VK-WSA catalyst was developed specifically for use in Haldor Topsoes WSA desulphurization

process. This process involves the direct oxidation of S! and for"ation of sulphuric acid in
hu"id process #ases. The catalyst process hi#her stren#th which is desira$le in the water vapour
containin# process #ases.
4.1 Catalyst support material
The support "aterial "ay $e exposed to the pyrosulphate "elt and "ust therefore $e
resistant to this. This re%uire"ent is fulfilled $y natural %uartz stones or shaped $odies of
stoneware.
The top support shall sta$ilize the pass and prevent the inco"in# #as fro" "ovin# the
catalyst. A &' ( )'' "" layer on top of the catalyst reco""ended.
The $otto" support shall prevent the catalyst fro" $loc*in# the slots or fallin# throu#h
the slots in the #rids. A &' ( )'' "" layer $elow the catalyst is reco""ended.
4.2 Loading of new VK catalyst
VK catalyst is nor"ally loaded $y e"petin# the dru"s into a "etal $in and hoistin# the
$in to a $elt conveyor that transport the catalyst into the converter.
+f the catalyst is supplied in ,i# ,a#s- these can $e hoisted $y their top straps- *eep
steady over a $elt conveyer and e"ptied via the $otto" chute.
The catalyst is "anually distri$uted over the cross section of the converter. The catalyst
should not $e du"ped "ore than ).& " .& feet/. 0or"ally- the distri$ution of the catalyst $e#ins
in the part of the $ed opposite the "anhole up to the desired level and then distri$utions
continues towards the "anhole in order to "ini"ize wal* upon the catalyst. The catalyst can $e
wal*ed upon if protected $y $oards- plates or panels of polywood.
Special attention when loading dust protection catalyst
When loadin# a dust protection catalyst layer in the shape of !& "" daisy- special
attention should $e paid not to wal* directly of the catalyst. 1ue to the lar#e size- the $i# daisy
rin#s are easy to $rea* when steppin# on the".
The sa"e special attention should $e paid for a possi$le top support installed on top of
the dust protection layer. The ed#es of the "uch harder natural %uartz stone or shaped $odies of
stoneware will exert an increased force on the !& "" daisy particles if wal*ed upon and there$y
increase ris* of $rea*a#e. The inert "aterial can $e wal*ed upon if protected $y $oards- plates or
panels of plywood.
Screenin# of new VK is nor"ally not necessary unless the dru"s have $een handled
rou#hly durin# transport- should this $e the case- any fines are retained in a$out the $otto" )'
liters of the dru"s. This portion "ay then $e screened $efore loadin#.
4.3 Loading of used VK
+n #eneral- used VK catalyst is stron#er than unused catalyst- however- the sa"e
precautions and procedurs should $e ta*en as for fresh catalyst.
2or the first pass- it is i"portant to reload the used catalyst- a #ood separation of the "ore
expensive caesiu" catalyst fro" the lower lyin# conventional catalyst is reco""ended durin#
loadin# in order to facilitate unloadin# and screenin#. This is also the case when new fresh "a*e-
up catalyst is loaded on the top of old layers of screened catalyst.
4.4 Top layer separation methods
2or plants usin# a top layer of caesiu" catalyst fro" the lower lyin# conventional
catalyst is reco""ended durin# loadin# in order to facilitate unloadin# and screenin#. This is
also the case when new fresh "a*e-up catalyst is loaded on the top of old layers of screened
catalyst.
The easiest way re%uires no physical "eans of separation in the converter- 3ust so"e #ood record
*eepin#.
The caesiu" catalyst or new top layer catalyst should si"ply $e installed on a
well levelled catalyst $ed and the exact depth of the top layer should $e recorded.
Another possi$ility is to install a physical $oundary layer- however- they each have their
draw$ac*s 4
5e$$les6cera"ics $oundary layer. This "a*es a nice visual "ar*er for the
screenin# crew. However- it adds si#nificant ti"e to loadin#- unloadin# and
screenin# process. +t also tends to increase the screenin# loses. Also the
pe$$les6cera"ics and wei#ht to the converter and ta*e up space in the converter
that "i#ht $e $etter used for catalyst.
