Haldor Topsøe Catalysing Your Business

Haldor Topsøe A/SEstablished: 1940

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

Annual turnover: ~ 700 MM EUR

Number of employees: ~ 2,050

Offices worldwide

HeadquartersCity of Topsøe officeResearchProductionEngineeringSale & Marketing

Copenhagen

MoscowBeijing Tokyo

Bahrain New Delhi

Buenos Aires

Los Angeles Houston

Business areasFertilizer 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&D60+ 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

ClientClient

A typical project relation with Topsøe

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

Technologylicensing

Researchand

development

Engineering

Catalysts

Sulphur 2009 – Sun CityHelge Rosenberg

WSA-DC – next generation Topsøe WSA technology for stronger SO2 gases and very high conversion

Topsøe milestones for H2SO4 technology

Late1970sWSA technologywas developed

and commercialized

1980First commercial

WSA plant in operation

1991First SNOX plant

in operation

Ongoing improvementand development of

WSA and VK catalysts

2008WSA plant

No. 80

2008/9WSA-DC

introduced

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

Acidcooling

Productacid

Coolingwater

SO2conversion

Gascooling

Acidconden-sation.

H2S richfeed

Incineration

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

HP superheated steamAtmospheric air Cooling

water return

Clean processgas to stack

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

SO2 + ½O2 = SO3 + 99 kJ/moleOxidationOxidationHydrationHydration

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

Totally 808 kJ heat per mole of H2S is generatedApprox. 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 SO2 converter

WSA technology

Combustor Waste heatboiler

Steam drum

Combustionair blower

SO2 converter

WSAcondenser

Coolingair blower

Acidvessel Acid

pumpAcid

cooler

Processgas cooler

1st and2nd

interbed coolers

BFW

H2S gas

Fuel gasfor start-up

Export steam

Cleaned gas

Sulphuricacid

product

CW

Stack

Combustion air

SO2 converter details

400- 420ºC

400 - 420ºC

400 - 420ºC

265 - 290ºC

Catalyst Layer

Interbed CoolerOff-gas withH2SO4 (gas)

Off-gaswith SO2

Cooling air inlet

Clean gas outlet

Hot air outlet

WSA condenser details

Sulphuric acidAcid gas inlet

WSA plant lay-out

WSA Plant (China)

Specifications:

70% H2S

10% HCN

65 MTPD H2SO4

WSA plants – status of todayReference 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

High energyefficiency

WSA vs. conventional DCDAConventional DCDA plant

SO2 GASFROM SCRUBBER

DRYING ABSORPTION ABSORPTION

H2SO4

HEATLOSS

CONVERSION

HEATEXPORT

HEATLOSS

HEATLOSS

CONVERSION

HEATEXPORT

High conversion (> 99.9%)Medium energy efficiency

WSA plant

H2SO4

SO2 GASFROM

SCRUBBER

CONDENSATIONCONVERSION

Medium conversion (< 99.6%)High energy efficiency

HEATEXPORT

HEATEXPORT

How do we achieve both high conversion and

high energy efficiency?

Double conversion gives high conversion efficiencyCondensation gives high energy efficiencyH2O/SO2 ratio balanced for 99% acid concentrationWSA-DC is capable of handling SO2 concentrations up to 13-15 vol.%

The new Topsøe WSA-DC technology

SO2 GAS

H2SO4

HEATEXPORT

HEATEXPORT

CONDENSATION CONDENSATIONCONVERSION

HEATEXPORT

CONVERSION

HEATEXPORT

High conversionHigh energy efficiency

WSA-DC is a wet gas sulphuric acid process with double conversion and double condensation, combining the features of today’s WSA technology with conventional sulphuric acid technology.

WSA-DC – process layout, SO2 feed

CW

Sulphuric acid

Water

SO2 Gas

SO2 Converter(3+1 beds)

1st WSACondenser

2nd WSACondenser

Clean gas

BFW

Heat recoverysteam system

HP export steam

Air

Air

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

Acid production cost comparison

0.50 €/m3Process water consumption

0.03 €/m3Cooling water consumption

Production costs perton of H2SO4, €

Annual costs (8,000 hrs/y)

8 €/tHP steam production

0.05 €/kWhElectricity consumption

40 €/tSulphur consumption

Annual costs

€

Consumption &

Productionper hour

Annual costs

€

Consumption &

Productionper 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

Conclusion

The advantages of the ”lean gas” WSA process is nowavailable 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