Clariant MegaMax 800 Achieves New Production Record at Zhongtian Hechuang Methanol Plants

On October 16, 2024, Clariant, a specialty chemical company committed to sustainability, announced impressive results for its MegaMax 800 methanol synthesis catalyst used at Zhongtian Hechuang. This facility operates two methanol units, each capable of producing 1.8 megatons of methanol annually through the Lurgi MegaMethanol™ process. Prior to the switch to the MegaMax 800, the units had successfully utilized Clariant’s previous catalyst, MegaMax 700, for approximately 3.5 years. The startup in July 2020 was also supported by Clariant's deep desulfurization systems, ActiSorb™ S2 and ActiSorb S6.

Over the four-year period, the results showcased exceptional catalyst efficiency and productivity, with operations running at 110% of the designed capacity. The combined yield of MTO-grade methanol reached 17,195 kilotons, while cumulative methanol production soared to 48,600 tons per metric ton of catalyst, marking a new record for global coal-based mega-methanol plants.

Georg Anfang, Vice President of Syngas and Fuels at Clariant Catalysts, expressed his satisfaction, stating, “We are thrilled that our MegaMax 800 catalyst has established a new standard in mega-methanol production. This success stems from our 50 years of expertise in methanol catalysis. Such a significant achievement was made possible through the robust collaboration between the skilled operations team at Zhongtian Hechuang and our technical experts.”

Xiaohua Chu, Secretary of the Party Committee of Zhongtian Hechuang Chemical Branch, praised the catalyst's performance, noting that it set new records for operational lifetime and cumulative production since the facility began operations. He emphasized that Clariant’s methanol catalyst has laid the groundwork for four years of continuous operation, efficient maintenance, and startup, and he anticipates even better results with the next batch of catalysts.

Zhongtian Hechuang Energy Co. Ltd., founded in 2007 in Eerduosi, Inner Mongolia, is a prominent energy and chemicals joint venture involving SINOPEC, China Coal Group, Shenergy Group, and Inner Mongolia Manshi Group. The company operates the largest coal-based methanol-to-olefin (MTO) production facility in the world, with an annual capacity of 3.6 megatons of methanol and 1.37 megatons of polyethylene and polypropylene. Its methanol units are also the largest globally, utilizing Air Liquide’s Lurgi MegaMethanol process and Clariant catalysts.

The MegaMax 800 catalyst demonstrates much greater activity compared to standard methanol synthesis catalysts, even under lower reactor temperatures and pressures. It also offers superior selectivity, excellent stability, and high poison tolerance, ensuring prolonged productivity and enhanced energy efficiency with reduced carbon emissions. Suitable for both large and small production units, it has demonstrated exceptional performance across various reactor types and feedstocks. For optimal catalyst performance, Clariant provides the CLARITY™ digital service portal, offering real-time data to improve plant reliability, safety, and profitability.

Given that methanol is a critical intermediate for Zhongtian Hechuang, the installation of ActiSorb S2 and ActiSorb S6 deep desulfurization systems has proven highly advantageous. These systems maintain sulfur concentrations below 10 ppb at the unit's outlet, safeguarding the downstream synthesis catalyst from sulfur fluctuations upstream. This advancement allowed Zhongtian Hechuang to forgo a turnaround cycle, leading to significant additional methanol production and economic gains.