A $etter way to ease the separation $y usin# pe$$les6cera"ics without $ein# ti"e
consu"in# and increasin# the screenin# loses is to distri$ute a few cera"ics .7-&
pieces6"!/ as indicator for the $order $etween the two catalyst types
Wire"esh4effective separation- however- ti"e consu"in#. The "esh will $e
exposed to the pyrosulphate "elt and "ust therefore $e resistant to this. +n so"e
cases pressure drop $uild-up due to $loc*in# of the "esh openin#s $y corrosions
products has $een experienced.
8oadin# .section 9/ .as well as unloadin# .section:/ / and screenin# .section ;/ should
ta*e place in such a way that the period durin# which catalyst is exposed to the at"osphere is
"ini"ized. The reason for this $ein# that sulphuric acid catalyst is hy#roscopic which is why it
should also $e protected a#ainst "oisture and precipitation.
. Start!"p
The catalyst "ust $e heated a$ove the dew point of the heatin# fuel6air "ixture to prevent
condensation in the catalyst $ed durin# start up. Heat up the converter $y dried hot air until
"ini"u" )&' o< .7''o2/ $efore the heatin# fuel6air "ixture is applied. nce the outlet
te"perature fro" each $ed is "ini"u" )&'o< .7''o2/- the catalyst can $e heated $y a direct
fire throu#h the plant. The heatin# oil- natural #as etc. can $e $urned and the =wet #ases> fro"
their co"$ustion can $e passed directly throu#h the converter without the fear of condensation in
the catalyst $ed.
VK catalyst are not affected $y rapid heatin#. Thus- the heat-up rate "ay $e the
"axi"u" per"esi$$le to the converter- heat exchan#ers and ductin#. When the first pass
catalyst is heated to an outlet te"perature of not less 7:'o< .?)&o2/ for VK-7: and VK-WSA
7&'o< .@@'o2/- process #as can nor"ally $e introduced to the catalyst. 1ependin# on
environ"ental re#ulations- it "ay $e necessary to heat every catalyst $ed to these te"peratures.
The reactions start i""ediately in )
st
pas #ivin# a te"perature rise. As VK is
presulphated when delivered - the additional heat for"ation is "odest. Therefore- also for the
first start-up of a converter loaded with new VK in all passes- the initial S! concentration can
$e &-?A. A few hours after the switch to process #as- the operation is ad3usted to nor"al
operatin# conditions.
#. $peration
VK should not $e operated continuously at $ed exit te"peratures a$ove @7'o< .))?'o2/.
+nlet te"peratures lower than VK-WSA 9)' .??'o2/.
%. Shut &own
The catalyst should not $e exposed to hu"idity and every effort should $e "ade to
protect the catalyst fro" any *ind of condensation or precipitation.
After havin# $een in operation- the catalyst is "ore sensitive to air hu"idity at a"i$ient
te"perature than the fresh catalyst- which is the reason for "ini"izin# the ti"e the catalyst is
exposed to a"$ient air. 1rau#ht of hu"id air trou#h the catalyst should $e prevented.
C'T'T'(
S! converter catalyst
The catalyst in S! converter !
nd
$ed suffer fro" heavi deterioration- at least in the upper
layers. A lar#e part of the catalyst peeets have $een pulverized- and a part of the
re"ainin# are $rittle. The cause of this would nor"ally $e water in the process #as-
co"$ined with operation as too low te"perature. As the catalyst )n )
st
$ed is not
afeected- the inter $ed cooler was suspected for stea" lea*a#e. However- no visual si#ns
od such a lea*a#e could $e seen- and further"ore a pressure test confir"ed the inter $ed
cooler to $e ti#ht. See also separate point on this test. S5V decided to screen the upper )'
to !' centi"eter of the catalyst !
nd
$ed in order to $rin# down the pressure loss. This
screenin# was carried out accordin# to an a#reed procedure- with a si#nificant screenin#
lost- as expected.
As no apparent for the catalyst da"a#e could deter"ind durin# the inspection- it was
a#reed- that spv supply all availa$le infor"ation re#ardin# operation and shut down in the
first operation period to T5SB. <atalyst sa"ples will also $e provided. Top soe will
investi#ate soonest possi$le. +t was also a#reed to install pressure point a$ove and $elow
!
nd
catalyst $ed- in order to "easure the pressure drrop. See also separate point
This note only descri$es to o$servations "ade durin# the inspection on site for futher
infor"ation on this su$3ect- reference is "ade to su$se%uent correspondence $etween
S5V and Topsoe.