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Synthesis catalysts for future ammonia & methanol production

Synthesis catalysts for future ammonia & methanol production. Henrik Larsen, General Manager, Haldor Topsøe A/S , Iran. Presentation outline. Efficient ammonia and methanol production. KM111, new ammonia synthesis catalyst. MK-151, new methanol synthesis catalyst. Process.

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Synthesis catalysts for future ammonia & methanol production

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

  2. Presentation outline Efficientammonia and methanolproduction KM111, new ammoniasynthesiscatalyst MK-151, new methanolsynthesiscatalyst Process Highlights Economical Benefits Experiences

  3. Ammonia plant Natural gas Ammonia Primary reforming Secondary reforming Ammonia synthesis Co-production plant Methanation Methanol Distillation Natural gas Primary reforming Methanol synthesis Secondary reforming Methanol plant Ammonia Ammonia synthesis Methanation Natural gas Methanol Primary reforming Methanol synthesis Distillation Co-production • 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 Shift CO2 removal Oxygen Air separation Auto thermal reforming

  4. Cost and energy effective solutions, examples

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

  6. Optimized ammonia production with KM 111 • Optimized for lower beds • Higher NH3 concentration • Lower temperatures • Favorable equilibrium S-300 KM1 S-50 KM111 KM111

  7. 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

  8. KM 111 benefits • Basis • 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 S-300 KM1 KM1 KM1 KM111 KM111 KM111 KM111 KM1

  9. KM1 market situation • 248 current references worldwide

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

  11. 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 The client procured MK-151FENCE

  12. Industrial benefits in a 2500 MTPD plant Catalyst activity Days on Stream 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™ 20% MK-121 20% MK-101 MK-151 FENCE™ MK-121 MK-101

  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 • PetroChinaGolmud, 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, China 2014

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

  16. Thankyou…

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