Fertiliser Plant

Synthesis Converter, LTS and

Methanator Catalyst replacement

Date : 16th Nov.’18

Synthesis Converter Catalyst

Current Synthesis Converter Catalyst :

Current catalyst charge of KM1R ( 3.7 m3) and KM1 catalyst ( 8.1 m3) from Topsoe was
installed in Nov 2012 and shall operate 88 months by Mar 2019

Previous Catalyst charge:

Previous catalyst charge was loaded in 2006 and had to be replaced in Nov 2012 during
emergency shutdown taken due to high pressure drop leading to load reduction for
~ 1.5 month.and leading to unscheduled turnaround

Previous catalyst charge history and reasons for replacement are as under:

1992 - 98 72 months
1998 - 00 24 months ( high pressure drop of ~13 Kg/cm2 at EOR )
2000 – 06 89 months ( high pressure drop ~ 15 Kg/cm2 at EOR )
2006 – 12 87 months ( unscheduled replacement due to high pressure drop
of 14 Kg/cm2 at 60% load )

Mechanical damage to basket has been observed in previous catalyst replacements

2
Synthesis Converter catalyst
Pressure Drop in current catalyst charge
Gradual increase in Pressure Drop from 3.7 Kg/cm2 in Nov 2012 ( SOR) to current level of 8.5
Kg/cm2
Continuous exposure to high pressure and temperatures leads to chances of basket failure
New catalyst shall reduce power ( ~200 kW equiv. to Rs 2.7 Crs for 2 yrs) and also increase
Ammonia production capacity

11

9
Pressure Drop
( kg/cm2)

1
15-Dec-16
15-10-2016

15-11-2016

18-Apr-17

29-Jun-18
1-Oct-17

1-Jan-18
15-May-17

1-Aug-17
7-Jul-17

1-Nov-17

23-Mar-18

26-May-18

20-Aug-18
15-Jun-17

20-Oct-18
15-Jan-17

1-Sep-17

31-Jan-18

16-Nov-18
15-Feb-17

21-Feb-18

18-Jul-18

11-Sep-18
1-Dec-17

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Synthesis Converter catalyst
Performance of current catalyst charge
The comparison of parameters from SOR and EOR conditions is as under:

Dec 2012 Nov 2018

SOR EOR
Inlet temp - 1st Bed oC 370 381
- 2nd Bed oC 426 416
Max Outlet Temp
- 1st Bed oC 534 542 Note -1
- 2nd Bed oC 505 498
Valve Opening
- Cold Shot % 55 100 Note -2
- Quench % 72 100
Pressure Drop Kg/cm2 3.7 8.5

Note : 1 : Design temperature is 540 oC and continuous operation above design temperature can lead to
mechanical damage to the basket
Note : 2 : No further margin to increase inlet bed temperatures
4
 Delta Ammonia %

10.0
10.5
11.0
11.5
12.0
12.5
13.0
13.5
14.0
14.5
15.0
15.5
16.0
16.5
17.5
18.0

17.0
11/20/2012
12/20/2012
1/31/2013
3/14/2013
4/25/2013
6/6/2013
7/18/2013
8/28/2013
10/11/2013
11/21/2013
1/2/2014
2/6/2014
3/20/2014
5/1/2014
6/12/2014
7/24/2014
9/4/2014
Synthesis Converter catalyst

10/23/2014
12/11/2014
1/22/2015
3/5/2015
5/14/2015
7/2/2015
8/20/2015
not working

10/1/2015
11/13/2015
12/31/2015
Outlet sample point

2/8/2016
5/18/2017
7/13/2017
8/24/2017
10/5/2017
11/16/2017
12/28/2017
Delta Ammonia concentration across Converter – Current Charge

2/7/2018
22.03.18
03.05.18
14.06.18
26.07.18
13.09.18
25.10.18
5
 Delta Ammonia %

