Sulfur resistant methanation catalyst. Final report, July 1, 1975--January 31, 1978

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Abstract
The purpose of this work was to develop a catalyst which would methanate a gasified-coal stream without prior sulfur removal. Fifty-eight activity tests have been completed on forty-nine different catalyst compositions which were studied as sulfur-resistant methanation catalysts. Most of the base-metal catalytically-active, transition elements were used to prepare the catalysts. These metals were combined or used singly with carriers such as alumina, silica, chromium oxide, magnesium oxide, magnesium silicate, and magnesium aluminate to provide the test catalysts for this work. In addition, a number of catalysts of identical chemical composition were prepared by several formulation methods. Test conditions, including temperature, gas composition, and steam levels were varied during the course of the work and computer data processing was used to analyze the test results. Two catalysts, namely nickel and chromium on magnesium silicate and nickel and chromium on magnesium aluminate, converted all of the carbon monoxide and part of the carbon dioxide to methane at 500/sup 0/F when reduced with only hydrogen and no sulfur in the process gas. This is equivalent to the performance of nickel-SNG type methanation catalysts. After sulfiding, the nickel--chromium on magnesium silicate catalyst retained a 60 to 80% methanation activity at 1100/sup 0/F withmore » low steam/gas ratios. It is important to note that 60 to 80% methanation activity has only been achieved when testing at 1100/sup 0/F. The final stages of a multiple reactor system usually operate at lower temperatures, 500 to 700/sup 0/F, where the equilibrium for the methanation reaction is more favorable, resulting in minimal carbon monoxide and hydrogen contamination of the product methane. Since a low temperature activity in the presence of sulfur was not obtained, it was recommended this research be abandoned. (LTN) « less

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