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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 outline Efficient ammonia and methanol production
KM111, new ammonia synthesis catalyst MK-151, new methanol synthesis catalyst Process Highlights Economical Benefits Experiences
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Co-production Ammonia plant Co-production plant Methanol plant
Primary reforming Secondary Natural gas Ammonia plant Co-production plant Primary reforming Secondary Distillation Natural gas Methanol synthesis Methanation Ammonia Ammonia synthesis Methanation Shift CO2 removal Primary reforming Natural gas Methanol plant 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 Air separation Oxygen Distillation Methanol synthesis Auto thermal reforming
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Cost and energy effective solutions, examples
Process scheme Stand-alone plants Traditional co-production IMAP Reforming units 2 1 Methanol synthesis Loop Once-through Ammonia synthesis Syngas compressors Natural gas consumption index 100 96 98 Investment cost index 85 75 Comment to range for investment cost
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New ammonia synthesis catalyst – KM 111
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Optimized ammonia production with KM 111
Optimized for lower beds Higher NH3 concentration Lower temperatures Favorable equilibrium S-300 KM1 S-50 KM 111 KM 111
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KM 111 activity and stability
Accelerated aging plot More than 1,200 industrial references for KM1 Significant activity gain with KM 111 Catalyst activity KM 111 KM1 Time on stream
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KM 111 benefits Basis Production increase Energy savings New plants
2,100 MTPD NH3 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 KM1 KM1 KM 111 KM 111 KM1
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KM1 market situation 248 current references worldwide
110 current references have operated KM1 for more than 10 years 63 current references have operated KM1 for more than 15 years 28 current references have operated KM1 for more than 20 years The majority of worldwide ammonia production is across KM1
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Leading edge methanol catalysts
Produced at state-of-the-art manufacturing facility in Denmark MK-151 FENCE™ is the 3rd generation of Topsøe methanol synthesis catalysts MK-101 MK-121 MK-151 FENCE
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Independent testing – Activity and Stability
Independent testing by a methanol producer in 2012 Three vendors approved to submit their latest generation methanol catalyst: Client ranking: MK-151 FENCE Catalyst A MK-121 Catalyst B So direct jump into it, we have a methanol producer who has made his own testing of the latest generation methanol catalyst from three vendors, Topsøe, SC and JM. We always invite the customers to make their own comparison testing Catalyst A: (APICO) pre-reduced from Johnson Matthey Catalyst B: MegaMax800 from Clariant (Sued Chemie) The client procured MK-151FENCE
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Industrial experience in a 2500 MTPD plant
Industrial benefits in a 2500 MTPD plant Industrial experience in a 2500 MTPD plant 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 MK-151 FENCE™ Days on Stream Catalyst activity 20% MK-121 20% MK-101 MK-151 FENCE™ MK-121 Lower recycle flow ratio: ~10% Lower loop pressure: ~10% 2500MTPD Statoil Norway, Topsøe fron-end and Lurgi synthesis loop And I will demonstrate the activity trend for all three generation topsoe methanol catalyst installed in statoil. PRESS AND MK-101 WILL COME UP WITH POINTS In this graph, we see development in catalyst activity as a function of time. The first catalyst installed in Statoils two parallel lurgi converters was the MK-101 during the start up in 1997. The activity development of the MK-101 can be seen in the figure. In 2000 they replaced the MK-101 with the MK-121(PRESS AND MK-121 WILL COME UP WITH POINTS) and we can clearly see the improvement of the catalyst activity. Statoil has run with three charges of the MK-121 and for their T/A in 2009, the MK-151 FENCE was tested by Statoil laboratories with other commercially available methanol catalysts and they rated the MK-151 to be the superior catalyst and it was decided to install MK-151 in September I was actually myself on the statoil site during the start up the MK-151 FENCE. The MK-151 FENCE has been running for more than 3 years now (PRESS AND MK-151 WILL COME UP WITH POINTS) and this activity trend confirms the expectations. It is evident that MK-151 has a superior activity – but most important, a superior stability. Also, the graph clearly illustrates the leading edge development of topsoes methanol synthesis catalysts going from each generation of catalyst. PRESS AND SEE THE POINTS AND TEXT Through our R&D work we have been able to increase the activity in the range of 20% from each generation catalyst. By choosing the MK-151, Statoil has benefited by consistently higher production rates while maintaining the amount of feed-stock to the methanol loop resulting in increased carbon efficiency, they have also reduced recycle flow and loop pressure with 10% leading to lower energy consumption. Furthermore, it has been possible to run with longer catalyst lifetimes…… and the MK-151 Fence will be the longest operating methanol catalyst charge in their plant history. As topsoe designs methanol plants it is also important to see how we best can utilize a improved methanol catalyst in the deign of a new plant. MK-101
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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
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References MK-151 FENCE Statoil, Norway 2009
PetroChina Golmud, China Yulin NG Chem, China Alto Parana, Argentina KMI, Indonesia Chemanol, Saudi A Linde Gas Inc., USA YPF, Argentina Xianyang, China Statoil 2500 MTPD lurgi designed bwc converter Second charge purchased Golmud 1000MTPD topsoe designed bwc converter Yulin 220 MTPD local designed bwc converter Alto Paran 160MPTD lurgi designed bwc converter Chemanol 700MTPD topsoe deisgned bwc converter Kaltim 2000MTPD lurgi designed bwc converter
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KM 111 and MK-151 Higher activity Increased production Energy savings
Long lifetimes
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Thank you…
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