Haldor Topsoe

Ammonia Process
Technology
Presentation to PT. WIKA
July 2021
Agenda
• HTAS Company Profile
• HTAS Ammonia Process Technology
• HTAS Ammonia Plant Catalysts
• HTAS IMAP Co-Production
• ClearView Ammonia
• Q&A

2
 HTAS Company Profile
3
 Haldor Topsoe
In brief
• Established in 1940 by Dr. Haldor Topsøe.
• Majority shareholder is the Topsoe Family (70%).
• Temasek Singapore are minority shareholder
(30%) as of March 2019.
• Market leader in heterogeneous catalysis and
surface science for more than 80 years.
• 2,300 employees in 15 countries.
2019 revenue
• Headquarters in Copenhagen, Denmark. DKK 5,931m
(~USD 890m)
• Catalyst production in Frederikssund, Denmark
and Houston, USA.
• Invests 8% of revenue on R&D. 2019 operating
profit DKK 927m
(~USD 94m)

4
We provide a full range of products and services for a broad range of
chemical processing, hydroprocessing, and emissions management processes

Chemical Processing Hydroprocessing Emissions Management

Ammonia
Syngas
Methanol
Hydrogen
SNG Naphtha
Sulfuric acid Kerosene
Dimethyl ether Diesel Sulfur removal
Formaldehyde VGO VOC abatement
Gasoline synthesis Resid Particulate filtration

Process design,
Engineering, & licensing + High Performance
Catalysts + Proprietary Equipment
+ Technical Services
+ Digital Services

5
Global presence

Copenhagen &
Frederikssund, Moscow,
Edmonton, Denmark Russia
Canada S H
P E R S E Beijing,
Los Angeles, S
Bayport & S China
California Houston, Shanghai &
Texas Essen, Khobar, Manama, S
Suzhou,
E
Germany Saudi Arabia Bahrain Malaysia
S P
S R
S SS S E

Kuala Lumpur,
Mexico City, New Delhi, Malaysia
Mexico India
S

Jakarta,
Buenos Aires, S
Indonesia
Argentina
Rio de Janeiro, S
S
Brazil
Perth,
Australia

H Headquarters P Production E Engineering S Sales & Service R Research & Development

6
HTAS Indonesia

• HTAS Indonesia Team

• Dody Firdaus (Country Manager, Jakarta)
• Arizka Alamsyah (Account Manager, Sales, Jakarta)
• Ikhwan Ashari (Sales, Jakarta)

• HTAS KL Technical Support for Indonesia

• M. Isa Isyana (Senior Technical Service Engineer, KL Based)
• HTKL Technical Service team supporting SEA, for all technologies

• HTAS Indonesia Office

• Office 8, Suite 17C, Jl. Senopati Raya 8B, Kebayoran Baru, Jakarta 12190

7
 HTAS Ammonia Process Technology
8
Haldor Topsoe’ design philosophy

Emission control Optimized

Energy efficiency CAPEX/OPEX
• New legislations
• Fuel balance • Local legislation • Taking local condition, raw
• Fuel consumption • Minimize effluents material cost, utilities., etc. into
• Steam balance • Reduced flaring considerations
• Energy losses (Stack, cooling • Low man-power requirements
water, ..) • Minimize utility requirements
• Economy of scale
• Location

Reliability Safety and operability

On-stream factor • More automation
• Reduced maintenance
• More automation
• Longer runtime
• Lower maintenance cost

9
The most trusted supplier of ammonia process
solutions and catalysts in the market

• More than 70 years experience in ammonia.

• Ensure reliable and safe operation with the lowest
possible energy consumption.
• From new plants to revamps, our expert services can
increase capacity, efficiency, and even feedstock
flexibility.
• We create the foundation for optimal day-to-day
operation and long-term success.
• Supplier of solutions for 50% of new ammonia plants
built within the past decade.
• More than 60% of the ammonia produced worldwide
is made using our catalysts.
• We have reduced the energy required to produce
ammonia by 50% over the years.

