Haldor Topsoe Exchange Reformer (HTER™)

Makes it easier to
go big in hydrogen
production
Use a Topsoe HTER solution to produce up to 30% more hydrogen
with 7% less feed and fuel. Even if there’s hardly any space available.

www.topsoe.com
02 Haldor Topsoe

Scaling up for a
flexible future
A Haldor Topsoe Exchange Reformer
(HTER) installation enables you to go
big in hydrogen production by putting
both feed and fuel to the most cost-
effective use for i.e, reforming rather
than just co-producing a lot of steam.

It’s a quick, cost efficient way to add

as much as 30% extra capacity to
any existing hydrogen production
setup – and using up to 7% less
fuel and feed per unit of hydrogen
produced.

It also provides you with a quick,

relatively inexpensive way to add
major flexibility to your hydrogen
production capabilities.

And if you’re planning a new hydrogen

plant, but don’t need the full capacity
right away, you can postpone a big
part of the investment until you
actually need it.

Key benefits:

30% 7% 40%

Boost hydrogen output Feed and fuel Cheaper than

minimum savings a new plant
Haldor Topsoe Exchange Reformer (HTER) 03
04 Haldor Topsoe
Making the most of what
you’ve got
The HTER technologies enable you to
make the most effective possible use
of the valuable thermal energy in the
reformer effluent by using it for
additional reforming rather than for
steam production. Less steam, more
hydrogen.
An HTER carries out steam reforming
in parallel with the primary steam
reformer. It is a very compact,
cost-effective piece of equipment.
Natural
gas
Purification
reforming
Fuel
Fig. 1. Energy conservation - Desired H2 product using less feed and fuel
Exploiting process heat for reforming with a tubular reformer (SMR) or with
saves fuel consumption. The steam a two-step reforming configuration
co-production could be made up by (an SMR followed by a secondary
another unit using a cheaper fuel reformer).
than the hydrogen plant, resulting in
significant savings.
An HTER setup enables you to carry
out steam reforming parallel with the
primary steam reformer.You can use
an HTER reformer in combination with
an autothermal reformer SynCOR™
Steam
Flue gas
Steam H2
HTER WHB Shift & PSA
~900°C ~600°C ~300°C
 Haldor Topsoe Exchange Reformer (HTER) 05

The benefits stack up

Conserves energy Compact and cost-effective Design flexibility
• Less feed and fuel used • Process intensification for • Easily configurable to individual
• Less steam export reforming and process/partial operating requirements
• Reduced emissions cooling • Customization ensures the best
• Can be fitted into even small possible return on investment
Safe, proven operation spaces
• Easy to operate
• 15+ years of proven installation
experience

Process steam

Prereformer
Tubular
reformer

Feed
Syngas
HTER

Flue gas

Fuel gas

Fig. 2. Typical installation of an HTER in a hydrogen plant

06 Haldor Topsoe
Process intensification
More with less
Reforming requires heat transfer into
the reforming tubes. The HTER
technology is based on the efficient
convective transmission of the heat
to the reforming catalyst, using many
years of practical experience and
detailed understanding of the setup
in terms of heat transfer, steam
Fig. 3. The HTER (blue) takes up very little space next to the steam reformer (grey) while adding up to 30% extra capacity
reforming, pressure drop, catalyst
temperature profile, and material
selection.
In an HTER, reforming and process
cooling are combined into a very
compact, cost-effective installation
that is typically 40% less than for a
new plant. You only need room for a
single slim reactor – which you can
locate in just about any small space
– rather than a conventional reformer.
It’s almost always the cheapest way
to build new capacity.

Hydrogen instead of steam
An HTER installation uses the
hydrogen plant’s high temperature
heat to provide additional reforming
capacity rather than for simply
producing steam. This reduce your
steam export by 45–60%. You can
produce that steam more cost-
effectively elsewhere, using cheaper,
simpler fuel.
Lower emissions
The smaller flue gas flow from an
HTER setup also enables you to
reduce CO2, NOx and other emissions
from your hydrogen plant.
Topsoe HTER installations have
resulted in documented 7% reduction
in CO2 emissions per unit of hydrogen
produced.
Safe choice
The HTER technology is an ideal
choice for larger-capacity hydrogen
production.
The convective reforming at the
heart of the HTER is a well-proven,
Haldor Topsoe Exchange Reformer (HTER)
reliable technology. It is also used in
flue gas-based convective reforming
(HTCR) and bayonet reformers (TBR).
It’s been comprehensively tested, and
the reliability and performance of the
HTER design are well-proven.
• The tube bundle inside the HTER is
inserted into a ceramic-lined steel
pressure shell and only subjected
to small differential pressures.
This greatly extends service life.
• A long service life because the
metallurgy in the reforming tubes
has been selected to cater for the
particular local gas composition
and temperatures, and to prevent
corrosion.
Small footprint path to more cost-
effective hydrogen production
For many refineries and hydrogen
installations, simple lack of space
can mean that a compact HTER
configuration is the only viable option
for expanding output.
The compact technology makes
it easy to exploit even a small
07
area to insert a remarkable 30%
output boost, with minimum capital
expenditure and operating costs.
HTER setups are equally effective
for debottlenecking and revamping
existing hydrogen plants and as an
integral part of high-efficiency new
hydrogen plants.
Rapid transitions
Installation of an HTER a setup can
usually be slotted into a normal
turnaround window because most of
the engineering and preinstallation
work is done offsite, and the reactor
can just be craned in quickly.
Time is money, and Topsoe experts
will help you make the switch as
quickly and effectively as possible.
30% more
hydrogen
with 7%
less feed
and fuel
 Haldor Topsoe Exchange Reformer (HTER) 09

