Haldor Topsøe Catalyzing your business

Haldor TopsøeCatalyzing your business

Aldo PeirettiChemicals General Manager Latin AmericaJornada sobre Gas de Síntesis y sus Derivados – Instituto Petroquimico Argentino (IPA)9 October 2013, Buenos Aires

¡ Established 1940¡ Ownership: Haldor Topsøe Holding A/S

(100%)¡ Annual turnover (2012): ~700 MM EUR

(~950 MM USD)¡ Number of employees ~2300

¡ Group management– Business units: Chemical,

Environmental, Refinery andNew Business

– Engineering Production– Catalyst Production– R&D

Topsøe Group’s headquartersin Lyngby, Denmark

Dr. Haldor Topsøe“The corporate world in itself

means nothing unless itimproves the lives of people

and the conditions in thepoor countries”

"El mundo corporativo en símismo no significa nada amenos que mejore la vida

de las personas y lascondiciones en los países

pobres"

Topsøe- A global supplier of catalysts and technologies

Copenhagen Moscow

BeijingBahrain

New Delhi

Buenos Aires

Alberta

Kuala Lumpur

Los Angeles Houston

Headquarters Topsøe offices Research

Production Engineering Sale & Marketing

SubsidiariesHaldor Topsoe, Inc.Haldor Topsøe International A/S, DenmarkHaldor Topsoe India Pvt. Ltd. IndiaZAO Haldor Topsøe, RussiaSubcontinent Ammonia Investment Company ApS (SAICA)Topsoe Fuel Cell A/S, Denmark

Rio

Cape Town

Tokyo

… and a leading market player¡ Market share between 15-25% for established products

¡ Supplier of solutions for 50% of new ammonia plants builtwithin the last decade

¡ More than 60% of ammonia is produced worldwide on Topsøecatalyst

¡ Supplier for 40% of catalysts for production of ultra-low sulfurdiesel

¡ > 30% market share of hydrogen catalysts

¡ Leading environmental catalysts and technologies

¡ > 35% market share of sulfuric acid catalysts

¡ 30% market share of FCC pretreatment catalysts

In short- Topsøe is dedicated to

Presentation outline¡ Syn-Gas Technologies

– Conventional scheme for Ammonia / Hydrogen / Methanol

– Developments

– Benefits

¡ Ammonia & Methanol Co-production

¡ New Technologies

– TIGAS

– SNG

¡ References

Technologies¡ Syngas technologies

– Ammonia

– Hydrogen

– Methanol

– Formaldehyde

– DME

– TREMP™ (SNG)

– TIGAS

Ammonia conventional schemeReformingDesulphurisation Shift

Process steam

Natural gas

Process air

Stack

Purge gas

Ammoniaproduct Ammonia synthesis

CO2-removal

Processcond.Methanation

Hydrogen typical flowsheet

Fuel gas

BFW

Combustion air

Flue gas

LPG/naphtha.

NG

S-removalPre-

reformerTubularreformer Shift PSA

(pressureswing

adsorption)

H2

Steam

Steam

Makeupcomp.

Methanolreactor

Raw methanol

Condensate

Steam reformer

Sulphur remov.

Sulphur removal

Naturalgas

Prereformer

Methanol production by one-step reforming

Steam

Pre-reformer

Secondaryreformer

Steam

Steam

Oxygen

Makeupcomp.

Light ends to fuel

Methanolreactor

Water

Rawmethanol

Raw methanol storage

Condensate

Steam reformer

Sulphur sat. removal

Hydrogenator

Naturalgas

Productmethanol

Methanol production by two-step reforming

Methanol production by ATROxygen/steam

Steam Steam

Raw methanol

Natural gas

Water CondensatePurge

gasHydrogenrecovery

Methanolreactor

Autothermalreformer

Hydro-genator

Sulphurremoval

Saturator Pre-reformer

Makeupcomp.

Rec.comp.

Economy of scale

Capacity

Cos

t

Tubular reformingOxygen plant

Naturalgas

Syngas

Naturalgas

AirOxygen

Syngas

Naturalgas

AirOxygen

Syngas

¡ One-step reforming– S/C ratio ~ 1.8 - 2.5

– up to ~ 2,500 MTPD

¡ Two-step reforming– S/C ratio 1.5 - 1.8

– 1,500 – 6,000 MTPD

¡ Autothermal reforming– S/C ratio 0.6

– > 5,000 MTPD.

