Producing syngas needed for methanol synthesis accounts for up to 60% of the operating costs of a methanol plant, making efficient and reliable syngas generation a critical factor in overall plant profitability.
Syngas production involves converting natural gas to a suitable stoichiometric syngas in the syngas generation section of your methanol plant. The conversion is normally carried out via tubular steam methane reforming (SMR), autothermal reforming (ATR), or a combination of these processes. However, there are other type of reforming such as heat exchanging reforming as well as adiabatic prereforming that are often used to increase capacity and/or efficiency of a process when applied together with steam methane reforming or autothermal reforming.
Whichever process you choose, it must be highly efficient and reliable to ensure profitable operation. The following Topsoe processes are designed specifically to help you maximize efficiency without compromising on reliability.
SynCOR technology
A proven technology with a strong track record for efficiency and reliability, Topsoe’s SynCOR consists of a reforming section based on a prereformer followed by an autothermal reformer. Both components operate at a uniquely low steam-to-carbon ratio (≤ 0.6). The low ratio means energy savings, smaller equipment and a smaller environmental footprint for your plant.
Steam reforming
Steam methanol reforming (SMR) is a more conventional method for converting natural gas to syngas. With its flexible tube-wall temperature control, Topsoe’s side-fired SMR design provides exceptional versatility, reduces the risk of hot bands, and enables operators to maintain more stable tube temperatures during plant operation. These benefits make our state-of-the-art SMR one of the most widely used designs in the industry.
Exchange reforming
Exchange reforming is a convenient and affordable method for adding extra capacity to your syngas generation unit. We offer several exchange reforming technologies that enable you to utilize waste heat and/or waste gas to boost capacity. These include our HTER technology, which lets you use thermal energy in your reformer effluent to add reforming capacity, and our HTCR technology, which adds reforming capacity using heat generated by natural gas, LPG, naphtha or off-gas.
Adiabatic prereforming
Adiabatic prereforming helps you maximize efficiency and boost reforming capacity using waste heat. Built in to every methanol process we design, our pre-reforming technology relies on the Topsoe AR-series catalyst. This catalyst ensures operational flexibility, safety and lower energy consumption, all thanks to exceptional resistance to carbon formation and the proven ability to operate with a steam-to-carbon ratio below 0.6.
Catalysts
Catalysts
The performance catalysts we supply for this application are listed below.
CatalystsAR-401
Pre-reduced pre-reforming catalyst suitable for feedstocks ranging from natural gas to naphtha.- Catalysts
R-87R HEAT-X™
Pre-reduced high activity reforming catalyst for heat exchange applications. - Catalysts
RA-67-7H
Reforming catalyst promoted for low ammonia formation used for tubular reforming. - Catalysts
RK-201
Low alkali promoted reforming catalyst used for tubular reforming of feedstocks ranging from natural gas to naphtha. - Catalysts
RK-202
High alkali promoted reforming catalyst used for tubular reforming of naphtha feedstocks. - Catalysts
RK-211
Pre-reduced low alkali promoted reforming catalyst used for tubular reforming of feedstocks ranging from natural gas to naphtha. - Catalysts
RK-212
Pre-reduced high alkali promoted reforming catalyst used for tubular reforming of naphtha feedstocks. - Catalysts
RK-400
Latest generation low alkali promoted reforming catalyst used for feedstocks ranging from natural gas to LPG. - Catalysts
RK-400R
Latest generation pre-reduced low alkali promoted reforming catalyst used for feedstocks ranging from natural gas to LPG. - Catalysts
RK-500 TITAN™
Tubular reforming catalyst With the RK-500 TITAN™ catalyst we have combined the superior carbon resistance of our conventional alkali catalysts with the unmatched stability of the low pressure drop RC-67 TITAN™. The catalyst is produced in the seven-hole cylindrical shape which yields both a very... - Catalysts
RKA-10
Noble metal-promoted top layer catalyst for oxygen-fired secondary and autothermal reforming. - Catalysts
RKC-2-7H
Secondary reforming catalyst RKC-2-7H is a nickel based reforming catalyst for secondary reforming. Application RKC-2-7H is used in the main bed of secondary air-blown reformers. Main bed The RKC-2-7H catalyst has high activity and the shape and size gives low start-of-run pressure drop.
Equipment
Equipment
The proprietary equipment we supply for this application are listed below.