10
Competitive Advantages
▪ Low Energy Ammonia process – Same proven process design used for small as
well as large capacity plants since 1960’ies.
▪ Continuous development of improved equipment designs and more active
catalysts through extensive and ongoing in-house R&D efforts.
▪ Completely tailor made design that can match steam and power integration
perfectly - a lot of experience with different EPC contractors in this aspect.
▪ Most experienced ammonia licensor (Topsoe) with numerous successful grass
roots ammonia/urea projects.
▪ Only process licensor with process technology and catalyst expertise within the
same company – this leads to optimized design, assuring lowest OPEX and CAPEX.
▪ Flexibility for next future plant development both Front End and Back End and
Co-Production
▪ Digitalization capabilities – TFM and ClearView

11
Competitive Advantages (Cont’d)

▪ Topsoe offers Technical Service function to assist in operation and maintenance

after start up of plant, covering both process technology and catalyst support.
▪ Long term relationship between Topsoe and client throughout the lifetime of the
plant.
▪ Low emissions and effluents – Low Nox and CO2 emissions, and optimal steam
balance integration between process plant and off-sites/utilities.

12
Key elements of Topsoe Ammonia Process

• Sidefired reformer – results in optimal heat transfer and long catalyst life

• Heat Exchange Reforming (HTER) - results in smaller reformer and in lower fuel consumption

• Radial flow ammonia converter (S-200 & S-300) – High conversion and low pressure drop

• Low emissions and effluents – due to DENOx, CATOx and efficient recovery of all process
condensate

13
 Topsoe Ammonia Process

Desulphurisation Reforming Shift

Process steam

Natural gas

Process air

Stack
Purge gas

CO2-
removal

Ammonia Process
product cond.
Ammonia synthesis Methanation
14
 Topsoe Ammonia Process – alternative with Pre-Reformer

Desulphurisation Reforming Shift

Process steam Prereforming (optional)

Natural gas

Process air

Stack
Purge gas

CO2-
removal

Ammonia Process
product cond.
Ammonia synthesis Methanation
15
 Topsoe Ammonia Process – alternative with HTER

Desulphurisation Reforming Shift

Prereforming (optional)
Process stream

Natural gas
(optional)
Process air HTER
Stack
Purge gas

CO2-
removal

Ammonia Process
product cond.
Ammonia synthesis Methanation
16
 Topsoe Ammonia Process – alternative with S-50 Ammonia Converter

Desulphurisation Reforming Shift

Prereforming (optional)
Process steam

Natural gas
(optional)
Process air HTER
Stack
Purge gas

(optional) CO2-
removal

Ammonia Process
product cond.
Ammonia synthesis Methanation
17
Topsoe Tool box – Reforming

Primary Secondary Autothermal

reforming reforming reforming

Pre-reforming HTER

18
Side fired vs Top fired
Tubular reformer types

Side fired Top fired (box furnace)

• More burners • Fewer burners

• Facilitates control of max tube wall • Easier start-up
temperatures • Easier flame surveillance

• Higher average heat flux • Lower average heat flux

• 75,000 kcal/m2/hr • 65,000 kcal/m2/hr
• Fewer tubes • “milder” conditions

• Radiation from walls • Radiation from gas

• Higher heat intensity (kcal/h/m3)index 135 • Heat intensity: index 100
• Higher wall surface area: index 100 • Wall surface area: index 60

19
Operational challenges
Risk of carbon formation is higher in a top-fired reformer

• Depending on the reformer type, the risk

of carbon formation might be higher or
lower
1000

• This is due to the difference in firing 900

• Top-fired reformer

TWT, °C
800
• Side-fired reformer
700

• Generally top fired reformers have a 600

End of run
higher risk of carbon formation Start of run

• More localized firing 500

0 20 40 60 80 100
• A higher peak in the tube wall temperature
Tube length, %

20
Haldor Topsoe Exchange Reformer - HTER
Process layout

Additional steam

Boiler

21
HTER benefits

• Smaller size primary reformer

• Reduced N.G. fuel firing

• Reduced steam production

• Reduced CO2 emissions to atmosphere

22
Topsoe Toolbox – Ammonia Converter Solutions

S-300 Converter S-50 Converter

23
Topsoe Ammonia Synthesis Loop

• Straightforward and simple layout

• Easy to expand capacity in future
• Equipment count is minimum
• Membrane or cryogenic purge gas recovery possible
• Loop pressure: 105-200+ barg

