Tag: Catalyst

The internals of ammonia synthesis converters are generally made of austenitic stainless steel to withstand the harsh operating conditions (high temperature, high pressure and synthesis gas containing hydrogen and ammonia). Since nitriding is the most critical material degradation for the converter internals, Casale has set up a large nitriding analysis campaign. In the last decade, samples of materials operated under different pressures and temperatures and for different time spans have been tested and analysed. The data obtained has been used to increase nitriding knowledge and to establish a correlation to predict nitriding rate to allow the most suitable material and relevant thickness to be selected. L. Redaelli and G. Deodato of Casale report on how this correlation was established and provide valuable insight on this phenomenon and how to predict and control it.

M. Østberg and M. Rautenbach of Haldor Topsoe describe ReShift ™ technology, a new high temperature CO 2 reforming process, where preheated CO 2 is added directly downstream of a main reformer and then equilibrated in an adiabatic reactor. This new technology makes use of the high temperature of the reformer effluent to circumvent carbon formation, while at the same time maintaining an overall minimum steam to hydrocarbon carbon ratio, depending on process specific conditions. An increase in the amount of CO 2 added to the process will result in an increased fraction of CO in the produced synthesis gas. Synthesis gas with H 2 /CO ratios in the range 0.5-3 can be produced. These CO-rich gases are typically utilised in the production of functional chemicals and synthetic fuels.

With demand for conventional fuels projected to peak and fall over the next decade, some refiners are looking to petrochemical production as a way of diversifying their product slate.

The Abu Dhabi National Oil Company (ADNOC) has awarded a $510 million engineering, procurement and construction (EPC) contract to Italy’s Saipem to expand production capacity at the Shah sour gas plant, as the UAE looks to increase its output of gas by 2030. The Optimum Shah Gas Expansion (OSGE) & Gas Gathering project has been awarded by ADNOC Sour Gas, a joint venture between ADNOC and US energy major Occidental. The contract will increase gas processing capacity at the Shah plant by 13% per cent to 1.45 bcf/d from 1.28 bcf/d by 2023 and supports ADNOC’s objective of enabling gas self-sufficiency for the UAE. The Shah gas plant currently meets 12% of the UAE’s total supply of natural gas, as well as producing 5% of the world’s elemental sulphur. The expansion will cumulatively represent a 45% increase on the plant’s original capacity of 1.0 bcf/d when it came on-stream in 2015.

Developments in sulphuric acid technology and engineering know-how are highlighted by recent project case studies from DuPont Clean Technologies, Metso Outotec and thyssenkrupp Uhde.

Reducing the carbon footprint in the synthesis of chemicals is a new global challenge as the world works towards providing sustainable products designed to minimise their environmental impacts throughout their whole lifecycle. This article looks at the role of blue technologies as part of a roadmap towards the decarbonisation of fuels and chemicals.

Ammonia synthesis catalysts have long lives and catalyst replacement is an infrequent activity. Many people will go through their careers in the ammonia industry without ever having to replace a synthesis catalyst and the infrequent nature of catalyst replacement means that many plants may not have direct experience of this activity. Ammonia synthesis catalyst can present a range of hazards throughout the replacement process, from transport through loading, reduction, start-up, shutdown and discharge, but the good practice illustrated in this article, and collaboration between catalyst suppliers and end users can ensure safe and successful catalyst changeouts.

This year’s SulGas conference, covering sulphur recovery and gas treating with a special focus on India and southeast Asia, was run as a virtual event from February 1st to 3rd 2021.

EcoMax™ tail gas catalysts offer a sustainable and cost effective choice for tail gas catalysts. They are made from spent hydroprocessing catalysts, which reduces the environmental and socioeconomic impacts of sourcing fresh cobalt and molybdenum and therefore supports operators’ sustainability goals. B. Visioli of Porocel (a part of Evonik) discusses the benefits of catalyst reuse from hydroprocessing for tail gas treating.

M. Baerends of Fluor reports on the conception, engineering, construction, commissioning and start-up of a new sulphuric acid plant that replaced an existing acid plant at a European sour gas processing terminal. This highly complex gas processing facility handles sour gas from an off-shore field, containing H2 S that must be removed to meet transmission grid specifications. Various issues encountered, their resolution by the joint owner, Fluor and Topsoe team, and plant operating results are discussed.