Haldor Topsøe Catalysing Your Business

Haldor Topsøe Catalysing Your Business

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

Offices worldwide Copenhagen Los Angeles Houston Moscow Beijing Bahrain New Delhi Tokyo Headquarters City of Topsøe 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

Topsøe s 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

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

A typical project relation with Topsøe Catalysts Research and development Technology licensing Engineering Client Topsøe offers single source know-how combining catalyst, process and engineering

WSA-DC next generation Topsøe WSA technology for stronger SO 2 gases and very high conversion Sulphur 2009 Sun City Helge Rosenberg

Topsøe milestones for H 2 SO 4 technology Late1970s WSA technology was developed and commercialized 1991 First SNOX plant in operation 2008 WSA plant No. 80 2008/9 WSA-DC introduced 1980 First commercial WSA plant in operation Ongoing improvement and development of WSA and VK catalysts

WSA = Wet (gas) Sulphuric Acid Technology Reduces sulphur compunds from process and off-gases by more than 99.6% Generates only one end product (H 2 SO 4 ) 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 2 S rich ed Incineration SO 2 conversion Gas cooling Acid condensation. Acid cooling Produc acid Atmospheric air HP superheated steam Combustion Oxidation Hydration Condensation H SO 2 SO 23 + 4 1.5 ½O H(gas) 2 O 2 = 2 H= SO 2 HSO 32 SO O + 4 + (gas) 4 99 SO (liquid) kj/mole 2 + 101 518 + 90 kj/mole Totally WSA process 808 kj is heat autothermal per mole of from H 2 S SO is 2 generated Approx. concentrations 90% heat above is recovered 3% at inlet as steam SO 2 converter or hot air and less than 10% is discharged by CW Cooling water return

WSA technology Export steam W Combustion air Steam drum Cleaned gas Combustion air blower S gas el gas start-up Combustor Waste heat boiler SO 2 converter 1st and 2nd interbed coolers Stack Cooling air blower Process gas cooler WSA condenser Sulphuric acid product Acid vessel Acid pump Acid cooler CW

SO 2 converter details Catalyst Layer Off-gas with SO 2 400-420ºC 400-420ºC 400-420ºC 265-290ºC Off-gas with H 2 SO 4 (gas) Interbed Cooler

Clean gas outle WSA condenser details Cooling air inle Hot air outlet Acid gas inlet Sulphuric acid

WSA plant lay-out

WSA Plant (China) Specifications: 70% H 2 S 10% HCN 65 MTPD H 2 SO 4

WSA plants status of today Reference situation: 81 reference plants within oil refining, metallurgical, gasification, coking, power generation etc. Up to 1,200,000 Nm 3 /hr gas and 1,140 MTPD H 2 SO 4 Performance: SO 2 concentration up to 6.5% 99.6% conversion High energy efficiency H 2 SO 4 concentration limited to 98%

WSA vs. conventional DCDA Conventional DCDA plant SO 2 GAS ROM SCRUBBER HEAT EXPORT HEAT EXPORT DRYING CONVERSION ABSORPTION CONVERSION ABSORPTION HEAT LOSS HEAT LOSS HEAT LOSS H 2 SO 4 High conversion (> 99.9%) Medium energy efficiency WSA plant HEAT EXPORT HEAT EXPORT Medium conversion (< 99.6%) High energy efficiency SO 2 GAS FROM SCRUBBER CONVERSION CONDENSATION H 2 SO 4

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

The new Topsøe WSA-DC technology HEAT EXPORT HEAT EXPORT HEAT EXPORT HEAT EXPORT SO 2 GAS CONVERSION CONDENSATION CONVERSION CONDENSATION H 2 SO 4 High conversion High energy efficiency Double conversion gives high conversion efficiency WSA-DC is a wet gas sulphuric acid process with double conversion Condensation and double gives high condensation, energy efficiency combining the features H 2 O/SOof 2 ratio today s balanced WSA technology for 99% acid with concentration conventional sulphuric acid technology. WSA-DC is capable of handling SO 2 concentrations up to 13-15 vol.%

WSA-DC process layout, SO 2 feed SO 2 Gas SO 2 Converter (3+1 beds) BFW Air 2 nd WSA Condenser Clean gas Heat recovery steam system 1 st WSA Condenser Water Air Sulphuric acid CW HP export steam

*) Sulphur-based plant, saturated steam WSA-DC - comparing features WSA DCDA WSA-DC SO 2 content, vol.-% 6.5 13 13 SO 2 conversion, % 99.6 99.92 99.95 SO 2 emission, ppmv 260 100 65 SO 3 emission, ppmv 10 5 5 Acid concentration, wt.% 98 99+ 99 Steam export, ton per ton acid* 1.9 1.4 1.9

Acid production cost comparison 540 MTPD sulphur-based plant Unit Cost Consumption & Production per hour WSA-DC Annual costs Consumption & Production per hour DCDA Annual costs Sulphur consumption 40 /t 7.36 t 2,355,000 7.36 t 2,355,000 Electricity consumption 0.05 /kwh 1,250 kwh 500,000 1,400 kwh 560,000 HP steam production 8 /t 34 t -2,176,000 25 t -1,600,000 Cooling water consumption 0.03 /m 3 95 m 3 22,800 930 m 3 223,200 Process water consumption 0.50 /m 3 4.1 m 3 16,400 3.3 m 3 13,200 Annual costs (8,000 hrs/y) ~ 720,000 ~1,550,000 Production costs per ton of H 2 SO 4, 4.0 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% SO 2 WSA-DC for gases up to 13% SO 2 WSA-DC increases heat recovery rate Sulphur recovery rate as high as 99.95%

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