Developments¡ High flux primary reformer with Prereformer

– better tube materialsè saving in number of tubes

¡ HTCR (Haldor Topsøe Convection Reformer)

¡ HTER (Haldor Topsøe Exchange Reformer)

¡ TBR (Topsøe Bayonet Reformer)

¡ New burner in secondary reformer

¡ New configuration on NH3 converters S-300 & S-350

¡ Improved catalysts

Today’s steam reforming technologyRadiant wall reformer (SMR)

15,000-200,000 Nm3/hConvection reformer (HTCR)

5,000-50,000 Nm3/h

Exchange reformer (HTER)+ ≤40,000 Nm3/h

Bayonet reformer (TBR)5,000-170,000 Nm3/h

Prereformer

Conventional scheme - prereformerReformingDesulphurisation Shift

Process steam

Natural gas

Process air

Stack

Purge gas

Ammoniaproduct Ammonia synthesis

Prereforming (optional)

CO2-removal

Processcond.Methanation

Prereformer benefits¡ Feedstock flexibility

¡ Reduced NG fuel firing

¡ Reduced steam production

¡ Reduced primary reformersize

¡ Potential for higher heat flux in primary reformer

¡ Increased run length/reliability of reformer and shiftcatalyst systems

HTCR - Convection Reformer

Tube bundle

Burner chamber

flue gas inlet

gas outlet process gas inletprocess gas outlet

flue gas outlet

The HTCR benefits

¡ High efficiency and no steam export

¡ High operating reliability

¡ Compact lay-out

¡ Short lead time

HTCR tube bundle

HTCR reformer tube bundle for 27 MMSCFD unit

HTCR twinä process

Feed

3 x

H2Steam

S-removal Prereformer HTCR twin reformer Shift PSA

Fuel

Flue gas Off-gas

Combustion air

HTER - Exchange ReformerFeed gas

Product gas

SMR effluent

Conventional scheme - HTERReformingDesulphurisation Shift

Process steam

Natural gas

Process air

Stack

Purge gas

Ammoniaproduct Ammonia synthesis

Prereforming (optional)

(optional)

CO2-removal

MethanationProcesscond.

HTER

HTER-p flowsheetSecondary reformerTubular reformer

Processsteam

HTER-p

Process air

Desulp.natural gas

HTER benefits¡ Smaller size primary reformer

¡ Reduced NG fuel firing

¡ Reduced steam production

¡ Reduced CO2 emissions to atmosphere

¡ ~ 10-25% reforming capacity revamp option

TBR – Topsøe Bayonet Reformer

Reformer tube

Catalyst

Center tube

Radiant wall Radiant wall

Process gas outlet

Process gas inlet

Bayonet Reformer benefits

¡ Improvement of traditional SMR technology

¡ Low or eliminated steam export

¡ High hydrocarbon efficiency

¡ Capital cost savings

¡ Feed + fuel savings

Bayonetreformer

Pre-reformer

S-removal

Feed

Stack

Combustion air

Fuel

Shift PSA

H2

The TBR flowsheet

Nozzle Burner benefits¡ Homogeneous gas and temperature distribution at the

inlet to the catalyst bed

¡ Effective mixing at the burner nozzles

¡ Low metal temperatures of the burner

¡ Less maintenance

Conventional scheme – S-50 ConverterReformingDesulphurisation Shift

Process steam

Natural gas

Process air

Stack

Purge gas

Ammoniaproduct Ammonia synthesis

Prereforming (optional)

(optional)

(optional)

CO2-removal

HTER

MethanationProcesscond.

Conventional scheme – S-50 Converter¡ Higher conversion è higher production

¡ Higher energy efficiency– Lower loop pressure

– Lower compressor power

– Higher steam generation

Recent catalyst developments

Prereforming catalyst¡ Feedstock flexibility

¡ High activity

AR-401

Hydrogenation¡ High activity

¡ Low pressure drop

Sulphur absorbent¡ High sulphur absorption capacity

¡ Hydrogenation activity

HTZ-51

TK-261

Recent catalyst developments

Methanol synthesis catalyst¡ Increased production & long lifetime

¡ Superior activity with lower by product level

Reforming catalyst¡ Alkali promotion technology

¡ Superior resistance to carbon formation

Shift catalyst¡ Superior high and stable activity

¡ Outstanding poison resistance

RK-400

LK-853 FENCE

MK-151 FENCE

Ammonia & Methanol

Co-production Technology

Ammonia and methanol production

CO2 removal AmmoniasynthesisMethanation

AmmoniaShiftPrimary

reformingSecondaryreforming

Naturalgas

Ammonia plant

Autothermalreforming Distillation

MethanolMethanolsynthesis

Airseparation

Oxygen

Primaryreforming

Naturalgas

Methanol plant

Co-production plant

Primaryreforming

Secondaryreforming

DistillationNaturalgas

Methanol

Methanolsynthesis

Methanation Ammoniasynthesis

Ammonia

Ammonia and methanol production

CO2 removalShiftPrimaryreforming

Secondaryreforming

Naturalgas

Co-production plant

Methanolsynthesis

AmmoniasynthesisMethanation

Ammonia

Methanol

Co-production plant

Primaryreforming

Secondaryreforming

DistillationNaturalgas

Methanol

Methanolsynthesis

Methanation Ammoniasynthesis

Ammonia

Integrated methanol, ammonia, urea plantProcess steam

Natural gas

Process air

StackPurge gas

Ammoniaproduct

Methanol product

CO2

Oxygen

Ammonia synthesis Methanation Methanol synthesis CO2 removal

Desulfurization Reforming Shift

Summary co-production technology¡ Flexibility in adjustment of the ammonia and methanol production capacities

