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Tailor-made catalyst solutions to meet the demands for lower SO2emissionsPresented by Osman Chaudhry, Haldor Topsøe A/S
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Haldor TopsoeIn brief
• Established in 1940 by Dr. Haldor Topsøe.
• Market leader in heterogeneous catalysis and surface science for over 70 years.
• 2,800 employees, 11 countries, five continents.
• VK catalyst production in USA and Denmark.
• Private 100% family owned company.
• Spend more than 10% of revenue on R&D.- 90 million USD
PelletsFirst
with Daisy
VK-WSA
VK69
VK59
25 mmVK-701 LEAP5
VK-WSX
First
with Rings
First
with Cs
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Most common approaches to meet the reduction of SO2 emission
• Invest in a double- or triple-absorption unit
• Increase your scrubber capacity
• Invest in a scrubber unit
• Better catalysts- VK59 & VK69- VK-701 LEAP5™
SO2+SO3
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Low temperature catalyst options – VK59
10-15%reduction in SO2 emission
Single adsorption
VK38
VK38
VK48
VK48VK59
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Low temperature catalyst options – VK69
50%reduction in SO2 emission
Double adsorption
VK38
VK38
VK48
VK38VK69
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Advantages of VK-701 LEAP5™
• Achieving remarkably low emission
• No extra chemicals or by-products
• Easily implemented in a existing plant
• No extra catalyst volume needed
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The key application areas for VK-701 LEAP5™
• Lower passes in single-absorption plants
• 3rd pass in 3+1 or 3+2 double-absorption plants
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SO3
SO3
(V O) O(SO ) OV -4
2 4 4
2V OSO (s)IV
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(V O) O(SO ) SOV
2 4 4 3
-4
(V O) O(SO )V
2 4 4
-4
(V O) O(SO ) OV
2 4 4 2
-4
2V O(SO )IV
4 2
-2
2SO4
-2SO2
O2
2
1
3
4
SO2 SO3
SO2
Source: O.B. Lapina et al (1999). Catalysis Today, 469-479.
V5+ is the active oxidation state
Mechanism of catalytic SO2 oxidation
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60
0380 400 420 440
Temperature, °C
Content of vanadium compounds (relative)
70
80
50
40
30
20
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VK-701 LEAP5
VK48
Bed 3 ConditionsV5+
VK59
V5+
V5+
VK-701 LEAP5™ operates with a higher content of Vanadium +5
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1000
100
1380 390 400 410 420 430 440 450 460
Temperature
°C
Relative activity
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VK-701 LEAP5
VK59
VK48
Bed 3 Conditions
Superior activity of VK-701 LEAP5™
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Performance of VK 701 LEAP5™ - Case Study…
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Case study 1Reduced emissions from a single-absorption plant
• Layout : 4-pass single-absorption
• SO2 source : Metallurgical off-gas
• Feed gas : 8.5% SO2, 14.7% O2
• Catalysts in beds 1/2/3 : VK38 / VK38 / VK48
• Conversion outlet bed 3 : 97.5%
Single adsorption
VK38
VK38
VK48
VK48VK59VK-701
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Case study 1
Catalyst in bed 4 VK48 VK59 VK-701 LEAP5
Inlet temperature, °C 425 415 407
Overall conversion, % 98.57 98.74 99.01
SO2 in the stack, ppm 1390 1220 970
Relative SO2 emission 100 88 70
SO2 emission reduced by 25% compared to VK59
SO2 emission reduced by 30% compared to VK48
Reduced emissions from a single-absorption plant
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Case study 2
• Layout : 3+1 double-absorptionplant
• SO2 source : S-burning
• Feed gas : 11% SO2, 10% O2
• Catalysts in beds ½ : VK38 / VK38
• Conversion outlet bed 2: 88.5%
Reduced emissions from a double-absorption plant
Double adsorption
VK38
VK38
VK48
VK38VK69
VK-701
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Case study 2Reduced emissions from a double-absorption plant
Catalyst in bed 3 VK48 VK48 VK-701 LEAP5
Inlet temperature, °C 440 440 423
Conversion outlet bed 3, % 95.45 95.45 96.43
Catalyst in bed 4 VK38 VK69 VK69
Intlet temperature, °C 425 395 395
Overall conversion, % 99.85 99.92 99.96
SO2 in the stack, ppm 200 100 64
Relative SO2 emission 100 50 32
36% SO2 reduction compared to VK48/VK69
68% SO2 reduction compared to VK48/VK38
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Performance of VK 701 LEAP5™ - In operation…
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CASE STORY 1 – VK-701 LEAP5™Example from North America:
Single adsorption
VK38
VK38
VK48
VK48VK69
VK-701
• Emission had to be reduced in the 3x1 plant from 350 ppm to approx. 165 ppm.
• Solution; to revamp and install VK69 and VK-701 LEAP5™
Plant and feed gas specification:
• 3+1 double absorption
• 2000 MTPD
• 11.7% SO2
• 9.3% O2
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CASE STORY 1 – VK-701 LEAP5™
• Start up June 2012
• After two years the activity of VK-701 LEAP5™ is still so high that Bed 3 runs into equilibrium.
* During this TOPGUN a leak was detected in one of the re-heat exchangers
Prior to loading
PredictedStart of
run1 year* 2 years
Production 2085 MTPD 2085 MTPD 2085 MTPD 2065 MTPD 2060 MTPD
SO2 11.50% 11.7% 11.80% 11.78% 11.95%
Conversion 99.75% 99.89% 99.92% 99.89% 99.89%
Emission 350 ppm 160 ppm 118 ppm 159 ppm 160 ppm
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CASE STORY 2 – VK-701 LEAP5™
• Sister plant to “Case Story 1”Reduce emission – VK-701 LEAP5TM, Good reference
Plant and feed gas specification:
• 3+1 double absorption
• 1379 MTPD
• 11.50 % SO2
• 9.45 % O2
Single adsorption
VK38
VK38
VK48
VK48VK69
VK-701
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CASE STORY 2 – VK-701 LEAP5™
• Start up May 2014
• VK-701 LEAP5™ in Bed 3 was performing better than expected at 100+% activity
Prior to loading
PredictedStart of
run(plant data)*
Start of run
(Analysis)
Production 1380 MTPD 1380 MTPD 1380 MTPD 1380 MTPD
SO2 11.50% 11.50% 11.50% 11.00%
Conversion 99.74% 99.88% 99.89% 99.89%
Emission 365 ppm 170 ppm 154 ppm 146 ppm* Plant data from June, 2014
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Conclusions
• Applicable in both Single & Double absorption plants• Cut SO2 emissions by up to 40% installing VK-701
LEAP5™
• Design new plants to meet tomorrows low emission demand• Avoid investment in a scrubber unit
• Avoid expensive converter revamp project
• VK-701 LEAP5™ performance confirmed industrially• Single & Double absorption plants
• Metal smelters & Sulfur burners