5.0
7.0
9.0
11.0
13.0
15.0
17.0
19.0
1/25/2007
5/3/2007
8/2/2007
11/29/2007
3/20/2008
6/26/2008
9/25/2008

earlier charge
12/25/2008
3/26/2009
8/21/2009
2/18/2010

Gradual deterioration of
5/27/2010
8/26/2010
12/16/2010
3/3/2011
in Nov 2012

6/9/2011
10/6/2011
Synthesis Converter catalyst

1/5/2012
4/12/2012
Fresh Catalyst Charge

7/12/2012
10/6/2012
1/3/2013
4/4/2013
7/4/2013
10/4/2013
1/2/2014
3/27/2014
6/26/2014
not working

9/25/2014
1/8/2015
5/7/2015
Outlet sample point

8/20/2015
11/19/2015
2/19/2016
5/12/2016
10/20/2016
1/26/2017
Comparison of Delta Ammonia concentration with previous charge

6/15/2017
9/14/2017
12/14/2017
15.03.18
14.06.18
20.09.18
6
Synthesis Converter catalyst

Topsoe has also recommended that synthesis catalyst should be replaced at next
shutdown due to high pressure drop and due to high catalyst bed temperature

Approach to equilibrium for top bed and bottom bed is also high and fine tuning of
bed temperatures is not possible due to full opening of quench and cold-shot
temperatures

Based on above, it is proposed to replace Synthesis catalyst during Mar 2019

shutdown

While offers have been obtained from Topsoe and Sud Chemie, it is proposed to
procure from Topsoe based on their technical design of the basket and its future
maintenance requirements

7
LTS Catalyst

8
 LTS Catalyst

Current LTS Catalyst :

Current catalyst charge of LTS is from Sud Chemie and was installed in Apr 2015 and
shall operate 4 Yrs by Mar 2019

Previous Catalyst charge:

Previous catalyst charge was loaded in Nov 2012 and had to be replaced pre-maturely in Apr
2015 after 2 years due to abnormal pressure drop of 3 Kg/cm2.

Catalyst Performance :

Unit Jul 09 – Sep 12 Sep 12 – Mar 15 Apr -15 - Todate

Pressure Drop Kg/cm2 1.1 1.1 1.1 3 0.63 0.75

Exit CO Slip % CO 0.11 0.41 0.12 0.17 0.14 0.31
Inlet temp oC 200 201 204 200 208

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 Inlet CO Slip from HTS ( % )

0.5
1.5
2.5

0
1
2
12.04.2015
15.05.2015
21.06.2015
21.07.2015
22.08.2015
21.09.2015
20.10.2015
19.11.2015
19.12.2015
LTS Catalyst

18.01.2016
16.02.2016
18.03.2016
18.04.2016
17.05.2016
16.06.2016
15.07.2016
13.08.2016
14.09.2016
29.10.2016
Trend of CO Slip for current LTS charge

28.11.2016
27.12.2016
25.01.2017
23.02.2017
gradual increase in HTS inlet temperature

26.03.2017
09.05.2017
08.06.2017
08.07.2017
06.08.2017
04.09.2017
05.10.2017
03.11.2017
02.12.2017
31.12.2017
29.01.2018
27.02.2018
28.03.2018
29.04.2018
28.05.2018
28.06.2018
27.07.2018
28.08.2018
30.09.2018
30.10.2018
0.05
0.15
0.25
0.35
0.45
0.55
0.65
0.75

-0.05
- LTS slip has increased even when HTS Slip has reduced due to high S/C ratio and

LTS Slip ( % CO )
10
 LTS Catalyst
Trend of Temperature in LTS
- LTS temperature has been increased gradually from 200 to 207 at present
- Reaction has shifted to bottom bed since Apr 17 ( for 2 years)

Current

SOR

Catalyst Volume ( % )

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 Inlet CO Slip from HTS ( % )

0.00
1.00
1.50
2.00
2.50

0.50
03.04.2012
30.04.2012
27.05.2012
23.06.2012
20.07.2012
16.08.2012
12.09.2012
LTS Catalyst

11.10.2012
22.11.2012
19.12.2012
17.01.2013
14.02.2013
14.03.2013
08.04.2013
05.05.2013
01.06.2013
28.06.2013
25.07.2013
21.08.2013
17.09.2013
14.10.2013
Catalyst changed in Oct 2012

