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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 1009698 Investment cost index 1008575

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-101 20% 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. 2013 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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