03 Rosenberg

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Haldor Topse

Catalysing Your Business


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Haldor Topse A/S

Established: 1940

Ownership: Haldor Topse Holding A/S (100%)

Annual turnover: ~ 700 MM EUR

Number of employees: ~ 2,050


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Offices worldwide

Headquarters

City of Topse office

Research

Production

Engineering

Sale & Marketing

Copenhagen

MoscowBeijing

Tokyo

Bahrain New Delhi

Buenos Aires

Los AngelesHouston


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Business areas

Fertilizer industry

The chemical and petrochemical industries

The refining industry

The environmental and power sector


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Topses business philosophy

To develop and commercialize technology and catalyst

through fundamental understanding of surface chemistryand physics (heterogeneous catalysis)

To strive to be second to non supplier of catalysts and

technology

To be a global player within heterogeneous catalysts


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Topse R&D

60+ years of research in

catalysts and technologies

Study of catalytic reactionsat atomic level

Sophisticated kinetic models

Activity and performance

prediction

Topse annually applies10% of gross revenues to

support these R&D efforts


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ClienClien

A typical project relation with Topse

Topse offers single source know-how combining

catalyst, process and engineering

Technology

licensing

Research

and

development

Engineering

Catalysts


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Sulphur 2009 Sun CityHelge Rosenberg

WSA-DC next generation Topse WSA technology

for stronger SO2 gases and very high conversion


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Topse milestones for H2SO4 technology

Late1970sWSA technology

was developed

and commercialized

1980

First commercialWSA plant in operation

1991

First SNOX plant

in operation

Ongoing improvementand development of

WSA and VK catalysts

2008

WSA plant

No. 80

2008/9

WSA-DC

introduced

WSA W t ( ) S l h i A id


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WSA = Wet (gas) Sulphuric Acid

Technology

Reduces sulphur compunds from process and off-gasesby more than 99.6%

Generates only one end product (H2SO4)

Treats the off-gas in wet condition i.e. no drying is

required


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Principles of the WSA Process

Hot combustion air

Acid

cooling

Produ

acid

Cooling

water

SO2conversion

Gas

cooling

Acid

conden-

sation.

2S rich

edIncineration

H2SO4 (gas) = H2SO4 (liquid) + 90 kJ/mole

HP superheated steam

Atmospheric air Cooling

water return

Clean process

gas to stack

H2S + 1.5 O2 = H2O + SO2 + 518 kJ/mole

CombustionCombustion

SO2 + O2 = SO3 + 99 kJ/mole

OxidationOxidationHydrationHydration

SO3 + H2O = H2SO4 (gas) + 101 kJ/mole

CondensationCondensation

Totally 808 kJ heat per mole of H2S is generated

Approx. 90% heat is recovered as steam or hot air

and less than 10% is discharged by CW

WSA process is autothermal from SO2concentrations above 3% at inlet SO

2converter


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WSA technology

Combustor

Waste heat

boiler

Steam drum

Combustion

air blower

SO2 converter

WSA

condenser

Cooling

air blower

Acidvessel Acid

pump

Acid

cooler

Process

gas cooler

1st and

2nd

interbed

coolers

W

S gas

el gas

start-up

Export steam

Cleaned gas

Sulphuric

acid

product

CW

Stack

Combustion air

SO t d t il


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SO2 converter details

400- 420C

400 - 420C

400 - 420C

265 - 290C

Catalyst Layer

Interbed CoolerOff-gas with

H2SO4 (gas)

Off-gas

with SO2


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Cooling air inl

Clean gas outl

Hot air outlet

WSA condenser details

Sulphuric acidAcid gas inlet


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WSA plant lay-out


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WSA Plant (China)

Specifications:

70% H2S

10% HCN

65 MTPD H2SO4


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WSA plants status of today

Reference situation:

81 reference plants within oil refining, metallurgical,

gasification, coking, power generation etc.

Up to 1,200,000 Nm3/hr gas and 1,140 MTPD H2SO4

Performance:

SO2

concentration up to 6.5%

99.6% conversion

H2SO4 concentration limited to 98%

High energyefficiency


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WSA vs. conventional DCDA

Conventional DCDA plant

SO2 GAS

ROM SCRUBBERDRYING ABSORPTION ABSORPTION

H2SO4

HEAT

LOSS

CONVERSION

HEAT

EXPORT

HEAT

LOSS

HEAT

LOSS

CONVERSION

HEAT

EXPORT

High conversion (> 99.9%)

Medium energy efficiencyWSA plant

H2SO4

SO2 GAS

FROM

SCRUBBER

CONDENSATIONCONVERSION

Medium conversion (< 99.6%)

High energy efficiency

HEATEXPORT

HEATEXPORT


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How do we achieve both high conversion

andhigh energy efficiency?


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Double conversion gives high conversion efficiency

Condensation gives high energy efficiency H2O/SO2 ratio balanced for 99% acid concentration

WSA-DC is capable of handling SO2

concentrations up to13-15 vol.%

The new Topse WSA-DC technology

SO2 GAS

H2SO4

HEAT

EXPORTHEAT

EXPORT

CONDENSATION CONDENSATIONCONVERSION

HEAT

EXPORT

CONVERSION

HEAT

EXPORT

High conversion

High energy efficiency

WSA-DC is a wet gas sulphuric acid process with double

conversion and double condensation, combining thefeatures of todays WSA technology with conventionalsulphuric acid technology.


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WSA-DC process layout, SO2 feed

CW

Sulphuric acid

Water

SO2 Gas

SO2 Converter

(3+1 beds)

1st

WSACondenser

2nd WSA

CondenserClean gas

BFW

Heat

recovery

steam

system

HP export steam

Air

Air


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WSA-DC - comparing features

Steam export,

ton per ton acid*

Acid concentration, wt.%

SO3 emission, ppmv

SO2 emission, ppmv

SO2 conversion, %

SO2 content, vol.-%

WSA-DCDCDAWSA

*) Sulphur-based plant, saturated steam

6.5

99.6

260

10

98

1.9

13

99.95

65

5

99

1.9

13

99.92

100

5

99+

1.4


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Acid production cost comparison

0.50 /m3Process water consumption

0.03 /m3Cooling water consumption

Production costs per

ton of H2SO4,

Annual costs (8,000 hrs/y)

8 /tHP steam production

0.05 /kWhElectricity consumption

40 /tSulphur consumption

Annual

costs

Consumption

&

Production

per hour

Annual

costs

Consumption

&

Production

per hour

DCDAWSA-DCUnit Cost540 MTPD

sulphur-based plant

7.36 t

1,250 kWh

34 t

95 m3

4.1 m3

2,355,000

500,000

-2,176,000

22,800

16,400

~ 720,000

7.36 t

1,400 kWh

25 t

930 m3

3.3 m3

2,355,000

560,000

-1,600,000

223,200

13,200

~1,550,000

4.0 8.6


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Conclusion

The advantages of the lean gas WSA process is now

available also for strong gases WSA-DC is a supplement to existing lean gas WSA

Lean gas WSA process for gases < 6.5% SO2

WSA-DC for gases up to 13% SO2

WSA-DC increases heat recovery rate

Sulphur recovery rate as high as 99.95%


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Thank you for your attention

www.topsoe.com

03 Rosenberg

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