SMR Refined.
HYCO1’s SMR+ Catalyst redefines what’s possible in syngas production, setting a new industry standard for performance, reliability, and efficiency.
Robust. Efficient. Flexible.
SMR+ supercharges your reformer with a second reaction that transforms unconverted methane and by-product CO2
As a breakthrough technology, it surpasses every SMR catalyst
that has come before, delivering unmatched operational robustness and flexibility to meet the evolving demands of industrial gas processing. With innovative features like pre-sintered design for exceptional high-temperature durability, non-coking properties for superior feedstock optimization, and an industry-leading crush strength, the SMR+ Catalyst is engineered to last longer and perform better under the most demanding conditions. Its advanced design ensures optimized heat transfer, minimized pressure drops, and consistent gas flow for unparalleled operational efficiency. Add to this the ability to precisely control the hydrogen-to-carbon monoxide ratio, and you have the most flexible, high-performance catalyst
ever created. Backed by HYCO1’s unwavering commitment to quality and innovation, the SMR+ Catalyst represents a transformative leap forward in syngas technology.
Key advantages of HYCO1’s SMR+ Catalyst
Robust
• Wider Operating Range: Capable of withstanding higher temperatures and more variable conditions compared to traditional SMR catalysts.
• Pre-Sintered Design: Eliminates common failure mechanisms like sintering and metal migration, ensuring long-lasting performance.
• Superior Durability: Industry-leading crush strength (2200 N) ensures resistance to wear and attrition over its extended service life.
Efficient
• Lower Steam Requirement: Reduces energy demand for steam production, cutting operational costs significantly.
• Production Debottlenecking: Frees up capacity in production pipelines, enabling increased throughput.
• Lower Carbon Intensity: Improves carbon monoxide (CO) output while minimizing overall carbon emissions.
• Reduced Environmental Impact: Achieves a lower carbon footprint and decreases greenhouse gas emissions.
• Optimized Energy Use: Enhances heat and mass transfer efficiency, leading to reduced energy consumption.
Flexible
• Tailored Syngas Ratios: Allows precise control of hydrogen-to-carbon monoxide ratios, ranging from 1.4:1 to 3.5:1, meeting diverse process requirements.
• Improved Steam-to-Carbon Ratio: Non-coking properties enable operators to fine-tune steam-to-carbon inputs for maximum efficiency and composition control.
• Versatility Across Applications: Adaptable to various syngas production processes, including steam reforming and dry methane reforming.
• Flexible Turndown Rate: The ability to slow feed by up to 50% with no change in conversion efficiency.
• Wider Operating Range: Capable of withstanding higher temperatures and more variable conditions compared to traditional SMR catalysts.
• Pre-Sintered Design: Eliminates common failure mechanisms like sintering and metal migration, ensuring long-lasting performance.
• Superior Durability: Industry-leading crush strength (2200 N) ensures resistance to wear and attrition over its extended service life.
Efficient
• Lower Steam Requirement: Reduces energy demand for steam production, cutting operational costs significantly.
• Production Debottlenecking: Frees up capacity in production pipelines, enabling increased throughput.
• Lower Carbon Intensity: Improves carbon monoxide (CO) output while minimizing overall carbon emissions.
• Reduced Environmental Impact: Achieves a lower carbon footprint and decreases greenhouse gas emissions.
• Optimized Energy Use: Enhances heat and mass transfer efficiency, leading to reduced energy consumption.
Flexible
• Tailored Syngas Ratios: Allows precise control of hydrogen-to-carbon monoxide ratios, ranging from 1.4:1 to 3.5:1, meeting diverse process requirements.
• Improved Steam-to-Carbon Ratio: Non-coking properties enable operators to fine-tune steam-to-carbon inputs for maximum efficiency and composition control.
• Versatility Across Applications: Adaptable to various syngas production processes, including steam reforming and dry methane reforming.
• Flexible Turndown Rate: The ability to slow feed by up to 50% with no change in conversion efficiency.
SMR+ outperforms traditional SMR catalysts
Low pressure drop in reformers
HYCO1 spheres pack evenly and predictably creating near uniform void patterns throughout a catalyst tube creating similar gas flow channels across the many tubes in the reactor. Spheres create an optimal void to active surface area of the catalyst for the maximization of reaction area to reformer volume.
Catalyst alloy surface impregnation
HYCO1 uses a proprietary method for catalyst coating that allows for improved surface area of the metal alloy while lowering the overall cost of production for the catalyst. The method allows for simplification and improved quality control in the catalyst production process. The method also results in a higher heat transfer coefficient (HTC), reducing the tube temperature while accelerating mass transfer of the reactants to the active catalyst sites providing an overall increase in operational efficiency.
