Haldor Topsoe

Flexible Solutions for

Hydrogen Production
for Refineries
Alexandra Karyagina
Regional Manager, Chemicals Department
Haldor Topsoe LLC
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 Agenda
roduction and organization of Haldor Topsøe A/S
• Challenges for modern refineries
• Topsoe technologies for refineries
• Topsoe steam reforming technology for Hydrogen Plants
• Industrial example – 135,000 Nm3/h (12 t/h) SMR hydrogen plant in
TANECO, Nizhnekamsk
• Topsoe radiant wall reformer (SMR)
• Prereformer
• Industrial example – 5,000 Nm3/h HTCR-based hydrogen plant in
Kuibyshev Refinery, Samara
• Topsoe Convection Reformer Process (HTCR)
• References in Russia
• Concluding remarks

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Challenges for modern refineries

Low OPEX and

CAPEX Refinery

Oil conversion Modern

depth refinery

Strict product
Emission free
specifications

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Hydrogen balance for refinery
Hydrogen sources

• Hydrogen rich off-gas of gasoline fractions catalytic

reforming
• Hydrogen produced by steam reforming of
hydrocarbons

Feed-stocks:
Multi-feed Haldor Topsoe
• Natural Gas Hydrogen Plant
• Butane
• LPG
Topsoe: >70 Hydrogen Plants
• Naphtha last 10 years
• Off-gas
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Topsoe technologies for refineries
• Full range of hydroprocessing
technologies
• ultra-low sulphur diesel production
• hydrotreating of oil fractions from naphtha to resid
• hydrocracking of heavy oil fractions
• dewaxing of diesel
• aromatics saturation
• Patented processes (Aroshift™ and HPNA Trim™)
• colour control
• hydroprocessing of renewable feeds –
co-processing or stand-alone – for gasoline, jet fuel and
diesel production

• Hydrogen technologies
Oil refineries

• Sulphur management, off-gas treatment

• WSA, DENOX, SNOX, CATOX

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Topsoe steam reforming technology for Hydrogen
Plants
Radiant wall reformer (SMR) Convection reformer (HTCR)
15,000-200,000 Nm3/h 5,000-30,000 Nm3/h

Prereformer

Heat-exchange reformer (HTER) Bayonet reformer (TBR)

+ ≤40,000 Nm3/h 5,000-170,000 Nm3/h

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JSC TANECO, Nizhnekamsk
135,000 Nm3/h (12 t/h) SMR hydrogen plant, part of
hydrocracking complex

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Background

• Contract concluded in 2006 Detailed Engineering:

VNIPIneft
• Basic Engineering Design Package submitted in
2007
Reformer Vendor:
• Construction, assembly 2012-2013 Heurtey Petrochem
• Commissioning 2013

2012 2013

2007

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 Topsoe scope of supply and guarantees

• License
• Basic Engineering Design Package
(Reformer Engineering Design Package)
• Catalyst supply:
– Hydrogenation, sulphur absorption, prereforming,
 Process performance
reforming, MTS catalysts
guarantees:
• Supervision services for: – Hydrogen plant capacity
– Site inspection (review of PFD, PID, refractory drying, – Net energy consumption
reformer inspection) – Product quality: H2, steam
– Catalyst loading – Turndown ratio
– Pre-commissioning, commissioning – Catalysts life time
– SOx, Nox emissions
• Operators’ training
• Technical support after start-up during
normal operation

• Support for VNIPIneft for PD development

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 The SMR-based hydrogen plant
- lay-out and key operating parameters
• Low S/C ( ≤ 2.0)
• High reformer outlet temperature ( > 900ºC)
De- Pre- Radiant wall
sulphurisation reformer reformer MT shift PSA Unit

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Topsoe radiant wall reformer
The only reformer with no direct firing towards tubes

Radiant wall Top-fired Bottom-fired Terrace wall

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Inside reformer - controlled firing

• Balancing heat input with heat

consumption in an optimal way
• Side-fired reformer is ideally
suited
• Radiant wall burners
• Flame directed to reformer wall
• No risk of flame impingement
• Counter-current of process gas
and flue gas