24
Converter Types Available from Topsoe

25
Topsoe S-300 Converter without Lower Heat Exchanger

26
Topsoe S-300 Converter with Lower Heat Exchanger

27
Topsoe S-200 Converter

28
Topsoe S-50 Converter

29
Topsoe S-300 Benefits

• Low pressure drop

• High conversion per pass
• Use of state-of-the art highly active ammonia catalyst KM -111

• Short implementation period to augment an additional capacity

30
Proprietary Hardware for Ammonia Projects

• Secondary reformer burner

• HTER (if applicable)

• Waste heat boiler package

• Ammonia converter

• Loop Waste Heat Boiler

• Topsoe Furnace Manager (TFM)

31
Selected Reference Plant, Duslo, Slovakia

• Plant capacity 1600 MTPD

• Reforming section operating at a steam to carbon ratio of 2.9
• HTER (Haldor Topsoe Exchange Reformer) included
• Two-stage shift conversion (HTS and LTS)
• MDEA CO2-removal system
• S-350 ammonia synthesis loop at 140 kg/cm2g with S-300 converter followed by S-50
converter in series.

32
Selected Reference Plant, Duslo, Slovakia (Cont’d)

• This ammonia plant has a capacity of 1600 MTPD of ammonia , and this plant will have the lowest
energy consumption of any Topsoe designed grassroots ammonia plant so far. The plant will
produce ammonia for urea and storage.

• Specific energy consumption is expected to be below 6.65 Gcal/MT of ammonia:

• Due to efficient reforming section with HTER

• Due to low pressure drop in front end (minimum flows compared to competition)
• Due to efficient CO2 removal based on MDEA.
• Due to highly efficient ammonia synthesis loop with S-350 converter and low loop pressure.

33
Topsoe Ammonia Plants Recent Started-up

Client Capacity MTPD Start-up

Acron, Russia 2060 2016

Petronas Samur, Malaysia 2100 2016
Hegang, China 1050 2016
Wulan, China 2300 2016
Zhongyan Kunshan, China 900 2016
Phosagro, Russia 2200 2017

34
Topsoe Ammonia Plants Recent Started-up (Cont’d)

Client Capacity MTPD Start-up

Socar, Azerbaidjan 1200 2018

Dangote, Nigeria 2x2200 2018
Eti Bakir, Turkey 300 2018
Olam, Gabon 2200 n.a.
Duslo, Slovakia 1600 2018
Turkmenhimiya, Turkmenistan 2000 2018
Uzkimyosanoat, Uzbekistan 2000 2018
Ramagundam, India 2200 2018

35
Topsoe Ammonia Plants
Since 2000
Number of plants: 60
Accumulated capacity, MTPD: 99,505

1 7
3

12
7 23

6
1

36
Ammonia Market Share
Awarded capacity since 2008
Other
8%

Uhde HTAS
13% 47%

KBR
32%

37
Perdaman Ammonia plant
3500 MTPD ammonia loop

• Single converter reactor

• 120 m3 of ammonia synthesis Catalyst
• Lowest cost of ownership

“Topsoe can achieve 3,500 MTPD using

equipment that has been field proven at
effectively the required process duty. Topsoe’s
synthesis loop efficiency equals or exceeds
the industrial standard. “
Mr. Keith. J. Stokes
Stokes Engineering Company, LLC, USA
Third party technical evaluation
38
 HTAS Ammonia Plant Catalysts
39
Novel carrier catalyzing optimal performance
Important reforming catalyst properties

High and Avoid carbon Resistance to High mechanical Low pressure

stable activity formation sulfur strength drop

40
Catalyst shape
Topsoe 7H the optimal combination

• Pressure drop
• Particle size • Heat transfer
• Particle shape • Flow properties
• Number and size of holes • Surface area
Topsoe 7H catalyst • Mechanical strength
The optimal combination

41
Calcium aluminate is not just “calcium aluminate”
The specific calcium phase is important for catalyst stability
Carrier stability

Calcium lean Hibonite

CaO(Al2O3)6 “Calcium-rich calcium aluminates
in a steam reforming catalyst are
not desirable because they can
Grossite
CaO(Al2O3)2 hydrate readily and damage the
integrity of the catalyst pellets.”
Calcium rich Calcium mono aluminate
CaO(Al2O3)

