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The catalytic SO2 converter is the heart of the sulfuric acid plant and the quality and characteristics of the selected catalysts are crucial to a reliable and energy-efficient operation.
The catalyst properties are influenced by the chemical composition, the physical properties including the nature of the support material and the manufacturing process. Topsoe VK catalysts are uniquely balanced to combine high and stable activity, robustness, low-pressure drop and a long service life.
Over the years Topsoe has brought major product breakthroughs to the market, providing the industry with new catalysts for more energy-efficient operation, lower SO2 emissions and higher production rates.
Topsoe’s VK series comprises five different formulations in a variety of sizes and shapes, effectively covering all operating conditions in any sulfuric acid plant.
Selecting the right catalysts for a SO2 converter has always been about balancing expenses and gains. The new VK38+ helps create that balance – and more.
White paper Tip the scales - get more from your sulfuric acid catalyst expenses with VK38+
The profitability of sulfuric acid production is closely related to the production rates achievable within SO2 emission limits. The optimal operating conditions of a plant depend strongly on the plant configuration, catalyst volumes and catalyst activities, and as SO2 emission limits are tightened, more active sulfuric acid catalysts are required to maintain the desired production rates.
White paper COST-EFFECTIVE BOOST OF PLANT PERFORMANCE WITH NEW LEAP5™ CATALYSTS FOR SO2 OXIDATION
The introduction of the first dust protection catalyst, VK38 in the shape of 20 mm rings in the 1970ies, provided invaluable savings for sulphuric acid plants suffering from pressure drop build-up as a result of dust present in the feed gas. Industrial experience from more than 60 installations shows prolonged production campaigns by minimum 50-75% and thereby, a reduction of time consuming and expensive shutdowns for catalyst screening as well as significant savings in blower energy over time
White paper New Improved dust protection catalyst.png "VK38+: Innovating on existing catalyst solutions")
Exploring a new catalytic solution for improving efficiency and energy balance in sulfuric acid plants
White paper VK38+: Innovating on existing catalyst solutions
Increased attention on emissions during startup of sulfuric acid plants calls for better understanding of the dynamics of the plants and the phenomena controlling the emissions of SO2 and acid mist.
White paper Understanding dynamics and emissions during sulfuric acid converter startup
Sulfuric acid plants often encounter transient phenomena such as emission spikes during unsteady operation. Emission spikes and related phenomena can be understood and predicted by considering the sulfur content of the V2O5-based catalyst used in sulfuric acid converters.
White paper Dynamic simulations Sulfuric acid
Profit margins are slim in the sulfuric acid business, and plants that want to succeed need feedstock flexibility, high conversion rates, low energy consumption and high reliability. They also have to meet increasingly strict limits on SO2 emission
Brochure The profitable way to sulfuric acid
VK-7XX LEAP5™ is the latest catalyst developed on the basis of the unique LEAP5™ techology. It is optimized for operation in converted strong gasses at 370-440°C/700-825oF, which is typical for the final passes of single-absorption plants
Brochure High activity at low temperature
Managing a sulfuric acid plant can be challenging on the best of days, but what happens when real trouble arises? Sudden changes in pressure drops or emissions may force a decrease in production or even a full shutdown for repairs. And even when everything is working, catalyst activity changes over time – and so should a plant’s operating conditions.
Brochure Troubleshoot, Monitor & Plan Ahead
The Guizhou Kailin Fertilizer company had two sulfuric acid plants in Guizhou, China that were experiencing similar problems. A severe pressure drop build-up over the first catalyst bed was increasing energy costs and eating away at margins. Dust was forcing the plant to shut down for unplanned screening maintenance and catalyst replacement.
Customer case Guizhou Kailin sulfuric acid plants combat dust to eliminate unplanned downtime and improve Opex
In 1997, VK69 was installed in the fourth pass of a large 1460 MTPD sulphuric acid plant in Asia. The plant burns elemental sulphur and the four-bed converter has intermediate absorption after the third pass.
Customer case Reduce SO2 emissions - Less than 100 PPM SO2 in the stack
The Chinese government has been tightening SO2 emissions regulations for years. In many regions, the targets are now set at 70 PPM. While some plants depend on conventional catalysts and scrubbers, Xiangguang Copper in Shandong Province wanted a long-term approach. the contacted Topsoe to find a catalyst solution to help them comply with stricter emission controls,
Customer case Yanggu Xiangguang copper takes new approach to meet emissions standards of 70 PMM SO2
Nuova Solmine, a sulfuric acid plant in Scarlino, Italy, had been operating with SO2 emissions averaging about 280 PPM. When new regulations capped emissions at 224 PPM; the plant had to make a choice: reduce production of sulfuric acid, resulting in loss of profit, or find a way to reduce emissions without cutting production.
Customer case Nuova Solmine cuts SO2 emissions by 50%, complying with emissions regulations without reducing production
Incitec Pivot's sulfuric acid at Mount Isa, Australia needed more sulfuric acid than they could produce, but transport of sulfur or sulfuric acid to the company's outback location was expensive.
Customer case With Topsoe's Leap5™ catalyst, Australia's Incitec Pivot increased production & reduced emissions
Topsoe has developed a new improved dust protection catalyst in the size of a 25 mm daisy in the proven VK catalyst formulation.
Leaflet New improved dust protection catalyst for sulphuric acid plants
Topsoe’s VK-701 LEAP5™ is optimized for operation in converted strong gasses at 410-460°C/770-895°F, which is typical for the 3rd pass of 3+1 double-absorption plants. At these conditions, VK-701 shows significant activity advantages compared to existing potassium and cesium-promoted catalysts.
Leaflet Proven SO2 emissions reduction in high temperature environments
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