent acid, and wet sulfuric acid plants have trusted Smart Catalyst Sulfuric Acid Catalyst Products to reliably and economically convert SO₂ to SO₃. As a world leader in sulfuric acid process technologies and catalyst production for nearly 10 years, our vast technical expertise and sulfuric acid production knowledge, coupled with our commitment to innovation, has enabled us to create a line of high-performance sulfuric acid catalysts for use in any type of converter.Our R&D department is devoted to Optimize the plant operation and then maximizing plant operation performance through — activity, pressure drop, hardness, and service life — to yield the best sulfuric acid catalyst. By balancing these features, a full range of high-quality catalysts that are trustworthy and durable has been developed to maximize conversion while reducing SO₂ emissions, and deliver optimum pressure drop and run time. Therefore, these feature enable smartcatalyst to produce a  high-performance catalysts to boost plant capacity and improve efficiency.

Catalyst Types

SC38

Optimum  activity of SC38 provides operating conditions suitable for all beds of any SO₂ converter. For stable operation SC38 provides an extensive temperature range of 400-630°C  and can endure frequent temperature spikes up to 650°C. SC38 is intended to initiate the reaction at a temperature as low as 360°C, guarantee a stable plant start-up, decreasing pre-heat time according to its greater catalyst activity. 

- 12 mm ribbed ring: energy efficiency of the plant improves with low initial pressure drop;
- 25 mm ribbed dust protection catalyst with 100% longer active time in comparison to the 12 mm ribbed in feed streams with high dust contents;
- 6 mm cylinder and 10 mm ring: suitable for very low velocity converters with even gas distribution.

SC48

SC48 is a high vanadium is specifically designed for lower bed, mainly where large amounts of SO₃ exists in the streams. The SO₂ conversion changes the balance between the active vanadium species in the catalyst. A perfect formulation must balance the ratio of the alkali-metal promoters which increases the vanadium content in SC48, ensuing in a significantly improved activity. SC48 proposes an important performance benefit With  high SO₃ content in the feed gas, such as the lower bed of single contact plants, or the third pass of a double contact plant.

- 12 mm ribbed ring: energy efficiency of the plant improves with low initial pressure drop;
- 25 mm ribbed dust protection catalyst with 100% longer active time in comparison to the 12 mm ribbed in feed streams with high dust contents;
- 6 mm cylinder and 10 mm ring: suitable for very low velocity converters with even gas distribution.

SC69

SC69 is designed specifically for the final pass(es) of double absorption plants. In the lean SO₂ gas environment after the inter-pass absorption tower, the unique SC69 formulation offers unmatched high activity throughout the entire operating temperature range. This affords existing plants the opportunity to greatly reduce SO₂ emissions and/or increase production rates. For new or revamped plants, SO₂ emissions of under 50 ppm are possible. Using cesium as a promoter, SC69’s extremely low ignition or “strike” temperature will significantly reduce pre-heat time and improve start-up performance. SC69 is manufactured in a unique 9 mm Daisy-shape. The high surface area contributes to the high activity in this gas environment and the high void-fraction ensures a low pressure drop and good dust tolerance.

Benefits

- possibility for over 50% reduction in SO2 emission from existing double absorption plants
- possibility for significantly increased production without increasing SO2 emissions
- less than 50 ppm of SO2 emissions possible from new or revamped plants–low ignition temperature for faster and cleaner start-ups
- long lifetime and low screening losses industrially proven since 1996

Low ignition temperature

SC69 have an exceptionally low ignition or “strike” temperatures of 320-330°C (610-625°F) that offer new possibilities for faster and cleaner start-ups. Autothermal restarts can be accomplished after a significantly longer idle time without the use of pre-heat.

9 mm Daisy

SC69 is produced in the unique 9 mm Daisy-shape. In the low SO₂ environment, after the intermediate absorption tower, the 9 mm size and Daisy-shape combination gives 30% extra activity compared to a 12 mm Daisy-shape, in part due to the higher surface area. Also, the Daisy-shape ensures remarkably low pressure drop. The high surface area of the 9 mm Daisy contributes to the high activity, and the high void fraction ensures a low pressure drop.

Dust Protection

25 mm Daisy – dust protection catalyst for catalyst beds suffering from rapid pressure drop increase due to dust in the feed gas, a top layer of Smart Catalyst 25 mm Daisy-shape catalyst can provide a cost effective remedy. The extra void fraction and a lower specific surface area allow a significantly higher capacity for dust, distributing it throughout a larger volume of the catalyst bed. The result is a lower rate of pressure drop increase providing improved energy efficiency and longer intervals between catalyst screenings.

Benefits

- 30-50% longer on-stream time compared to existing ring shaped dust protection catalysts
- 100% longer on-stream time compared to 12 mm Daisy
- maintenance cost savings due to less frequent catalyst screening
- energy cost savings due to lower plant pressure drop
- production increase due to longer time at maximum rate before pressure drop forces production delay