haldor topsoe - david bray.pdf

7/18/2019 Haldor Topsoe - David Bray.pdf

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Innovativesolutions for methanol &formaldehyde productionMr. Khalid Moharrum, Chemanol

Dr. David Bray, Haldor Topsoe A/S



2

INNOVAT

IS CREATINGBY DOING NEW



3

InnovationWhat about risk?



4

ChemanolAn innovative company since 1991

”We want to be a major player in methanol-based

specialty products while remaining committed to theenvironment, safety, competitiveness, efficiency andinnovativeness”

• Revenue:

• 18 expansion projects over 24 years

• Product portfolio

• Methanol, formaldehyde and their derivatives

2004 USD 60 mil

2013 USD 240 mil



5

FormaldehydeMethanol’s largest market

•

Formaldehyde production• 20.6 million tons

• 55% of production in China

Methanol Demand 2014

Formaldehyde Fuel MTBE/TA

DME MMA MTO



6

0

50

100

150

200

250

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

M i l l i o n U S D

Sales revenue vs. GDP

GDP

Sales revenue

Source: International Monetary Fund

ChemanolGrowth through innovation

•

Revamp with Topsoe formaseries reactor

• Using leading edge catalyst

• HTZ-31Promoted zinc oxide

• RK-400 Alkali-promoted steacatalyst

• MK-151 FENCE™ Methanol s

MK-151 FENCE™



7

Revamp with Topsoe formaldehyde series reactorBoosting capacity with 80%

•

MeOH injection in two steps• Increased formaldehyde concentration in

the absorber

• Less gas re-circulated

• Energy savings

• Reactor bypass possible

• No downtime during catalyst replacement

Air

MeOH



8

Topsoe series reactorBoosting capacity by 80%

Parallel Series

Capacity (37%) 400 MTPD 400 MTPD

Total gas from blower 54500 29600

Reactor tubes 2 x N N ; 1.2 x N

Catalyst volume V 1.1 x V

Catalyst lifetime (months) 18 30/18

Total heat load on absorber (Gcal/h) 7.16 6.3

Tail gas (Nm3/h) 15424 16000

Incinerator catalyst volume (m3) 1.2 1.2

Electricity per ton of AF-37 (kWh) 67 49



9

Chemanol and TopsoeExpansion projects over 23 years

67 MTPD

formaldehyde

1991

67 MTPD

formaldehyde

1993

120 MTPD

formaldehyde

1996

400 MTPD

formaldehyde

2008

Revamp

(117) MTPD

2002

Re

(117

2

Revamp

(220) MTPD

1998

700 MTPD

Methanol

2009



10

Leading edge methanol synthesis catalystDiscovering potential with MK-151 FENCE™

•

MK-151 FENCE™ installed in May 2013• First plant in Middle East to benefit from the

unique FENCE™ technology

• Advantages achieved:

• Plant load of 107%

• SOR operating conditions after more than 20

months on-stream

• Significant energy savings in loop anddistillation section



11

Recycle flowChemanol operating data

• ~30% lower recycle flow with the MK-151FENCE™

• Power savings in the compressor

0 500

R e c y

c l e F l o w , N m 3 / h

Days on St



12

BWTChemanol operating data

• Consistently lower BWT

• Same methanol production level

• Lower by-product formation

• Power savings

0 500

B o i l i n g

w a t e r t e m p e r a t u r e , ° C

Days on Str



13

By-product formationChemanol operating data

• 20-30% lower byproduct formation

• Lower BWT

• Improved catalyst selectivity

• Energy savings in distillation

0 500 10

E t O H , p p m

Days on Stream



14

MK-151 FENCE™ Higher activity over the entire operational lifetime

• The FENCE™ technology inhibits sintering

• 20% higher catalyst activity over the entirecatalyst lifetime

• Higher conversion per pass

• Operate at lower boiling watertemperatures

• Lower by-product formation

• Less recycle flow



15

Innovation in Haldor TopsoeMore than 10% of Revenue invested in R&D

2005

TK-261

2006

AR-401

2009 2011 2012010

HTZ-51

MK-151 FENCE™

LK-853 F

PK

2008

LK-817 HTZ-31RK-400LSK-2

Syngas catalystdevelopments



Thank you foryour attention

haldor topsoe - david bray.pdf

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