Ammonia Synthesis Catalysts

KM
KM1/KM1R

KM
The Heart of the Ammonia Plant
 Topsøe’s KM1 and KM1R
catalysts are available in a
variety of standard particle
sizes. The most commonly
used size is 1.5–3 mm.
Proven by Performance

The ammonia synthesis catalyst is the very heart in the ammonia plant. Stability,
high conversion and high poison resistance are essential parameters for a long
lifetime.

Continuous feedback from the industry combined with close co-operation between
Topsøe’s Catalyst Group, R&D Department and manufacturing facilities enables
Topsøe to continually optimise the ammonia synthesis catalyst KM1 both in the
unreduced and in the prereduced version, KM1R.

Topsøe has more than 50 years of experience in manufacturing ammonia synthesis

Our World of Cats

catalysts and the ongoing optimisation has resulted in a high-quality, versatile

catalyst, which has been successfully utilised for many years in ammonia synthesis
converters worldwide.

The KM1 and KM1R catalysts are characterised by:

High and stable activity

Unmatched high mechanical strength
Remarkable resistance towards oxygen poisoning
Low screening loss

These features have been widely acknowledged throughout the world and today,
more than half of the world’s ammonia production is synthesised over Topsøe KM1
or KM1R catalyst.
KM
The Product
KM
KM1/KM1R
Topsøe KM1 and KM1R catalysts are manufactured
from carefully selected raw materials according to
closely supervised procedures, thereby ensuring high
and uniform catalyst quality.
The unreduced KM1 catalyst mainly consists of
magnetite (iron oxide) with an approximate composi-
tion of Fe3O4. The balance of the catalyst consists of
promotors; mostly oxides of calcium, aluminum and
potassium.
The prereduced catalyst KM1R is manufactured
through a controlled reduction of KM1 and
subsequent stabilisation. The stabilisation involves a
skin oxidation of the external and internal catalyst
surfaces, with a total oxygen uptake of about 2 wt %.
The catalyst promoters are not affected by the
prereduction process. The stabilised KM1R is non-
pyrophoric in air at ambient temperatures and can
easily and safely be handled and loaded in
accordance with given procedures.
Multiple Sizes
The KM1 and KM1R catalysts are available in a
variety of standard particle sizes. The choice of
catalyst size depends on the converter design.
Smaller sizes offer the advantage of higher surface
area and thus higher bulk activity, but result in a
higher pressure drop across the catalyst bed.
Choosing the correct catalyst size thus requires
optimising the catalyst loading to obtain the highest
possible ammonia synthesis activity while maintaining
converter and loop pressure characteristics within
acceptable limits.
High and Stable Activity
The KM1 and KM1R catalysts possess a very high and
State of the Art Catalysts
stable activity, thereby providing long useful run
times. In most plants, the catalysts operate success-
fully for over 10 years, and lifetimes of 15 years or
longer are not unusual.
High Mechanical Strength
The ammonia synthesis catalyst can be exposed to
very rapid changes in both temperature and pressure
particularly during upsets. Therefore, the demands to
strength are probably higher than for any other
catalyst in the ammonia plant.
Topsøe’s ammonia synthesis catalysts fully meet the
strength requirements. Over the years, Topsøe has
supplied well over 1,000 charges of ammonia
synthesis catalyst, which have proven the outstanding
mechanical strength, and thus have optimised the
catalyst performance. The catalysts can easily
withstand the impact of loading. This is particularly
important when loading with vibration or using
dense-loading techniques, e.g. in radial-flow con-
verters such as Topsøe S-200 and S-300 converters.
Stable Pressure Drop
Due to the very high mechanical strength of KM1
and KM1R, the pressure drop across the catalyst bed
remains low and practically unchanged throughout
the life, which is important for obtaining a long life at
low operating costs.
High Resistance towards Poisoning
Although gas purity in modern ammonia plants
normally is high, there is still the possibility of plant
upsets where the synthesis catalyst is exposed to
poisons such as oxygen compounds. KM1 and KM1R
have excellent resistance to poisoning, and full
catalyst activity may be regained even after serious
oxygen poisoning.
KM
KM
Catalyst Operation
Catalyst Activation – Benefits of KM1R
The KM1/KM1R catalysts are activated by heating in
normal synthesis gas. Prereduced KM1R catalyst is
activated at considerably lower temperatures and
generates much smaller quantities of water during
reduction, enabling a more rapid commissioning of a
charge of KM1R catalyst than that of unreduced KM1
catalyst.
Figure 1 illustrates the time required to attain full
ammonia production in a plant using a full charge of
KM1R, a combined charge of KM1R (25%) and KM1
(75%), and a full charge of KM1.
A charge of KM1R will reach full ammonia production
rate just 1-11/2 days after initiating the activation, as
compared to 5-7 days for a charge of unreduced
KM1, or 3-4 days using the 25%/75% combined
charge of KM1R and KM1.
Additionally, the total amount of water released
during reduction of KM1R is less than 10% of that
produced during reduction of KM1. As a result, the
total quantity of aqueous (off-spec) ammonia
produced is substantially lower for a charge of KM1R.
Consequently, the use of a full or partial charge of
prereduced KM1R results in a substantial ammonia
production gain during the first week of operation,
as well as a faster, smoother and more trouble-free
start-up. For this reason, full or partial charges of
KM1R are used by the majority of ammonia plants
operating with Topsøe ammonia synthesis catalyst.
Operation of KM1/KM1R
The conversion occurring in ammonia converters is a
function of composition of process gas, space
velocity, system pressure, catalyst temperatures, and
activity of the catalyst itself. The first 4 of these para-
meters partially depend on design of the synthesis
loop and converter as well as on catalyst activity.
The high activity of KM1 and KM1R allows operation
at a higher inert level, resulting in a lower purge gas
rate (and thus a higher production rate) and/or a
lower loop pressure (and thus a savings of
compression energy). The high activity also allows
operation at lower catalyst temperatures, where the
ammonia equilibrium conditions are more favourable,
leading to a higher ammonia concentration. The
exact catalyst temperatures depend on converter
design and feed gas composition. However, it is
Topsøe’s experience that in most ammonia
converters, optimum conversion per pass is achieved
by operating at catalyst temperatures resulting in an
approach to equilibrium of about 10°C (20°F) at the
outlet of the last catalyst bed.
 FIGURE 1 · AMMONIA PRODUCTION RATES USING KM1, KM1R/KM1 AND KM1R

