Highlight word(s) in header by changing the font to Open Sans (Headings) + Bold Insert a background picture by clicking on the Insert frontpage picture-button placed in Haldor Topsøe-menu

Highlight word(s) in header by

changing the font to Open

Sans (Headings)

+ Bold 1

Haldor Topsoe Flexible Solutions for Hydrogen Production for Refineries Alexandra Karyagina Regional Manager, Chemicals Department Haldor Topsoe LLC

2

Agenda

roduction and organization of Haldor Topsøe A/S

• Challenges for modern refineries

• Topsoe technologies for refineries

• Topsoe steam reforming technology for Hydrogen Plants • Industrial example – 135,000 Nm3/h (12 t/h) SMR hydrogen plant in

TANECO, Nizhnekamsk

• Topsoe radiant wall reformer (SMR)

• Prereformer

• Industrial example – 5,000 Nm3/h HTCR-based hydrogen plant in Kuibyshev Refinery, Samara

• Topsoe Convection Reformer Process (HTCR)

• References in Russia

• Concluding remarks

3

Challenges for modern refineries

Low OPEX and CAPEX

Oil conversion depth

Strict product specifications

Emission free

Modern refinery

Refinery

4

Hydrogen balance for refinery Hydrogen sources

• Hydrogen rich off-gas of gasoline fractions catalytic reforming

• Hydrogen produced by steam reforming of hydrocarbons

Feed-stocks:

• Natural Gas

• Butane

• LPG

• Naphtha

• Off-gas

Topsoe: >70 Hydrogen Plants last 10 years

Multi-feed Haldor Topsoe Hydrogen Plant

5

Topsoe technologies for refineries

• Full range of hydroprocessing technologies • ultra-low sulphur diesel production

• hydrotreating of oil fractions from naphtha to resid

• hydrocracking of heavy oil fractions

• dewaxing of diesel

• aromatics saturation

• Patented processes (Aroshift™ and HPNA Trim™)

• colour control

• hydroprocessing of renewable feeds – co-processing or stand-alone – for gasoline, jet fuel and diesel production

• Hydrogen technologies

• Sulphur management, off-gas treatment • WSA, DENOX, SNOX, CATOX

Oil refineries

6

Topsoe steam reforming technology for Hydrogen Plants Radiant wall reformer (SMR) 15,000-200,000 Nm3/h

Convection reformer (HTCR) 5,000-30,000 Nm3/h

Heat-exchange reformer (HTER) + ≤40,000 Nm3/h

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

Prereformer

7

JSC TANECO, Nizhnekamsk 135,000 Nm3/h (12 t/h) SMR hydrogen plant, part of hydrocracking complex

8

Background

• Contract concluded in 2006

• Basic Engineering Design Package submitted in

2007

• Construction, assembly 2012-2013

• Commissioning 2013

2012 2013

2007

Detailed Engineering:

VNIPIneft

Reformer Vendor:

Heurtey Petrochem

9

Topsoe scope of supply and guarantees

• License

• Basic Engineering Design Package

(Reformer Engineering Design Package)

• Catalyst supply: – Hydrogenation, sulphur absorption, prereforming,

reforming, MTS catalysts

• Supervision services for: – Site inspection (review of PFD, PID, refractory drying,

reformer inspection)

– Catalyst loading

– Pre-commissioning, commissioning

• Operators’ training

• Technical support after start-up during

normal operation

• Support for VNIPIneft for PD development

Process performance

guarantees:

– Hydrogen plant capacity

– Net energy consumption

– Product quality: H2, steam

– Turndown ratio

– Catalysts life time

– SOx, Nox emissions

10

The SMR-based hydrogen plant - lay-out and key operating parameters

• Low S/C ( ≤ 2.0)

• High reformer outlet temperature ( > 900ºC)