- Equipment
Air-fired Secondary Reformer
The air-fired secondary reformer is essential in natural gas-based ammonia plants as it is the simplest way of introducing the nitrogen required for ammonia synthesis. Unlike the upstream tubular primary reformer, the secondary reformer is adiabatic, and the operating conditions are more severe... - Equipment
Catalyst bed support structure
The catalyst bed support in the SynCOR™ unit serves both as structural support for the catalyst bed and as an outlet flow distributor guiding the syngas from the catalyst bed into the transfer line to the waste heat recovery system downstream the reformer. - Equipment
Convection Reformer HTCR
Haldor Topsoe Convection Reformer™ (HTCR) technology is a compact, high-efficiency heat exchange reformer that provides refinery operators with a straightforward, inexpensive way to meet the growing demand for hydrogen. - Equipment
Heat Exchange Reformer (HTER)
The introduction of gas heated reforming for synthesis gas production will enable you to effectively utilize the valuable heat in the reformer effluent to create more reforming capacity. The Topsoe HTER can be used in combination with an autothermal reformer (ATR), with a tubular reformer (SMR), or... - Equipment
HTZR™ target tiles
Topsoe’s SynCOR™ unit incorporates a floor of zirconium-based ceramic target tiles, HTZR™, as an integral part of the reactor design. The purpose of the HTZR™ target tiles is to: Act as the partition between the combustion chamber and the catalyst bed Protect the catalyst from any direct impact... - Equipment
Oxygen-fired Secondary Reformer
In large-scale methanol plants, each added day of operation is worth as much as a million euros. Plant reliability and availability are of utmost importance. Meeting these needs requires continuous equipment development and process optimization. One of the important pieces of equipment used in the... - Equipment
Reactor refractory lining
The SynCOR™ pressure shell is manufactured from low-alloy steel. It is protected against the extremely harsh operating conditions in the combustion chamber by an internal lining of a multi-layer refractory. The lining is exposed to extremely high temperature and radiation intensity from the... - Equipment
SynCOR™ - Autothermal Reformer (ATR)
Autothermal reforming at low steam-to-carbon ratio The majority of the world’s syngas-producing plants apply steam methane reforming, with the specific type of reforming technology depending on application and operating conditions. Topsoe offers several types of reforming technologies and has... - Equipment
SynCOR™ CTS™ burner
The CTS™ (Cool Tip Swirl) burner is a crucial piece of equipment, and its importance in reformer reliability and availability cannot be underestimated. Good burner performance is characterized by: Short and centralized flame Low metal temperatures on burner nozzles Soot-free operation Easy... - Equipment
Topsoe Bayonet Reformer (TBR)
The Topsoe Bayonet Reformer TBR combines the novel properties of convection and radiant heat transfer in one steam reformer. The development and introduction of the TBR is a result of Topsoe’s continuous striving towards more energy efficient ways of producing hydrogen by steam reforming of... - Equipment
Topsoe Furnace Manager TFM
How can you predict and prevent your furnace from unexpected and costly downtime? How can you integrate communication between furnace operation and plant optimization? How can you increase your furnace and personal safety? Asset Protection Previously, plant operators relied on proactive repairs and... - Equipment
Tubular radiant wall steam reformer
The radiant wall steam reformer consists of a number of catalyst tubes in a single line in one or two fired boxes with burners placed at the walls at several elevations. The burner flames are directed backwards against the furnace wall, eliminating any risk of flame impingement of the catalyst...
Services
Services
- Services
Catalyst Loading
All plants – even those with lots of turnaround experience – can run into trouble during loading. When a problem occurs, it can lead to longer turnarounds and, in the worst case, result in an underperforming catalyst. That makes proper loading an important step in profitable plant operation. Topsoe... - Services
General Technical Service
Optimal interaction between catalyst and technology is crucial if your plant is to perform at its best. Topsoe’s General Technical Service employs the full weight of our knowledge and experience to advise, inform and guide you towards improvement. All General Technical Service is provided as in-... - Services
Internal Visual Inspection
A Topsoe Internal Visual Inspection is your first line of defense against faults in valves, piping, boilers, heat exchangers and adiabatic catalytic reactors, or even larger systems such as steam reformers. As a key component in your preventative maintenance program, an Internal Visual Inspection... - Services
Plant Assessment / Optimization
Refineries and chemical plants are complex and vulnerable to changes over time. These changes can degrade performance and impact negatively on day-to-day operations and, ultimately, your bottom line. Whether you choose a catalyst performance evaluation or full-scale process and catalyst... - Services
Sampling & Analysis
As a general rule, the more you know about a plant or unit’s operating conditions, the better you’ll be able to keep performance, cost-efficiency and profits high. Our Sampling & Analysis service is your direct route to the detailed insight it takes to make better decisions. During start-ups... - Services
Start-up & Reduction / Activation
Starting up your plant or unit is a complicated and time-consuming procedure that involves monitoring numerous parameters and ensuring the right start-up sequencing. If not performed correctly, it can result in delays or even damage to your catalysts, unit or plant. Our Start-up & Reduction/... - Services
Steam Reformer Assessment / Optimization
Steam reforming is right at the heart of your plant, and the performance of your steam reformer has a direct impact on your overall plant performance and, ultimately, your bottom line. Topsoe’s Steam Reformer Assessment/Optimization service is a proven means of ensuring optimal performance... - Services
Troubleshooting
Catalysts and processes normally operate smoothly, yet suboptimal performance can occur from time to time. Since most issues have multiple root causes – usually originating in external factors – the process of solving an issue can be difficult and complex. Our Troubleshooting service draws on the...
Training
Training
The training services we supply for this application are listed below.
- Training
Damage Mechanisms: Causes and prevention
Understanding how critical equipment is affected by aggressive components and operational failures can help you prevent damage and increase the lifetime of your plant. - Training
General Plant Understanding
Learn the basics of plant design, processes and catalyst theory - Training
Steam Reformer Assessment / Optimization
Learn to maintain & improve the health of your steam reformer
Project development
Project development
- Project development services
Facilitating Investments
Benefit from the extensive experience of our project finance teams. - Project development services
Project development
Holistic and integrated approach from idea to financial close.
Process licensing
Process licensing
We offer a full range of process solutions, ranging from technology process licensing to revamps of existing units.
- Process licensing
One-step methanol
Low cost technology for small to medium capacity This technology uses only steam reforming as synthesis gas generator. Operating cost is higher than for than for technologies involving Oxygen reforming but capital cost is low. The optimal capacity range is from 500 up to 2500 MTPD. This can be... - Process licensing
SynCOR Methanol™
Proven large scale process for new built This is the most cost efficient industrially proven methanol technology available on the market. The optimal single train capacity is 500 MTPD up to 10.000 MTPD. The highly efficient, fully automated SynCOR™ syngas generator based on oxygen reforming at... - Process licensing
Two-step methanol
State-of-the-art technology This is the most commonly used methanol technology today. It uses a combination of tubular steam reforming and oxygen reforming as synthesis gas generator to produce a stoichiometric methanol synthesis gas. The advanced Haldor Topsoe tubular reforming technology provides...