42
Calcium aluminate carrier material
Advantages of hibonite phase-based carriers

• Compared to calcium-rich calcium

aluminates:
• Hibonite has higher stability
• Hibonite has higher porosity
• Easier to make small Ni crystals
• Easier to maintain Ni crystal size
• Higher activity
• Higher sulfur capacity
• How to obtain more hibonite?
• TiO2 addition increases the formation of
hibonite

SEM image showing the plate-like

crystal morphology of Hibonite

43
 Hibonite content in TITAN™ and competitor catalyst
TITAN™ is superior on activity and sulfur capacity

120 60
Relative activity/sulfur capacity, %

100 50

Hibonite content, wt %
80 40

60 30

40 20

20 10

0 0
TITAN™TITAN
RC-67 series Competitor
Industrial A 1
reference Competitor
Industrial B 2
reference

Activity Sulfur capacity

S-cap Hibonite

44
TITAN™ reforming catalyst
TITAN™ has a very stable potassium content throughout the catalyst lifetime

Avoid carbon formation

in the full catalyst lifetime RK-500 TITANTM
100

Potassium content, %
75

50
Conventional
catalyst

25
• Very stable alkali content
• Long-term catalyst carbon resistance
• Alkali reservoir in the carrier continuously
replenishes the catalyst active sites 0
Accelerated aging

45
Alkali-promoted TITAN™ series
Alkali reservoir in the carrier material provides long-term carbon resistance

>> Carbon deposition <<

Conventional
alkali catalyst TITAN™ series
46
Alkali-promoted TITAN™ series
Alkali reservoir in the carrier material provides long-term carbon resistance

>> Carbon deposition <<

Conventional
alkali catalyst TITAN™ series
47
TITAN™ reforming catalyst
TiO2 promoted calcium aluminate carrier

• Stable activity
RC-67 TITAN™
• TiO2 promoted carrier
• High hibonite content
• Low pressure drop
• Shape optimized 7-hole catalyst
• High strength and stability
• High hibonite content
• Unmatched mechanical strength across the
temperature range

48
Haldor Topsoe KM1R and KM 111 Ammonia Synthesis Catalyst
Overview

• Over the years, Topsoe has supplied over 1,200 charges of KM series
catalyst. The high and stable activity of the catalyst has resulted in an
extensive track record of very long lifetimes achieved in industrial
operation and record high production rates.
• KM111 is our latest developed high active ammonia synthesis catalyst
• KM111 is a magnetite-based catalyst with which is optimized for the
conditions in the lower beds of the ammonia converter
• In the first bed prereduced KM1R is installed
• The preduced KM1R has a skin oxidised layer allows safe handling during
catalyst loading and also enables faster activation of the catalyst in the
lower beds. It provides :
− Unparalleled high & stable activity
− Increased ammonia production
− Reduce energy consumption
49
Magnetite vs Wustite Base Catalyst
Comparison

• Unlike Topsoe KM catalysts, some competitor’s ammonia synthesis catalysts are Wustite-
based
• Wustite (FeO) based catalysts typically have a good initial activity but have also proven in
many plants not to have the same high theromostability as the Topsoe magnetite based KM
catalysts
• As the Topsoe Magnetite KM catalysts are very thermostable the will maintain a higher
activity throughout their lifetime leading to higher production rates

50
 Ammonia synthesis catalyst
KM 111 vs competitor

• Activity test with multiple heat cures at

500˚C
• KM 111
KM 111 • Looses 10% compared to SOR
• Competitor
Activity

• Similar initial activity (SOR)

• Looses 30% compared to SOR
Competitor

KM 111 shows superior thermostability

100 300

51
Performance of wüstite-based catalyst
Case Study - Ammonia Plant in North America

1.2
• Challenge

Relative activity compared to SOR

• Changed catalyst after 14 years of successful 1
operation
• New wüstite type catalyst loaded showed rapid 0.8
deactivation
• Solution 0.6
• Had to increase loop pressure after less than 1
year in order to reach nameplate capacity
• Evaluation revealed drastic drop in catalyst 0.4
activity compared to SOR
• Outcome 0.2 KM
• In order to compensate for the lower catalyst Wüstite
activity, the ammonia loop is operated at an
elevated pressure resulting in a higher energy 0
consumption 0 24 48 72 96 120 144 168
Catalyst age, months
52
 HTAS IMAP Co-Production
53
Missing out on potential…?
Price developments