10.11.2013
07.12.2013
03.01.2014
30.01.2014
26.02.2014
Trend of CO Slip for previous LTS charge ( 2012 – 2015 )

25.03.2014
21.04.2014
18.05.2014
14.06.2014
11.07.2014
10.08.2014
06.09.2014
05.10.2014
04.11.2014
02.12.2014
29.12.2014
26.01.2015
25.02.2015
0.00
0.10
0.30
0.40
0.50
0.60
0.80
0.90
1.00

0.20
0.70

LTS Slip ( % CO )
12
 LTS Catalyst
Life of previous catalyst charge

Till Mar 2019

Months in operation

Years of Operation

13
 LTS Catalyst

Summary :

CO2 Slip from LTS exit has increased from 0.14 % at SOR to 0.31% at EOR

The temperature profile and Approach to Equilibrium indicates that the reaction is
occurring at bottom bed of LTS

Methanator Delta T is presently 28 oC mainly due to high LTS CO Slip and is

presently constrain even at currently reduced plant load

The CO Slip will increase exponentially with time and can reach ~0.6-0.7 % in 2
years making it difficult to operate the plant

The current charge has operated for 4 years which is in line with life achieved in
previous charge

It is proposed to replace the LTS catalyst in Mar 2019

Fresh LTS charge shall also improve in energy consumption

14
Methanator Catalyst

15
Methanator Catalyst

Current Methanator Catalyst :

Current catalyst charge of Methanator is from Sud Chemie and was installed in Aug 2011
and shall operate 7.5 Yrs by Mar 2019

Previous Catalyst charge:

Previous catalyst charge was loaded in Sep 06 and was replaced in Aug 2011.

Catalyst Performance :

Unit Sep 06 – Aug 11 Sep 11 – To-date

SOR EOR SOR EOR
Pressure Drop Kg/cm2 0.36 0.39 0.16 0.26
Inlet Temperature oC 270 285 280 300

CO and CO2 slips have been less than 10 ppm for all charges

16
Methanator Catalyst
Trend of Temperature rise over Methanator catalyst ( 2011 – todate )

Months in operation
Temp oC

Catalyst Volume ( % )

17
 -
CO2 Slip ( ppm)

0.00
0.50
1.00
1.50
2.00
3.00
3.50
4.00
4.50
5.00

2.50
16.04.2015
13.05.2015
09.07.2015
12.08.2015
23.09.2015
21.10.2015
25.11.2015
16.12.2015
13.01.2016
30.01.2016
Methanator Catalyst

17.02.2016
27.04.2016
CO2 Slip from Methanator exit

01.06.2015
29.06.2016
27.07.2016
31.08.2016
15.10.2016
09.11.2016
07.12.2016
04.01.2017
01.02.2017
28.02.2017
12.04.2017
17.05.2017
21.06.2017
12.07.2017
09.08.2017
06.09.2017
04.10.2017
08.11.2017
06.12.2017
28.12.2017
24.01.2018
07.03.2018
09.05.2018
06.06.2018
04.07.2018
01.08.2018
12.09.2018
24.10.2018
CO / CO2 slip has been maintained steady due to continuous increase in Methanator inlet temperature

18
Methanator Catalyst
Life of previous catalyst charges
- Life of current charge shall be among highest ever

Till Mar 2019

Months in operation

Years of Operation

19
Methanator Catalyst
Summary :
Pressure drop has been steady for this batch of catalyst

Inlet temperature has increased to 300oC and further increase results in increase in front –end
pressure drop

The temperature profile has marginally shifted to lower volume of the catalyst

Any deterioration in performance of catalyst is difficult to detect due to low ppm of CO & CO2
at exit

During last 2 years, high pressure drop has been observed on Cold Heat Exchanger which is
due to build-up of Carbamate which can be attributed to deterioration of activity of catalyst
– This leads to additional energy consumption in Synthesis loop

The current charge has operated for 7.5 years which is highest ever life obtained

It is proposed to replace the Methanator catalyst in Mar 2019

Fresh Methanator catalyst shall also reduce the poisoning risk to new Synthesis Catalyst being
planned in Mar 2019

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Thank You

21