CAP (Catalyst Activity Profile) is an advanced loading plan concept that combines catalysts of different activities to match the capabilities of a specific plant. CAP allows the heat of the reaction to be more evenly distributed along the length of the reactor tube, boosting the efficiency of the limited heat transfer area available. Each CAP loading plan is customized for each plant, taking into account not only the reactor design parameters, but also the individual customer's preferred operating conditions and capacity requirements.
CAP 3.0 (T)
The original CAP 1, introduced in 2003, allowed the methanol inlet to be increased to 10 vol%, which dramatically enhanced the productivity of formaldehyde plants and lowered the operating costs. Since then, we have developed the concept further and launched CAP 2.0 and CAP 2.0T with improvements achieved in terms of catalyst lifetime, yield and power consumption. The most recent development has been the CAP 3.0(T) concept. Thanks to the usage of KH-CAP 3.0 INI CAT in the CAP 3.0(T) loading plan, we get better control of the heat release and reduced ageing of the catalyst compared to CAP 2.0. This allows an increase of the productivity by CAP 3.0(T) being able to handle a methanol inlet of up to 11 vol%, or if an increase in productivity is not required, a significant improvement of the catalyst lifetime.
Most JM Formox customers have switched to a CAP type of loading plan - and continue to use it every time. For further details regarding the different CAPs, please contact us.