Case
Revamp with HTER solution helps Indian refinery boost
hydrogen production by 27%
“This success will definitely be repeated at other refineries looking to boost
hydrogen production via a cost-effective revamp of existing plants.”
— Mr. Bimlesh Gupta, Chief Manager (Technical Services), Numaligarh Refinery, India

Challenge Solution Outcome

More stringent fuel content
regulations are forcing refineries to
desulfurize and dearomatize more
than ever, boosting the demand for
hydrogen at refineries around the
world. In India, the government’s
auto fuel policy, which stipulated
production of E-III and IV grade fuel
starting in April 2010, led to a sharp
rise in hydrogen needs at Numaligarh
Refinery. To decide how best to meet
these needs, Numaligarh performed
a thorough cost-benefit analysis with
input from Topsoe.
The cost-benefit analysis showed
that revamping Numaligarh’s existing
unit would provide the required
additional capacity at the lowest
total cost, so the refinery went ahead
and implemented the revamp. As part
of this project, Numaligarh decided
to incorporate a Haldor Topsoe
Exchange Reformer solution tailored
to meet the refinery’s exact needs.
The solution fits easily into a small
additional plot area, and no changes
to the refinery’s existing reformer
were required, which helped keep the
implementation time and costs at a
minimum.
The project has been a great success,
reducing feed and fuel consumption
per 1,000 Nm3 hydrogen produced
by 6.5% and reducing steam export,
while enabling the plant to meet its
target of boosting hydrogen capacity
by 27% or 14,600 Nm3/h. The
integration into the hydrogen section
and startup were trouble-free, and
since 2010 the plant has delivered
the hydrogen needed to meet the
stricter environmental requirements.
10 Haldor Topsoe

Related technologies

Scaling up hydrogen production

with hydroprocessing
Hydroprocessing is the common name for the units
that consume all the hydrogen made in refinery
hydrogen plants. Hydrotreating removes sulfur from
the oil components, and hydrocracking breaks the
heavier hydrocarbons into lighter hydrocarbons in order
to optimize the value of the product slate. Topsoe is
the leading licensor of all types of hydroprocessing
units and holds a complete catalyst portfolio within this
area. The main operating cost of these units is the
hydrogen. Therefore, knowledge of hydrogen
consumption and purity requirements has huge
influence on the refinery profitability. The
hydroprocessing units can be streamlined to fit a
certain hydrogen production. The top of the league
catalysts can assure that this flexibility is available
from Topsoe.

WSA (Wet gas Sulfuric Acid)

H2S gas is a byproduct of the hydroprocessing
technologies. H2S gas treatment traditionally means
WSA production of elemental sulfur by the Claus process,
but Topsoe has a smarter way. Around 90% of all sulfur
produced in Claus plants is turned into sulfuric acid
zooner or later. The Topsoe WSA (Wet gas Sulfuric Acid)
technology is developed with the purpose of turning
gaseous sulfur compounds into high-quality
concentrated sulfuric acid. You can utilize the large
amount of superheated high-pressure steam from the
WSA unit in other process plants or turn it into
electricity to cut your power bill. Ammonia and
hydrocarbons in the feed gas are the troublemakers in
a Claus unit, which are fully combusted in the WSA
process that also deals elegantly with variations in flow
and composition of the feed without having to deal
with keeping a delicate balance between H2S and SO2.
The WSA technology achieves at least the same high
sulfur removal efficiency as an advanced Claus unit
with tail gas treatment, but does it at a lower
installation and operation cost.
 Haldor Topsoe Exchange Reformer (HTER) 11

Why partner with

Haldor Topsoe?
The Topsoe advantage lies not just in individual solutions,
but in how our solutions work together

When you partner with Haldor

Topsoe, you partner not only with the
world’s experts in catalysis, surface
science and emissions management.
You also partner with a company that
takes a uniquely holistic approach to
your plant and your business.

When we look at your plant,

we look at the big picture – and
then apply the full breadth of our
expertise to deliver a thoroughly
tailored solution where individual
components work together to
maximize your plant’s performance
and your business success.
Haldor Topsoe is a world leader in catalysis and surface science,
committed to helping our customers achieve optimal performance.
We enable companies to get the most out of their processes and
products, using the least possible energy and resources, in the
most responsible way. We are headquartered in Denmark and do
project development, R&D, engineering, production, and sales &
service across the globe.

Get in touch today

www.topsoe.com
Haldor Topsoe A/S, cvr 41853816 | CCM | 0269.2019/Rev.0