Topse hydrogen technology
energy efficient and flexible solutions
Topse hydrogen technology
processes for today and the future
Continuous development Process steps
Topse offers a range of innovative technologies for hydrogen Feed purification
production based on steam reforming of hydrocarbons. These Feed purification effectively removes sulphur and chlorine
technologies are continuously improved by integrating new compounds and saturates olefins, including di-olefins in the
catalysts and technology features based on knowledge hydrocarbon feedstocks.
acquired from our in-house R&D as well as industrial experience
with our catalysts and designs. Topse hydrogen technology is Prereforming
applicable for the design of new plants as well as for revamps. Prereforming is used for steam reforming of all higher
hydrocarbons in the hydrogen plant feed resulting in stable and
Common features of Topses hydrogen technologies are: mild operating conditions for the steam reformer. Today more
than 50 Topse hydrogen plants incorporate our prereformer
-- high energy efficiency design.
-- feedstock flexibility
-- tailor-made and flexible design Steam reforming
-- high on-stream availability The steam reforming process is the heart of the hydrogen
-- safe and reliable operation production process and the right choice of technology is crucial
-- minimum manpower requirements for the overall plant economics. The use of Topses reforming
-- low maintenance costs technology results in high energy efficiency and covers a wide
-- low investment range of capacities and client requirements.
CO conversion
The shift section is designed to maximise the hydrogen yield.
The shift section consists of a high temperature shift reactor
(HTS) or a medium temperature shift reactor (MTS), sometimes
combined with a low temperature shift reactor (LTS).
Purification
Topse hydrogen technologies are based on hydrogen
purification by a PSA unit optimised for maximum hydrogen yield
and purity. Topse works with several PSA unit vendors.
Steam reforming technologies Haldor Topse Convection Reformer
The Haldor Topse Convection Reformer (HTCR) is a heat
exchange steam reformer in which the process gas is heated
Radiant wall steam reformer mainly by flue gas. An HTCR is very compact and suited for new
The radiant wall steam reformer consists of a number of catalyst
hydrogen units and for revamps for capacity increase of existing
tubes in a single line in one or two fired boxes with burners
plants.
placed at the walls at several elevations.
The HTCR consists of a number of bayonet reformer tubes
The burner flamesare directed backwards against the furnace
contained in a refractory-lined vessel. The heat from the
wall, eliminating any risk of flame impingement of the catalyst
flue gas is transferred to the process gas inside the bayonet
tubes. This burner arrangement enables full control of the
reformer tubes resulting in low feedstock consumption and very
temperature profile along the entire catalyst tube length.
importantly zero steam export.
Therefore, the radiant wall steam reformer is able to operate at
low steam to carbon ratios, unmatched high average heat fluxes,
An HTCR unit is to a high degree skid-mounted minimising
and at high outlet temperatures.
erection time and cost on site. Topse can supply an HTCR unit
including all equipment and materials within battery limits.
Topses radiant wall steam reformer design has been in
operation for more than 50 years and we have designed more
Industrial experience with HTCR includes more than 30 plants
than 250 units.
with capacities ranging from 5,000 to 30,000 Nm3/h (4.5 to 27
MMSCFD).
Haldor Topse Exchange Reformer Topse Bayonet Reformer
The Haldor Topse Exchange Reformer (HTER) is a heat The Topse Bayonet Reformer (TBR) combines the principle of
exchange steam reforming technology in which the reaction heat convection heat transfer known from HTCR and radiant heat
is provided by hot process gas. The HTER is used in hydrogen, transfer known from the radiant wall steam reformer.
ammonia and methanol plants in combination with a radiant wall
steam reformer for additional capacity. TBR provides hydrogen production with low hydrocarbon
consumption and little or no steam export.
