Haldor Topse Catalysing Your Business

Haldor Topse A/S

Established: Ownership: Annual turnover: Number of employees: 1940 Haldor Topse Holding A/S (100%) ~ 700 MM EUR ~ 2,050

Offices worldwide

Copenhagen Moscow Los Angeles Beijing Houston Bahrain New Delhi Tokyo

Headquarters City of Topse office Research Production Engineering Sale & Marketing

Buenos Aires

Business areas
Fertilizer industry The chemical and petrochemical industries The refining industry The environmental and power sector

Topses business philosophy

To develop and commercialize technology and catalyst through fundamental understanding of surface chemistry and physics (heterogeneous catalysis) To strive to be second to non supplier of catalysts and technology To be a global player within heterogeneous catalysts

Topse R&D
60+ years of research in catalysts and technologies Study of catalytic reactions at atomic level Sophisticated kinetic models Activity and performance prediction Topse annually applies 10% of gross revenues to support these R&D efforts

A typical project relation with Topse

Catalysts

Research and development

Technology licensing

Engineering

Client

Topse offers single source know-how combining catalyst, process and engineering

WSA-DC next generation Topse WSA technology for stronger SO2 gases and very high conversion
Sulphur 2009 Sun City Helge Rosenberg

Topse milestones for H2SO4 technology

Late1970s WSA technology was developed and commercialized

1991 First SNOX plant in operation

2008 WSA plant No. 80

2008/9 WSA-DC introduced

Ongoing improvement and development of WSA and VK catalysts 1980 First commercial WSA plant in operation

WSA = Wet (gas) Sulphuric Acid Technology

Reduces sulphur compunds from process and off-gases by more than 99.6% Generates only one end product (H2SO4) Treats the off-gas in wet condition i.e. no drying is required

Principles of the WSA Process

Hot combustion air Clean process gas to stack Cooling water

H2S rich eed

Incineration

SO2 conversion

Gas cooling

Acid condensation.

Acid cooling

Produc acid

Atmospheric air HP superheated steam

Cooling water return

Condensation Combustion Oxidation Hydration

H SO SO O H (gas) O = = = H = SO H H SO SO O + (gas) 99 SO (liquid) kJ/mole + + 518 + kJ/mole kJ/mole kJ/mole Totally WSA process 808 kJ heat autothermal per mole of from H101 S SO is90 generated 2 2 2S 2+ 3 41.5 2O 2 2is 2 2 3 2 4+ 4 2
concentrations above 3% at inlet SO2 converter Approx. 90% heat is recovered as steam or hot air and less than 10% is discharged by CW

WSA technology
Export steam Combustion air
Steam drum Combustion air blower

Cleaned gas

FW

2S

gas
Combustor Waste heat boiler SO2 converter 1st and 2nd interbed coolers Stack Cooling air blower

uel gas r start-up

Process gas cooler

WSA condenser

Sulphuric acid product

CW
Acid vessel Acid pump Acid cooler

SO2 converter details

Catalyst Layer

Off-gas with SO2

400- 420C

400 - 420C

400 - 420C

265 - 290C

Off-gas with H2SO4 (gas)

Interbed Cooler

WSA condenser details

Clean gas outle

Cooling air inle

Hot air outlet

Acid gas inlet

Sulphuric acid

WSA plant lay-out

WSA Plant (China)

Specifications: 70% H2S 10% HCN 65 MTPD H2SO4

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 energy efficiency

WSA vs. conventional DCDA

Conventional DCDA plant
HEAT EXPORT DRYING CONVERSION ABSORPTION HEAT EXPORT CONVERSION ABSORPTION

SO2 GAS FROM SCRUBBER

HEAT LOSS

HEAT LOSS

HEAT LOSS H2SO4

High conversion (> 99.9%) Medium energy efficiency

HEAT EXPORT SO2 GAS FROM SCRUBBER CONVERSION

WSA plant
HEAT EXPORT CONDENSATION

Medium conversion (< 99.6%) High energy efficiency

H2SO4

How do we achieve both high conversion and high energy efficiency?

The new Topse WSA-DC technology

HEAT EXPORT SO2 GAS CONVERSION HEAT EXPORT CONDENSATION HEAT EXPORT CONVERSION HEAT EXPORT CONDENSATION

H2SO4

High conversion High energy efficiency

Double conversion gives high conversion efficiency WSA-DC is a wet gas sulphuric acid process with double Condensation gives high energy efficiency conversion and double condensation, combining the features of todays WSA technology with conventional H2O/SO 2 ratio balanced for 99% acid concentration sulphuric acid technology. WSA-DC is capable of handling SO2 concentrations up to 13-15 vol.%

WSA-DC process layout, SO2 feed

SO2 Gas

SO2 Converter (3+1 beds) Heat recovery steam system

2nd WSA Condenser

BFW Air

Clean gas

1st WSA Condenser

Water Air Sulphuric acid CW

HP export steam

WSA-DC - comparing features

WSA DCDA WSA-DC

SO2 content, vol.-% SO2 conversion, % SO2 emission, ppmv SO3 emission, ppmv Acid concentration, wt.% Steam export, ton per ton acid*
*) Sulphur-based plant, saturated steam

6.5 99.6 260 10 98 1.9

13 99.92 100 5 99+ 1.4

13 99.95 65 5 99 1.9

Acid production cost comparison

540 MTPD sulphur-based plant Unit Cost WSA-DC
Consumption & Production per hour Annual costs

DCDA
Consumption & Production per hour Annual costs

Sulphur consumption Electricity consumption HP steam production Cooling water consumption Process water consumption Annual costs (8,000 hrs/y) Production costs per ton of H2SO4,

40 /t 0.05 /kWh 8 /t 0.03 /m3 0.50 /m3

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 4.0

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 8.6

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%

Thank you for your attention

www.topsoe.com