Topspe process

The pressure (26.38 MPa) of synthesis loop for the Topspe process is higher than other processes, and it uses the two-stage ammonia cooler and separates in front in 

In order to meet the need to process with lesser energy consumption, the Topsoe corporation designed a synthesis loop (S-250 series), which included two converters, three beds and two waste heat boilers in order to by-produce high pressme steam as much as possible as shown in Fig. 9.3. The Topsoe S-250 series is composed of a radial-flow S-200 converter (1) with two beds and a radial-flow S-50 converter, and (2) with one bed. The outlet of every converter has the waste heat boiler to 

3 Process flow of Tops0e S-250 synthesis loop 1-Syngas compressor, 2-Converter, 3-Waste heat boiler, 4-Pre-heater of boiler, 5-Interchanger, 6-Water cooler, 7-Cool exchanger, 10-Ammonia-cooler for fresh syngas. 

There are three catalyst beds to reaction in the S-250 series so that the net value can be increased further and more high-pressure steam can be produced, and thereby the consumption energy is decreased. 

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In principle, the SBA/Topspe process consists in mixing the burner exit gases with steam and sending the mixture to a fixed-bed reactor on a nickel base catalyst, at about 2.10 Pa absolute and about 950 C This technique, sometimes called partial catalytic oxidatioEu is only applied to the conversion of natural gas, LPG and naphthas, particularly because, if heavier feeds are used, problems arise in the prior separation of sulfur derivatives that cannot be t[Pg.42]

It is well known that the conversion of hydrogen and nitrogen per pass is only 20%-30% for the present catalytic ammonia synthesis technology (Table 1.4). Most synthesis gases need to be returned to the reaction system, which increases power consumption. In order to increase conversion per pass, it must increase the outlet ammonia concentration of reactor. Accordingly, it can be seen from Table 1.4 that it is necessary to increase reaction pressure for small and medimn scale aimnonia plants and Topspe process, or to reduce the content of inert gas in sjmthesis gas for Topspe and Braun processes, or to reduce ammonia concentration in the inlet of converter for small and medium scale ammonia plants and Kellogg process. But all of these operations will add the power consumption or unit gas consumption. 

Haldor Topspe s fixed-bed alkylation (FBA ) technology is a compromise between liquid and solid acid-based processes. It applies a supported liquid-phase catalyst in which liquid triflic (trifluoromethanesulfonic) acid is supported on a porous material (206,241). The acid in the bed is concentrated in a well-defined catalyst zone, in which all the alkylation chemistry takes place at the upstream... 

Fig. 18. Haldor Topspe s FBA alkylation process. Adapted from Ref. (206).

The RKN process uses steam reforming to make hydrogen from hydrocarbon gases (from natural gas to naphtha). Haldor Topspe developed this process in the 1960 s. By 1974, 24 plants based on this technology were operating2. 

Some of the ammonia process technologies that are available include KAAP/ /m.s , Haldor Topspe, LAC (or Linde Ammonia Concept), LCA (or Leading Concept Ammonia), Ammonia Casale, and Uhde. 

Synthesis gas is compressed to the synthesis pressure, typically ranging from 140 to 220 kg/cm2g, and converted into ammonia in a synthesis loop using radial flow synthesis converters, either the two-bed S-200, the three-bed S-300 or the S-250 concept using a S-200 converter followed by a boiler or steam superheater and a one-bed S-50 converter. Ammonia product is condensed and separated by refrigeration. All the catalysts used in the catalytic process steps for ammonia production are supplied by Topspe. 

Commercial plants More than 60 plants use the Tbpspe process concept. In addition, many plants based on other feedstocks use the Topspe ammonia synthesis technology. Since 1988, 52% of all new ammonia production capacity has been based on Tbpspe technology. 

Fig 5. Deactivation of CH and tar steam reforming catalyst if a bed of dolomite is placed before the bed of catalyst (three-stage process), Variation of the tar conversion and CH4 content in the exit gas with time-on-stream. (Space-time= 0 2 kg Topspe + 0.2 kg dolomite) h/kgr or 0 4 kg h/kg if Topsee is only used Tgasifier= 750°C Tcat.bed 790°C particle diameter between 1 0 and 2 5 mm )... 

In a subsequent study, the effects of different operating variables, namely space velocity (between 18 and 75 kh ), temperature (between 180 and 250 °C), and ammonium nitrate feed content (between 20 and 100 % of the stoichiometric feed concentration), were systematically investigated over a commercial V-based Haldor Topspe catalyst in order to identify the best process conditions [34]. Data from this study confirmed the occurrence of the very active Enhanced SCR reaction over the V-based catalyst, and pointed out that the added NH4NO3 itself was totally and selectively converted. As shown for example in Fig. 9.12, the addition of AN to the feed stream at 200 °C leads to a significant increase in the NOx conversion compared to the Standard SCR reaction at all the investigated space velocities. The upper Fast SCR bound was approached, but the substoichiometric AN feed contents (100 and 200 ppm) limited the NO conversions associated with the E-SCR reaction. Notably, the NOx conversions were identical within experimental error when feeding either ammonium nitrate (AN) or NO2 in the same proportions (i.e., same AN to NO or NO2 to NOx feed ratio). 

HaUor Tops0e WSA-SNOX. The WSA-SNOX process was developed by Haldor Topspe A/S, Denmark, and is offered in the U.S. by ABB Combustion Engineering, Inc. The process is one of the most highly developed of the combined NOj,/S02 systems. Several industrial systems are in operation in Europe, and a demonstration unit has been operated in the U.S. (Kingston et al., 1990). 

Regenerative heat exchange can be used with catalytic as well as thermal oxidation. Such a system is offered by Haldor Topspe A/S as the REGENOX process (Haldor Topspe, 1990). In this process the catalyst also acts as the heat transfer medium for regenerative heat... 

Typical operating conditions and performance for the REGENOX regenerative heat exchange catalytic oxidation process as provided by Haldor Topspe (1990) are conversion efEciency >99%, heat exchange efficiency 95%, operating temperature in hottest zone 300°C (572°F). The system uses a metal oxide-based catalyst that is capable of operating at temperatures up to 600 C (1,112°F). 

Andreasen. J., 1988, Air Pollution Control by Catalytic Processes, presented at the World Bank Seminar. Washington, D. C., March, reprint provided by Haldor Topspe, Inc. 

TREMP [Tops0e Recycle Energy-efficient Methanation Process] A process for making substitute natural gas from a variety of carbon feedstocks. In addition, it produces superheated steam for use in a steam turbine. Developed by Haldor Topspe from the EVA-ADAM process. Licensed to CPI Xinjiang Energy Co. in 2012 for completion in 2014. 

Conventional sulfuric acid plants dehydrate ( dry ) their feed gases prior to SO2 oxidation and subsequent acidmaking (Chapter 6). The Haldor Topspe ITet gas Sulfuric Acid (WSA) process ... 

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