The HTER utilises a bayonet tube or a two-bed system allowing
for optimal utilisation of the heat transfer areas. The hot steam The TBR consists of bayonet reformer tubes in a furnace box
reformer effluent is used as heating medium where the high heated by radiant wall burners. Improved heat utilisation in
pressure enables a very effective heat transfer. combination with a high average heat flux in the TBR tubes
significantly reduces the size and capital cost of the hydrogen
The inclusion of an HTER unit reduces fuel consumption and plant.
steam production and may increase capacity up to 20-30%.
Therefore, the HTER is well suited for both capacity revamps as The combination of high energy efficiency and low steam export
well as new units where factors such as low steam export and results in a uniquely low production of carbon dioxide per unit of
compactness are important. hydrogen in the TBR.
Since 2005 when the first HTER went into successful operation,
the HTER technology has been adopted in several Topse
designed hydrogen plants.
Revamp of existing hydrogen units The Methanol-to-Shift process is a revamp option suitable for
Revamping an existing hydrogen unit may be an economically peak-shaving applications based on methanol reforming over
attractive solution to increase capacity and decrease specific a Methanol-to-Shift catalyst. This option makes it possible to
energy consumption. A revamp can also enable a plant to produce additional hydrogen at low capital cost.
operate on additional types of feedstock.
In order to determine the feasibility of a revamp, Topse will
Traditional debottlenecking may often give the desired result for perform a revamp feasibility study to provide the client with the
a minor capacity increase (5-10%). When a significant capacity optimal solution. The study will take into account the various
increase is desired (10-30%), installation of additional reformer requirements of the client as well as prevailing conditions
capacity in the form of a heat exchange reformer (HTCR or such as availability and price of feedstock, plot plan, minimum
HTER) operating in parallel or in series with the existing steam downtime for revamp etc.
reformer is often an attractive solution.
The Topse approach Environmental and safety aspects
Topse hydrogen plants are designed for minimum impact on the
environment. The use of low NOx burners and full re-utilisation
Continued improvement of process condensate is standard. Carbon dioxide emissions
Extensive collaboration between Topses engineering disciplines,
from Topse hydrogen plants are inherently low due to the high
Research and Development and industrial feedback ensures fast
energy efficiency of the technology. Topse also offers solutions
implementation of new ideas and design features for constant
for carbon dioxide abatement and NOx reduction by selective
improvement of our technologies.
catalytic reduction (SCR) for incorporation in the plant design to
comply with any environmental requirements.
Topses product portfolio includes catalysts, licensing of
technologies, engineering of processing units, supply of hardware
Topse hydrogen plants are designed to meet the highest
and technical services during the project and during the operation
international safety standards in all aspects of plant operation
of the plant. Proprietary knowledge in these areas makes Topse
providing a safe and reliable plant.
a valuable business partner for our clients.
The Topse business portfolio Supply and services
For a hydrogen plant project Topses scope of supply ranges
When working with Topse, you will benefit not only from our
from supply of license, basic engineering and catalyst to supply
long-term involvement in the hydrogen industry but also from
equipment and materials as well as advisory services during the
our broad scope of supply. In addition to our technology and
entire project phase.
catalysts for hydrogen production, Topse is also a leading
supplier of innovative catalyst and technology solutions for
hydroprocessing for the refining industry and for the production As after sales service, the Topse technical service team is
of ammonia, methanol, DME and synthesis gas for the ready to provide clients with professional advisory services to
petrochemical industry. ensure safe, reliable and efficient plant operation. The Topse
organisation includes a full range of engineering resources with
access to Topse R&D and catalyst divisions to identify and solve
even the most complex problems encountered.
Corporate PR 06.2009.2
Haldor Topse A/S - Nymllevej 55 - 2800 Kgs. Lyngby - Denmark
Tel. +45 4527 2000 - Fax. +45 4527 2999 - www.topsoe.com
The information and recommendations have been prepared by Topse specialists having a
thorough knowledge of the catalysts. However, any operation instructions should be considered to
be of a general nature and we cannot assume any liability for upsets or damage of the customers
plants or personnel. Nothing herein is to be construed as recommending any practice or any
product in violation of any patent, law or regulation.
