Professional Documents
Culture Documents
methanol low
temperature shift
catalyst at Petrokemija
Authors:
This article was first published at Nitrogen and Syngas Conference, 5-8
March 2013, Berlin, Germany
This paper will look at how the operators of an ammonia plant selected
their LTS catalysts and the criteria that they used when comparing
catalysts, including legislation and operational constraints. This case study
will present the design conditions and will compare its actual performance
with previous charges in respect of both methanol formation and the
water gas shift reaction.
INTRODUCTION
Copper is the active component in the LTS catalyst for the water gas
shift and methanol synthesis reaction, since the both reactions can
take place simultaneously across the LTS catalyst, according to the
:
following reactions:
Figure 2 shows the current system for the LTS converter and the
related equipment for the LTS catalyst reduction, with the process
condensatestream to the process condensate stripping system and
subsequent CO2 stream to downstream users. The main process
stream treated in the process condensate stripping system is the CO
:
shift converter e"uent condensate. Treatment of condensate is
carried out by steam stripping in a packed tower which operates at
close to atmospheric pressure. The combined process condensate
stream at 116°C enters the top of the stripper and flows down through
two packed sections where, on contact with steam, the bulk of the
ammonia, carbon dioxide, methanol and dissolved gases are stripped
out. According to the design basis, condensate feed is expected to
have up to 1000 ppm of NH3, 3000 ppm of CO2 and from 200 to 2000
ppm of CH3OH depending of activity and selectivity of the LTS catalyst
in the ammonia unit. The high activity of the LTS catalyst results in the
production of relatively large amounts of CH3OH in the process
condensate and at times levels of up to 2000 ppm can be expected.
The residual CH3OH content of the treated process condensate is
expected to vary depending upon the amount in the stripper feed. On
average this is expected to be in the order of 100ppm. The overhead
vapours from the stripper column, containing mainly steam, NH3, CO2
and CH3OH are vented to atmosphere. Stripped process condensate is
pumped from the bottom of the column to the process condensate
treatment facility that uses ion exchange resins.
:
FROMTHEHTS
CONVERTER
HYDROGEN
STEAM
CO:TO
DOWNSTREAM
USERS
CONDENSATE
BENFIELDSYSTEM CW CW
FORCO.REMOVAL
NITROGEN
10€
CONDENSATE
STRIPPEDPROCESSCONDENSATETO
WATERTREATMENTUNIT
(IONEXCHANGERESIN)
Fig. 2: LTS process loop with related equipment for LTS catalyst
reduction and process condensate stripping system
Decreasing the contact time between the process gas and the LTS
catalyst (increasing the space velocity) will also decrease the amount of
methanol make. In plants with only one LTS converter a reduction in
catalyst volume will also lead to reduction in catalyst life.
1. minimum CO slip,
2. low and stable pressure drop,
3. robustness to operational upsets,
4. minimum by-products ( methanol and amine),
5. long life and economic performance,
6. good self guarding for sulphur and chloride poisons,
7. fast procedure of reduction and start-up.
The low temperature shift converter contains one bed of catalyst with
a volume of 108.8 m3. As the catalyst is self-guarding, the whole of the
bed provides shift activity throughout the life of the charge, with the
top portion of the bed retaining trace amounts of sulphur and chloride
poisons that pass through the high temperature shift converter.
1. CO slip
2. pressure drop through the bed of catalyst
3. concentration of the methanol in the condensate at the inlet to the
column of the stripper condensate
The process conditions for all three charges of LTS catalyst wereas
follows:
Figure 7 shows pressure drop during the life time of the catalyst. In the
case of ordinary catalyst KATALCOJM 83-3/ CCE C18-HCSthere was an
increase inpressure drop which had a negative influence on the energy
demand at the front end of the plant.
Fig. 7: Pressure drop through the catalyst bed for three charges of
the LTS catalysts, 1998 to 2012
The last installed charge of LTS catalyst KATALCOJM 83-3X has been in
operation since February 2012. The performance of the charge has
been continuously monitored via the concentration of the methanol in
the raw CO2 from the top of the stripper column in the Benfield
system by one of the end users of the CO2 (Figure 9). The medium for
the washing the synthesis gas in the absorption column is a hot
solution of potassium carbonate with the mass concentration of 29.0
to 30.0% and activator LRS 10 with a mass concentration around 3.0%.
The purity of CO2 is always higher than 99.0%. The temperature of the
process gas at the outlet of the vessel for the process condensate
separation is below 120°C. The concentration of methanol in the raw
CO2 is between 40 ppm and 80 ppm, which is 20 to 25% of the overall
methanol concentration from the outlet of the LTS converter. The
:
archived result is consistent with literature data, which says that when
operating in a temperature regime below 120°C, 50 to 70% of the
overall methanol content remains in the process condensate.
The value of pressure drop is also very significant and from the
industrial experience it can be concluded that lowering the pressure
:
drop for 1 bar saves around €120.000 per year. In the case of
Petrokemija with yearly production of 450.000 tonnes of liquid
anhydrous ammonia and steam to gas ratio of 3.5 at the inlet of
primary reformer, the savings resulting from the installation of the
charge of KATALCOJM 83-3X equate to approximately €450.000. This
estimate is based on savings due to less methanol production
improving ammonia production, and does not include the impact of
the lower pressure drop in the front end of the plant or the lower
methanol content in the synthesis loop that acts as an inert gas.
CONCLUSIONS
One of the main problems during the water gas shift reaction step in
ammonia production is the simultaneously reaction to make
methanol. The impact of the methanol synthesis reaction during the
ammonia production is variable and the main constraints are the
impact on operability, profitability, legislation and environmental
pollution in water and air. Due to this, ammonia operators must take
certain measures to satisfy all relevant requirements. One of the best
measures is to install the right LTS catalyst which will insure the
maximum operability and reliability of the plant, energy savings,
meeting the legislation requirements and prevention of the all
environmental issues.
ABBREVIATIONS
References
Latest news
Recent Publications
Habonim Ammonia Isolation Valves
:
Habonim Ammonia Isolation Valves
Applications
June 25, 2022