Topsoe:
Constructed
>250 tubular
reformers

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SMR technology. Topsøe radiant wall reformers

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 Prereformer
CnHm + nH2O => nCO + (n + ½ m) H2 - Q
CO + 3H2 <=> CH4 + H2O + Q
CO + H2O <=> CO2 + H2 + Q

Prereformer
Tubular
Reformer

Topsoe pre-
reformer market
share is >60%
worldwide

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 Actual operating data

• Feed:
– Natural gas
– Propane + natural gas 135,000 Nm3/h SMR Hydrogen Plant

• Process gas temperature at outlet

of reformer 915°С
• S/C ratio 2
• MTS reactor inlet temperature
210°С
• Commissioning: 11 November 2013
– first feed supply to reformer
• 18-19 December - 100-105% load
achieved

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HTCR-based hydrogen plant. Kuibyshev Refinery,
Samara

• Capacity 5,000 Nm3/h +

PSA 12,000 Nm3/h
• Feed – LPG
• Commissioning in 2009
• Energy consumption:
• Guaranteed
3.5 Gcal/1000 Nm3 H2
• Achieved
3.3 Gcal/1000 Nm3 H2

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HTCR – Convection Reformer
outlet (600 °C)

Flue gas Process gas

outlet (600 °C)
inlet (450 °C)

Tube bundle
Process gas
outlet catalyst
(850 °C)
Catalyst

Burner chamber

Flue gas
inlet (1200°C)
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 Topsoe Convection Reformer Process (HTCR)

S-removal Pre-reformer HTCR reformer Shift PSA

H2
Steam
3x

Feed
Combustion air

Flue gas Off-gas

Fuel
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HTCR reactor tube bundle

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HTCR: compact lay-out and fast assembly

HTCR Plant
15 000 Nm3/h

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HTCR scope of supply
 License, Basic Engineering, Detailed Engineering
 Package supply of equipment, materials and
catalysts
 Supervision at site
 During assembly
 During start-up and test-run
 Personnel training

+ technical service after supply via Moscow office

Topsoe:
Constructed 35 heat
exchange reformers

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Topsoe radiant wall reformers – SMR hydrogen plants in
Russia
Capacity Т outlet
Client Feed type S/C ratio Start-up
Nm3/h reformer, оС
TANECO, Nizhnekamsk NG/propane 135 000 920 2.0 2013
Gazpromneft
NG/LPG 77 000 920 2.0 2012
NIS Pancevo, Serbia
96 000 H2
Rosneft-ANKHK, Angarsk Naphtha/ROG 915 2.0 2015
+10 000 CO

Rosneft – KNPZ, Samara NG/LPG 50 000 915 2.0 2015

Rosneft – SNPZ, Syzran NG/LPG 50 000 915 2.0 2015

Lukoil-
NG/Naphtha 120 000 910 1.8 2016
Volgogradneftepererabotka
Gazpromneft, Moscow NG/VGO HC
105 000 915 1.9 2020
Refinery, Moscow vent H2 gas

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Topsoe HTCR Plants in Russia

Client Process Feed type Nm3/h Start-up

NLMK, Lipetsk HTCR NG 3 X 2,000 2004

LPG (+Н2 rich 5 000
Rosneft-KNPZ, Samara HTCR 2009
gas) (12 000)

ShchekinoAzot, Tula NG (+MeOH 15 000

HTCR 2012
region purge gas) (26 000)

TANECO, Nizhnekamsk HTCR Twin NG 30 000 2015

Antipinsky Refinery,
HTCR Twin NG 30 000 2015
Tyumen

Volkhovneftekhim,
HTCR NG 2 000 2017
Volkhov

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Concluding remarks

• Wide range of state-of-art efficient technologies for hydrogen

production
• Impressive experience with hydrogen plants for refineries in
Russia:
• Various process lay-outs
• Large capacity range
• Flexibility in projects implementation and scope of supply

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