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Synthesis catalysts for future ammonia & methanol production Henrik Larsen, General Manager, Haldor Topsøe A/S, Iran.

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Presentation on theme: "Synthesis catalysts for future ammonia & methanol production Henrik Larsen, General Manager, Haldor Topsøe A/S, Iran."— Presentation transcript:

1 Synthesis catalysts for future ammonia & methanol production Henrik Larsen, General Manager, Haldor Topsøe A/S, Iran

2 Presentation outline Process Economical Benefits Highlights Efficient ammonia and methanol production KM111, new ammonia synthesis catalyst MK-151, new methanol synthesis catalyst Experiences

3 Co-production CO 2 removal Ammonia synthesis Methanation Ammonia Shift Primary reforming Secondary reforming Natural gas Ammonia plant Auto thermal reforming Distillation Methanol synthesis Air separation Oxygen Primary reforming Natural gas Methanol plant Co-production plant Primary reforming Secondary reforming Distillation Natural gas Methanol synthesis Methanation Ammonia synthesis Ammonia Common reforming section Low unit cost compared to stand-alone Well-proven technology Full flexibility in product split Topsøe supplies full range of technology and catalysts

4 Cost and energy effective solutions, examples Process scheme Stand-alone plants Traditional co-production IMAP Reforming units211 Methanol synthesisLoopOnce-through Ammonia synthesisLoop Syngas compressors 211 Natural gas consumption index Investment cost index

5 1 1 1 N N KM New ammonia synthesis catalyst – KM 111

6 Optimized ammonia production with KM 111 KM1 KM 111 Optimized for lower beds Higher NH 3 concentration Lower temperatures Favorable equilibrium S-300 S-50

7 KM 111 activity and stability Time on stream Catalyst activity Accelerated aging plot More than 1,200 industrial references for KM1 Significant activity gain with KM 111 KM1 KM 111

8 KM 111 benefits KM1 KM 111 Basis 2,100 MTPD NH 3 plant 190 Bar operating pressure Production increase Up to 1.9% Increased production One week extra production per year Energy savings 3.5 Bar reduced operating pressure New plants Smaller converter size Decreased catalyst volume KM1 KM 111 S-300

9 KM1 market situation 248 current references worldwide

10 Produced at state-of-the-art manufacturing facility in Denmark MK-151 FENCE™ is the 3rd generation of Topsøe methanol synthesis catalysts Leading edge methanol catalysts MK-101MK-121MK-151 FENCE

11 Independent testing – Activity and Stability  Client ranking: –MK-151 FENCE –Catalyst A –MK-121 –Catalyst B The client procured MK-151FENCE Independent testing by a methanol producer in 2012 Three vendors approved to submit their latest generation methanol catalyst:

12  Increased energy efficiency –Lower recycle flow ratio –Lower loop pressure  Increased carbon efficiency –Additional production during 2.5y 24,000 MT –Additional production until today 920,000 MT  Longer catalyst lifetime –Record with MK-151 FENCE Industrial experience in a 2500 MTPD plant Days on Stream Catalyst activity MK-151 FENCE™ MK-121 MK % MK-151 FENCE™ MK-121 MK-101 Industrial benefits in a 2500 MTPD plant

13 Improved plant design with MK-151 FENCE™ Synthesis gas preparation Lower throughput Reduced front-end size Methanol synthesis Reduced converter size Lower loop pressure Distillation Reduced size Lower energy consumption

14 References MK-151 FENCE Statoil, Norway 2009 PetroChina Golmud, China 2010 Yulin NG Chem, China 2011 Alto Parana, Argentina 2012 KMI, Indonesia 2012 Chemanol, Saudi A Linde Gas Inc., USA 2013 YPF, Argentina 2013 Xianyang, China2014

15 KM 111 and MK-151 Higher activity Increased production Energy savings Long lifetimes

16 Thank you…


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