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 Exploiting process heat for reforming with a tubular reformer (SMR) or with
make the most effective possible use saves fuel consumption. The steam a two-step reforming configuration
of the valuable thermal energy in the co-production could be made up by (an SMR followed by a secondary
reformer effluent by using it for another unit using a cheaper fuel reformer).
additional reforming rather than for than the hydrogen plant, resulting in
steam production. Less steam, more significant savings.
hydrogen.
An HTER setup enables you to carry
An HTER carries out steam reforming out steam reforming parallel with the
in parallel with the primary steam primary steam reformer.You can use
reformer. It is a very compact, an HTER reformer in combination with
cost-effective piece of equipment. an autothermal reformer SynCOR™
Steam
Flue gas
Natural
gas Steam H2
Purification HTER WHB Shift & PSA
reforming
~900°C ~600°C ~300°C
Fuel
Fig. 1. Energy conservation - Desired H2 product using less feed and fuel
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, pressure drop, catalyst single slim reactor – which you can
Reforming requires heat transfer into temperature profile, and material locate in just about any small space
the reforming tubes. The HTER selection. – rather than a conventional reformer.
technology is based on the efficient
convective transmission of the heat In an HTER, reforming and process It’s almost always the cheapest way
to the reforming catalyst, using many cooling are combined into a very to build new capacity.
years of practical experience and compact, cost-effective installation
detailed understanding of the setup that is typically 40% less than for a
in terms of heat transfer, steam new plant. You only need room for a
Fig. 3. The HTER (blue) takes up very little space next to the steam reformer (grey) while adding up to 30% extra capacity
Haldor Topsoe Exchange Reformer (HTER) 07
Hydrogen instead of steam reliable technology. It is also used in area to insert a remarkable 30%
An HTER installation uses the flue gas-based convective reforming output boost, with minimum capital
hydrogen plant’s high temperature (HTCR) and bayonet reformers (TBR). expenditure and operating costs.
heat to provide additional reforming It’s been comprehensively tested, and HTER setups are equally effective
capacity rather than for simply the reliability and performance of the for debottlenecking and revamping
producing steam. This reduce your HTER design are well-proven. existing hydrogen plants and as an
steam export by 45–60%. You can integral part of high-efficiency new
produce that steam more cost- • The tube bundle inside the HTER is hydrogen plants.
effectively elsewhere, using cheaper, inserted into a ceramic-lined steel
simpler fuel. pressure shell and only subjected Rapid transitions
to small differential pressures. Installation of an HTER a setup can
Lower emissions This greatly extends service life. usually be slotted into a normal
The smaller flue gas flow from an turnaround window because most of
HTER setup also enables you to • A long service life because the the engineering and preinstallation
reduce CO2, NOx and other emissions metallurgy in the reforming tubes work is done offsite, and the reactor
from your hydrogen plant. has been selected to cater for the can just be craned in quickly.
particular local gas composition Time is money, and Topsoe experts
Topsoe HTER installations have and temperatures, and to prevent will help you make the switch as
resulted in documented 7% reduction corrosion. quickly and effectively as possible.
in CO2 emissions per unit of hydrogen
produced. Small footprint path to more cost-
effective hydrogen production
Safe choice For many refineries and hydrogen
The HTER technology is an ideal installations, simple lack of space
choice for larger-capacity hydrogen can mean that a compact HTER
production. configuration is the only viable option
for expanding output.
The convective reforming at the The compact technology makes
heart of the HTER is a well-proven, it easy to exploit even a small
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 The cost-benefit analysis showed The project has been a great success,
regulations are forcing refineries to that revamping Numaligarh’s existing reducing feed and fuel consumption
desulfurize and dearomatize more unit would provide the required per 1,000 Nm3 hydrogen produced
than ever, boosting the demand for additional capacity at the lowest by 6.5% and reducing steam export,
hydrogen at refineries around the total cost, so the refinery went ahead while enabling the plant to meet its
world. In India, the government’s and implemented the revamp. As part target of boosting hydrogen capacity
auto fuel policy, which stipulated of this project, Numaligarh decided by 27% or 14,600 Nm3/h. The
production of E-III and IV grade fuel to incorporate a Haldor Topsoe integration into the hydrogen section
starting in April 2010, led to a sharp Exchange Reformer solution tailored and startup were trouble-free, and
rise in hydrogen needs at Numaligarh to meet the refinery’s exact needs. since 2010 the plant has delivered
Refinery. To decide how best to meet The solution fits easily into a small the hydrogen needed to meet the
these needs, Numaligarh performed additional plot area, and no changes stricter environmental requirements.
a thorough cost-benefit analysis with to the refinery’s existing reformer
input from Topsoe. were required, which helped keep the
implementation time and costs at a
minimum.
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