Methanol
Price

Ammonia

Urea

Time
54
When to consider co-production
Opportunity rationale

Methanol Ammonia Urea

Plant type

Challenge Plant surplus H2 Plant surplus CO2 Import of methanol/UFC

Increase potential revenue Increase potential revenue

through new profit pools through new profit pools Significant savings by avoiding
Outcome & cost of import
opportunity Address market demand for CO2 utilization
local and export ammonia Plant self-sufficiency
Address local methanol demand

55
IMAP Ammonia+™ process – serial configuration
Simplified process layout

Air Ammonia
conversion
S-300
Steam

Separator
Tubular Ammonia

Methanation
product

Methanol

Methanol
reforming

synthesis

synthesis
Sulfur removal
Hydrogenation

temperature
temperature
High

shift
shift

Low
Secondary
reforming

CO2

Separator

Separator

Separator
CO2 removal

Methanol
Process product
Natural gas + hydrogen condensate

56
IMAP Ammonia+™ process – parallel configuration
Simplified process layout

Air Ammonia
conversion
S-300
Steam

Separator
Tubular Ammonia

Methanation
reforming product
Sulfur removal
Hydrogenation

temperature
temperature
High

shift
shift

Low
Secondary
reforming

Methanol

Methanol
synthesis

synthesis
CO2

CO2 removal

Process
Natural gas + hydrogen condensate

Separator

Separator

Separator
Methanol
product

57
IMAP Urea+TM
Ultimate market agility
Desulfurization Reforming Shift
Process steam Oxygen

Natural gas

Process air
Stack

Purge gas

Ammonia product
CO2

Methanol product
Ammonia synthesis Methanation Methanol synthesis CO2 removal
58
Summary of key benefits

• Shared reforming section

• Once-through methanol synthesis loop
• Lower unit cost than by stand-alone plants for any capacity
• Well-proven process steps
• Any ammonia-methanol product split
• Shared utilities
• Staff requirements corresponds to that of one
• 10–25% savings on capital expenditures
• Up to 4% savings on operating expenses

59
 Topsoe IMAPTM Co-production
Customer Feedstock IMAPTM Methanol Ammonia Start-up
Site solution capacity capacity
Country MTPD MTPD
SEMADCO *) Natural gas Ammonia+TM 72 286 1993
Talkha, Egypt
Terra Industries, Inc. *) Natural gas Ammonia+TM 363 600 1994
Woodward, Oklahoma, USA
Heilongjiang Chemical Plant *) Natural gas Ammonia+TM 120 600 1999
Qiqihar, Heilongjiang, P.R. China
Petronas Fertiliser (Kedah) SdnBhd Natural gas Ammonia+TM 200 1,125 1999
Kedah, Malaysia
Sichuan Lutianhua Stock Co., Ltd. *) Natural gas Ammonia+TM 136 314 2003
Sichuan, P.R. China
Tatarstan Natural gas Ammonia+TM 670 1,382 2015
Russia
Lavan Natural gas Methanol+TM 3,000 900 2017
Iran (exp.)

SchekinoAzot Natural gas Methanol+TM 1,350 415 2017

Russia (exp.)

*) Revamp of existing plant

60
 ClearView Ammonia
61
ClearView™ concept
Meet your targets every day

62
ClearView™ software objective
Creating value in 3 main areas

What: How:
Plant Performance Identify performance gap as “optimal” Opportunity
Optimization vs “as-is” (constraints, feed & operating
changes, catalyst activity…)

What: How:
Short-Term Health Early event detection of fast occurring
Monitoring failures (Hydrocarbon cracking,
condensation on catalyst…) Identify earlier

What: How:
Long-Term Health Detect slowly degrading performance Identify earlier
Monitoring in noisy data (catalyst deactivation,
equipment fouling, heat exchanger
leaks, pressure drop build-up…)

63
Combining world-class expertise and experience
Strategic alliance between Topsoe and Honeywell

• Technology licensor
• Catalyst supplier
• TechService provider

• DCS and APC supplier

• Connected Plant
platform
• Connected Services
by UOP
64
Thank You