KATALCO PERFORMANCE efficiency improvements Johnson Matthey

In today’s competitive landscape, companies operating inefficient plants find that they are becoming unfeasible when compared to those paying much less for energy. 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  KATALCO 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 include:

  • Revamp studies
  • Pre-reformer scoping
  • Gas heated reformer (GHR) design and supply
  • Secondary reformer high intensity burner
  • Energy management consulting
  • Reformer surveys
  • Continuous reformer monitoring system (see below)


KATALCO PERFORMANCE Continuous Reformer Monitoring System

A poorly balanced reformer can lead to

  • Reduced production
  • Higher energy consumption
  • Increased NOx emissions
  • Reduced tube life

​For a reformer to be truly well balanced, process gas temperatures, flue gas temperature and compositions, and tube temperatures should all be uniform. This is rarely achieved in practice because most reformers do not have sufficient instrumentation to measure all the above parameters. As a result, conventional reformer balancing is often based on tube temperature measurements.

Johnson Matthey now offers a continuous reformer monitoring system in which additional insight is provided by the use of advanced measuring techniques such as thermal imaging and tunable diode laser absorption spectroscopy. Information from these techniques (“in line”, “off line” and/or “at line”) is combined with data from existing plant information systems (“in line”, “off line” and/or “at line”) and interpreted using KATALCO PERFORMANCE software to produce the following outputs on a daily, shiftly, weekly or other agreed frequency which are used both to improve plant performance and to sustain that improvement.

  • Data reconciliation
  • Economic model with opportunity cost of suboptimal operation
  • Recommendations for balancing 
  • Predicted and measured tube temperature history and remnant life estimate

The system can be provided as part of a KATALCO PERFORMANCE remote monitoring and optimization system. 


Page updated 05/01/17