Synthesis catalysts for future ammonia & methanol production

Henrik Larsen, General Manager, Haldor Topsøe A/S

, Iran

Presentation outline

Process EconomicalBenefits

Highlights

Efficient ammonia and methanol production

KM111, new ammonia synthesis catalyst

MK-151, new methanol synthesis catalyst

Experiences

Co-production

CO2 removalAmmoniasynthesis

MethanationAmmonia

ShiftPrimaryreforming

Secondaryreforming

Natural gas

Ammonia plant

Auto thermalreforming

DistillationMethanolMethanol

synthesis

Airseparation

Oxygen

Primaryreforming

Natural gas

Methanol plant

Co-production plant

Primaryreforming

Secondaryreforming

DistillationNatural gas

Methanol

Methanolsynthesis

Methanation Ammoniasynthesis

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

Cost and energy effective solutions, examples

Process schemeStand-alone

plantsTraditional

co-production IMAP

Reforming units 2 1 1

Methanol synthesis Loop Once-through Once-through

Ammonia synthesis Loop Loop Loop

Syngas compressors 2 1 1

Natural gas consumption index 100 96 98

Investment cost index 100 85 75

111NN

KM

New ammonia synthesis catalyst – KM 111

Optimized ammonia production with KM 111

KM1

KM 111

KM 111

• Optimized for lower beds

• Higher NH3 concentration

• Lower temperatures

• Favorable equilibrium

S-300

S-50

KM 111 activity and stability

Time on stream

Ca

taly

st a

ctiv

ity

• Accelerated aging plot

• More than 1,200 industrial references for KM1

• Significant activity gain with KM 111

KM1

KM 111

KM 111 benefits

KM1

KM 111

KM 111

• 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

KM1

KM1

KM1

KM 111

KM 111

S-300

KM1 market situation

• 248 current references worldwide

• 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-101 MK-121 MK-151 FENCE

Independent testing – Activity and Stability

Client ranking:– MK-151 FENCE

– Catalyst A

– MK-121

– Catalyst B

The client procured MK-151FENCE

60

70

80

90

100

110

120

SOR

EOR

Catalyst BMK-121 MK-151 Catalyst A

Rela

tive

acti

vity

• Independent testing by a methanol producer in 2012• Three vendors approved to submit their latest generation methanol

catalyst:

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

Ca

taly

st

acti

vit

y

MK-151 FENCE™

MK-121MK-101

20%

20%

MK-151 FENCE™

MK-121

MK-101

Industrial benefits in a 2500 MTPD plant

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

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, China 2014

KM 111 and MK-151

• Higher activity

• Increased production

• Energy savings

• Long lifetimes

Thank you…