¡ Two-step reforming unit using optional enriched air in the secondary reformer

¡ Once-through methanol synthesis at standard pressure

¡ High pressure methanator

¡ Low energy consumption

¡ The simple layout increases reliability

¡ Low CO2 emissions (reduced by ~36% from CO2 section in ammonia plant & ~20%from reformer flue gas stack if an HTER is introduced)

¡ Results in lower investment cost than individual plants

¡ Well-proven scheme with 5 plants in operation

¡ First reference has been in operation since 1993 – and the latest referenceplant is under construction in Russia

¡ Topsøe supplies full range of technology and catalysts

Topsøe experience list co-production plantsLocation Methanol capacity

MTPDAmmonia capacity

MTPDStart-up

Middle East 72 286 1993

USA 363 600 1994

China 120 600 1999

Malaysia 200 1,125 1999

China 136 314 2003

Russia 670 1,382 2015 (exp.)

Middle East 3,000 900 2015 (exp.)

Middle East 3,000 900 2015 (exp.)

Russia 1350 415 2016(exp.)

New Technologies

New technologies¡ TIGAS

– Topsøe Integrated GAsolineSynthesis

– Methanol to gasoline

– Syngas to gasoline

¡ TREMP– Topsøe REcycle Methanation

Process

– Production of SNG (SyntheticNatural Gas)

A brief overview of the TIGAS technology¡ Topsøe Intergrated GAsoline

Synthesis

¡ Raw material for TIGAS– Methanol

– DME

– Syngas

¡ The product has 88-92 octane

¡ The TIGAS product can be useddirectly in the gasoline pool

¡ The process has been demonstratedin large scale for 4 years

¡ Methanol-to-gasoline (MTG)

¡ Syngas-to-gasoline (STG)

Synthesis gas Methanolsynthesis

Gasoline

C3-C4

Water

TIGAS

Process options for TIGAS

Synthesis gas MeOH/DMEsynthesis

Gasoline

C3-C4

Water

TIGAS

A brief overview of the TREMP technology¡ SNG generated by methanation

of syngas– CO + 3H2 → CH4 + H2O

– CO2 + 4H4 → CH4 + 2H2O

¡ Typical raw material for thesyngas– biomass, waste, coal, petcoke

¡ Markets for SNG– Where NG resources limited

– Where the raw materials areabundant

– Strategic energy sourcing

First modern SNG plant¡ Largest single train SNG plant

– 1.4 billion Nm3/year– Contract awarded in September 2009

¡ Contract includes:– Licence– Engineering– Catalyst– Services– Procurement assistance

¡ Start-up in autumn 2013¡ Xinjiang Qinghua Coal Based Co. Ltd. in China

Principales clientes en America Latina¡ PETROBRAS (ULSD, Hidrógeno, WSA/SNOX, Amoniaco)

- Refinerias RNEST, REFAP, REVAP, REGAP, REDUC, UFN-5, etc.

¡ PEMEX (8 nuevas unidades ULSD, Hidrógeno, Amoníaco)

¡ PDVSA (Petropiar, Petrocedeño, Amuay, Cardon)

¡ PEQUIVEN (FertiNitro, Metor, SuperMetanol, Morón, El Tablazo)

¡ YPF (Lujan de Cuyo: ULSD, Hidrógeno, WSA – Huincul: Metanol)

¡ PETROPERU (Refinería Talara: ULSD, Hidrógeno y WSA)

¡ PROFERTIL (Amoniaco)

¡ ENAP (Refineria BioBio y Aconcagua, catalizadores para Hidrocraqueo)

¡ STAATSOLIE, Suriname (Hidrógeno y WSA)

¡ ANCAP (ULSD)

¡ MOLYMET (WSA)

¡ CUVEMPEQ (Amoníaco)

Haldor Topsøe en Argentina¡ PROFERTIL, Bahia Blanca – Planta de amoniaco, 2,000 mtpd

¡ AIR LIQUIDE, Campana – Planta de Hidrogeno, 15,000 Nm3/h

¡ ENSI – Planta de Agua Pesada, Neuquen – Sintesis de NH3 y crackers de NH3

¡ YPF Refineria Lujan de Cuyo – Planta de Hidrogeno, 6,000 Nm3/h

¡ YPF Planta de Metanol, Plaza Huincul - Catalizadores Metanol

¡ YPF Refineria Lujan de Cuyo, Internos Rxs y catalizadores de Hidrotratamiento -Catalizadores hidrocraqueo ISOMAX - Reactor Design Package & Internos Rxs &catalizadores para Unidad HDS-3 – Catalizadores planta de hidrogeno – BEDP paraplanta WSA

¡ YPF Refineria La Plata – Internos Rxs HTG – Hidrotratamiento de gas oil – BEDPpara planta WSA

¡ Axion Energy, Campana – NHT catalysts

¡ Bunge, Campana – Catalizadores para planta de amoniaco

¡ Alto Paraná, San Martin – Catalizadores para la Sintesis de Metanol

¡ Catalizadores para Acido Sulfurico en DGFM / Meranol / Akzo Nobel

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