Joy Industries: Cobalt Oxide Catalyst

Cobalt Oxide Catalyst for Ammonia Oxidation reduces Catalyst cost up to 75%

Nitric Acid or Nitrogen Oxide have been produced basically the same way since the beginning using Platinum/Rhodium catalyst. Cobalt Oxide Catalyst is used as an alternative to solve several problems such as the high cost of platinum; the short operating cycles; and the by-product reaction producing N²O. Cobalt oxide catalyst is used in nitric acid plants as an alternative to the Platinum-based catalyst. By using cobalt oxide catalyst, plants have shown increased production at significantly reduced operating costs.

Cobalt oxide catalyst technology improves operating cycles and increase efficiency over the platinum catalyst technology.

Benefits of Cobalt Oxide Catalyst in Ammonia Oxidation

The following are a few of the many benefits of using Cobalt Oxide Catalyst Systems:

Higher ammonia conversion efficiencies:

95% + for high pressure plants (90-120 psig)
98% + for low pressure plants (0-25 psig)

No plant shutdowns due to the catalyst
No need to change out the catalyst charges
No more catalyst inventory costs due to strength and longevity of the catalyst
Lower operating temperatures (about 1550 ºF) results in less heat exchanger failures
Reduced maintenance costs since there are no shutdowns to change out catalyst. Also, longer runs and lower temperatures reduce equipment failures due to thermal cycling
Lower pressure drop in the system reduces steam consumption or increases the production through the plant
Much less N²O, which is an environmental pollutant

Economics of Plant Conversion using Cobalt Oxide Catalyst

Cobalt Oxide Catalyst Systems offer a simple short term payback of less than one year on the initial investment and provides significant long term savings by reducing catalyst operating costs; reducing maintenance cost; longer production runs; and improved ammonia conversion. These outstanding savings are possible because Cobalt Catalyst System reduces basic catalyst operating costs from $3-$4 per ton to $0.50-$0.75 per short ton of nitric acid. Imagine a 350t/d plant saving more than $400,000 per year in operating expenses alone. Add increased production from the improved efficiency and reduced maintenance from longer run times and that plant could see a yearly savings exceeding $500,000.

Some plant evaluations have even shown that they can recover 75% of the capital conversion costs from the sale of the platinum/rhodium gauze in inventory.

The first step towards using this state-of-the-art technology is a detailed plant engineering study where firm costs and benefits can be defined. Send us the details of your plant and we will be glad to help you.