MT shift Radiant wall

reformer

Pre-

reformer

De-

sulphurisation PSA Unit

11

Radiant wall Bottom-fired Top-fired Terrace wall

Topsoe radiant wall reformer

The only reformer with no direct firing towards tubes

12

• Balancing heat input with heat consumption in an optimal way

• Side-fired reformer is ideally suited

• Radiant wall burners

• Flame directed to reformer wall

• No risk of flame impingement

• Counter-current of process gas and flue gas

Inside reformer - controlled firing

Topsoe: Constructed >250 tubular reformers

13

SMR technology. Topsøe radiant wall reformers

14

Prereformer

Tubular Reformer

Prereformer

CnHm + nH2O => nCO + (n + ½ m) H2 - Q

CO + 3H2 <=> CH4 + H2O + Q

CO + H2O <=> CO2 + H2 + Q

Topsoe pre-reformer market share is >60% worldwide

15

Actual operating data

• Feed: – Natural gas – Propane + natural gas

• Process gas temperature at outlet

of reformer 915°С

• S/C ratio 2

• MTS reactor inlet temperature

210°С

• Commissioning: 11 November 2013

– first feed supply to reformer

• 18-19 December - 100-105% load

achieved

135,000 Nm3/h SMR Hydrogen Plant

16

HTCR-based hydrogen plant. Kuibyshev Refinery, Samara

• Capacity 5,000 Nm3/h + PSA 12,000 Nm3/h

• Feed – LPG

• Commissioning in 2009

• Energy consumption: • Guaranteed

3.5 Gcal/1000 Nm3 H2

• Achieved 3.3 Gcal/1000 Nm3 H2

17

HTCR – Convection Reformer

Flue gas inlet (1200°C)

Process gas Flue gas outlet (600 °C)

Tube bundle

Burner chamber

Process gas

outlet catalyst

(850 °C)

outlet (600 °C)

inlet (450 °C)

Catalyst

18

Topsoe Convection Reformer Process (HTCR)

Fuel

Flue gas

Feed

Combustion air

Off-gas

3 x

H2 Steam

S-removal Pre-reformer HTCR reformer Shift PSA

19

HTCR reactor tube bundle

20

HTCR: compact lay-out and fast assembly

HTCR Plant 15 000 Nm3/h

21

22

23

24

HTCR scope of supply

License, Basic Engineering, Detailed Engineering

Package supply of equipment, materials and catalysts

Supervision at site

During assembly

During start-up and test-run

Personnel training

+ technical service after supply via Moscow office Topsoe:

Constructed 35 heat exchange reformers

25

Client Feed type Capacity

Nm3/h

Т outlet

reformer, оС S/C ratio Start-up

TANECO, Nizhnekamsk NG/propane 135 000 920 2.0 2013

Gazpromneft

NIS Pancevo, Serbia NG/LPG 77 000 920 2.0 2012

Rosneft-ANKHK, Angarsk Naphtha/ROG 96 000 H2

+10 000 CO 915 2.0 2015

Rosneft – KNPZ, Samara NG/LPG 50 000 915 2.0 2015

Rosneft – SNPZ, Syzran NG/LPG 50 000 915 2.0 2015

Lukoil-

Volgogradneftepererabotka NG/Naphtha 120 000 910 1.8 2016

Gazpromneft, Moscow

Refinery, Moscow

NG/VGO HC

vent H2 gas 105 000 915 1.9 2020

Topsoe radiant wall reformers – SMR hydrogen plants in Russia

26

Topsoe HTCR Plants in Russia

Client Process Feed type Nm3/h Start-up

NLMK, Lipetsk HTCR NG 3 X 2,000 2004

Rosneft-KNPZ, Samara HTCR LPG (+Н2 rich

gas)

5 000

(12 000) 2009

ShchekinoAzot, Tula

region HTCR

NG (+MeOH

purge gas)

15 000

(26 000) 2012

TANECO, Nizhnekamsk HTCR Twin NG 30 000 2015

Antipinsky Refinery,

Tyumen HTCR Twin NG 30 000 2015

Volkhovneftekhim,

Volkhov

HTCR

NG

2 000 2017

27

Concluding remarks

• Wide range of state-of-art efficient technologies for hydrogen production

• Impressive experience with hydrogen plants for refineries in Russia: • Various process lay-outs

• Large capacity range

• Flexibility in projects implementation and scope of supply

28

To find out more or get in contact

www.topsoe.com To stay up to date regarding

upcoming events, product launches, cases and other

developments get connected and follow us:

.com