Heating and cooling of tubes
Traditionally, as hot tubes expand and cool, the catalyst repositions, leading to uneven catalyst levels and increased pressure drops. These pressure drops place additional strain on the tubes, accelerating wear and reducing their operational lifetime. In contrast, HYCO1’s SMR+ spheres remain largely stationary in the central core, preserving their original arrangement. This stable core and uniform packing prevent the formation of large voids, avoiding cascading pellet shifts, significant rearrangements from the initial loading, and the associated strain on the tubes. Optimized gas flow
HYCO1’s sphere shaped SMR+ catalyst offers superior performance over irregularly shaped traditional catalysts by ensuring consistent airflow and uniform contact within the reformer. The spherical shape promotes even packing within the catalyst bed, minimizing voids or gaps that can disrupt flow patterns. This uniform arrangement facilitates a steady, predictable airflow, reducing the risk of pressure fluctuations that can impact reformer efficiency. Additionally, the consistent contact between the spheres and reactants optimizes the catalytic reaction, enhancing heat and mass transfer efficiency. These characteristics contribute to more stable reformer operations, improved reaction rates, and reduced energy consumption compared to traditional, irregularly shaped catalysts.
HYCO1 spheres pack evenly and predictably creating near uniform void patterns throughout a catalyst tube creating similar gas flow channels across the many tubes in the reactor. Spheres create an optimal void to active surface area of the catalyst for the maximization of reaction area to reformer volume.
Catalyst alloy surface impregnation
HYCO1 uses a proprietary method for catalyst coating that allows for improved surface area of the metal alloy while lowering the overall cost of production for the catalyst. The method allows for simplification and improved quality control in the catalyst production process. The method also results in a higher heat transfer coefficient (HTC), reducing the tube temperature while accelerating mass transfer of the reactants to the active catalyst sites providing an overall increase in operational efficiency.
Heating and cooling of tubes
Traditionally, as hot tubes expand and cool, the catalyst repositions, leading to uneven catalyst levels and increased pressure drops. These pressure drops place additional strain on the tubes, accelerating wear and reducing their operational lifetime. In contrast, HYCO1’s SMR+ spheres remain largely stationary in the central core, preserving their original arrangement. This stable core and uniform packing prevent the formation of large voids, avoiding cascading pellet shifts, significant rearrangements from the initial loading, and the associated strain on the tubes. Optimized gas flow
HYCO1’s sphere shaped SMR+ catalyst offers superior performance over irregularly shaped traditional catalysts by ensuring consistent airflow and uniform contact within the reformer. The spherical shape promotes even packing within the catalyst bed, minimizing voids or gaps that can disrupt flow patterns. This uniform arrangement facilitates a steady, predictable airflow, reducing the risk of pressure fluctuations that can impact reformer efficiency. Additionally, the consistent contact between the spheres and reactants optimizes the catalytic reaction, enhancing heat and mass transfer efficiency. These characteristics contribute to more stable reformer operations, improved reaction rates, and reduced energy consumption compared to traditional, irregularly shaped catalysts.
Three ways to transform your syngas strategy
From retrofitting existing units to launching turnkey syngas systems, HYCO1’s flexible integration models make carbon-efficient production easier than ever. Choose the path that fits your goals:
Catalyst swap
Replace your existing SMR or ATR catalyst with our high-performance SMR+ Catalyst for immediate efficiency gains.
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New projects
License our technology and build with decarbonization in mind using HYCO1’s CUBE™ Technology for new or expanded syngas facilities.
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Syngas supply
Let us deliver. HYCO1 designs, owns, and operates low-CI syngas, H2, or CO over-the-fence gas production plants.
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Bring HYCO1 CUBE™ Technology
Directly to your projects
Ammonia
Maximize CO yield and slash natural gas costs with the most advanced syngas catalyst engineered for fertilizer production.
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Biogas
Turn your waste into wealth and discover how HYCO1 transforms biogas into high-value syngas.
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Methanol
Unlock flexible H2 : CO ratios, higher throughput, and CO2 feedstock integration, purpose-built for methanol synthesis.
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Refining
Boost hydrogen purity, reduce flare losses, and improve reformer performance with precision syngas innovation.
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Steel
Produce cleaner steel with CO-rich syngas from CO2 and methane, engineered for high-reactivity iron reduction.
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Synthetics
Achieve exact gas ratios and lower carbon scores with advanced syngas tailored for synthetic fuel and polymer output.
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