Tailor-made catalyst solutions to meet the demands for lower SO2 emissions

Transcription

1 t word(s) eader by g the font en Sans eadings) + Bold Highligh by chang Sans (H Tailor-made catalyst solutions to meet the demands for lower SO2 emissions Presented by Osman Chaudhry, Haldor Topsøe A/S 1 Insert a b by clickin Insert fr button pl Haldor T

2 Agenda 1. Introduction of Haldor Topsoe 2. Low emissions during Start-up 3. Low emissions during Steady State Operation 2

3 Haldor Topsoe In brief Established in 1940 by Dr. Haldor Topsøe. Market leader in heterogeneous catalysis and surface science for over 70 years. 2,800 employees, 11 countries, five continents. Buenos Aires main office in South America VK catalyst production in USA and Denmark. VK69 VK59 VK-WSX 25 mm VK-701 LEAP5 Private 100% family owned company. Spend more than 10% of revenue on R&D. VK-WSA First with Cs First with Daisy First with Rings Pellets 3

4 4 02 Low Emissions During Start-up

5 Reaction rate: Standard catalyst 10% SO 2, 11% O 2, inlet temperature 390 C Reaction rate 5 Depth in bed SO 2 (g) + ½ O 2 (g) ó SO 3 (g) + Heat

6 Reaction rate: Too cool? Too hot! Catalyst limited? Equilibrium limited Reaction rate 6 Depth in bed SO 2 (g) + ½ O 2 (g) ó SO 3 (g) + Heat

7 Temperature profile: Standard catalyst VK38 10% SO 2, 11% O 2, inlet temperature 390 C 580 Temperature C 380 Depth in bed 7 SO 2 (g) + ½ O 2 (g) ó SO 3 (g) + Heat

8 Effect of Inlet Temperature 390 C vs 420 C 10% SO 2, 11% O 2, inlet temperatures 390 C and 420 C 580 Temperature C 390 C Depth in bed Faster Activation of the Catalyst Bed and Reduced Catalyst Needs

9 Effect of Inlet Temperature 390 C vs 420 C 10% SO 2, 11% O 2, inlet temperatures 390 C and 420 C Reaction rate 420 C 390 C Depth in bed 9 Faster Activation of the Catalyst Bed and Reduced Catalyst Needs

10 Going from 390 C inlet! 420 C inlet? Higher inlet temperature = Lower total bed conversion Time consuming preheating Cost of heating oil, natural gas, etc. 10

11 Handling 390 C inlet - Use of Cesium Ignition Layer Cesium ignition layer - VK59 Standard catalyst - VK38 Bed 1 11

12 10% SO 2, 11% O 2, inlet temperature 390 C Reaction rate VK59 VK38 VK38 Depth in bed 12 Dramatic Increase in Ignition Capability Maintain Maximum Conversion with Low Catalyst Volume

13 Effect of Ignition Layer 10% SO 2, 11% O 2, inlet temperature 390 C 580 Reaction rate VK59 and VK38 VK Depth in bed Dramatic Increase in Ignition Capability Maintain Maximum Conversion with Low Catalyst Volume

14 Handling 370 C inlet - Use of Cesium Catalyst in last bed (after IAT) Cesium promoted last bed VK69 Bed 4 Ø Accommodates faster & cleaner start-ups Ø Less preheating time Ø Savings in preheating fuel 14

15 15 03 Low emissions during Steady State Operation

16 Low temperature catalyst options VK % reduction in SO 2 emission Single adsorption VK38 VK38 VK48 VK48 VK59 16

17 Low temperature catalyst options VK69 50% reduction in SO 2 emission Double adsorption VK38 VK38 VK48 VK38 VK69 17

18 VK-701 LEAP5 Boosting the conversion further Achieving remarkably low emission Key application areas: Lower passes in single-absorption plants 3 rd pass in 3+1 or 3+2 double-absorption plants 18

19 Mechanism of catalytic SO 2 oxidation SO 2 SO 3 2SO 4-2 SO 3 V (V O) O(SO ) O 2 IV 2V O(SO ) IV 2V OSO 4 (s) 4 1 V (V O) O(SO ) SO V (V O) O(SO ) O SO 2 V 5+ is the active oxidation state SO 2 SO V -4 3 (V O) O(SO ) O Source: O.B. Lapina et al (1999). Catalysis Today,

20 VK-701 LEAP5 operates with a higher content of Vanadium Bed 3 Conditions VK-701 LEAP5 V 5+ V 5+ V 5+ Content of vanadium compounds (relative) VK59 VK Temperature, C

21 Superior activity of VK-701 LEAP Bed 3 Conditions 100 VK-701 LEAP5 Relative activity 10 VK59 VK Temperature C

22 22 Performance of VK 701 LEAP5 - Case Study

23 Case study VK-701 LEAP5 Reduced emissions from a double-absorption plant Layout : 3+1 double-absorption plant Double adsorption SO 2 source : S-burning Feed gas : 11% SO 2, 10% O 2 Catalysts in beds ½ : VK38 / VK38 Conversion outlet bed 2: 88.5% VK38 VK38 VK-701 VK48 VK38 VK69 23

24 Case study VK-701 LEAP5 Reduced emissions from a double-absorption plant 36% SO 2 reduction compared to VK48/VK69 68% SO 2 reduction compared to VK48/VK38 Catalyst in bed 3 VK48 VK48 VK-701 LEAP5 Inlet temperature, C Conversion outlet bed 3, % Catalyst in bed 4 VK38 VK69 VK69 Intlet temperature, C Overall conversion, % SO 2 in the stack, ppm Relative SO 2 emission

25 25 Performance of VK-701 LEAP5 - In operation

26 Case story VK-701 LEAP5 Example from North America: Emission had to be reduced in the 3x1 plant from 350 ppm to approx. 165 ppm. Solution; to revamp and install VK69 and VK-701 LEAP5 Double adsorption Plant and feed gas specification: 3+1 double absorption 2000 MTPD 11.7% SO 2 9.3% O 2 VK38 VK38 VK-701 VK69 26

27 Case story VK-701 LEAP5 Start up June 2012 Prior to loading Predicted Start of run 1 year * 2 years Production 2085 MTPD 2085 MTPD 2085 MTPD 2065 MTPD 2060 MTPD SO % 11.7% 11.80% 11.78% 11.95% Conversion 99.75% 99.89% 99.92% 99.89% 99.89% Emission 350 ppm 160 ppm 118 ppm 159 ppm 160 ppm * During this TOPGUN a leak was detected in one of the re-heat exchangers After 2 years the activity of VK-701 LEAP5 was still so high that Bed 3 ran into equilibrium. 27

28 Conclusions Lowering SO2 emissions Start-up Low ignition temperature cesium catalyst for faster and cleaner start-ups. Steady operation High active cesium catalyst for significant reduction in SO2 emission. VK-701 LEAP5 for unmatched activity in SO3 rich process gas. 28

29 29 Osman Chaudhry,