PERCENT OF FULL AMMONIA PRODUCTION RATE

100

80

60

40

KM1R
KM1R/KM1
20 KM1

0 20 40 60 80 100 120 140 160 180

TIME ELAPSED, HOURS

Catalyst Poisons
Temporary Poisons reaction stops. Once the source of poison is
Temporary poisons are those causing catalyst removed, the catalyst activity will be restored slowly.
deactivation during the period of exposure, with Industrial experience has shown that Topsøe KM1
recovery of activity following removal of the poison and KM1R catalysts have regained full activity even
source. The primary poisons of this type are oxygen following severe upsets causing heavy oxygen
compounds, including carbon oxides, water and poisoning. An example of temporary oxygen poison-
oxygen itself. The presence of carbon oxides in the ing during operation is shown on the next page.
make-up gas is a result of a poorly functioning
methanator. Water (and carbon dioxide) can be
TOTAL AMOUNT OF O EQUIVALENTS, PPM:
present in the converter feed gas resulting from
inadequately operating make-up gas dryers, 0-2 PPM O EQV.: IDEAL
carry-over from a secondary ammonia separator, 2-4 PPM O EQV.: CONTINUED OPERATION FOR A FEW MONTHS.
or leaks in certain synthesis loop heat exchangers. 4-6 PPM O EQV.: CONTINUED OPERATION FOR A FEW WEEKS.
The degree of poisoning is a function of the total 6-10 PPM O EQV.: CONTINUED OPERATION FOR A FEW DAYS.
concentration of oxygen equivalents (O eqv),
which is determined as follows: Table 1: Oxygen Equivalent in Converter Feed Gas
– Recommended Maximum Period of Operation

ppm O eqv = 2 x (ppm O2) + 2 x (ppm CO2)

+ ppm CO + ppm H2O
Table 1 summarises the effect of various concentra-
tions of oxygen compounds in the converter feed
gas. A concentration of oxygen equivalents of less
than 2 ppm (vol.) is considered ideal and will not
cause poisoning of the synthesis catalyst. Oxygen
concentrations above 2 ppm (vol.) will poison the
catalyst, and the higher the oxygen concentration,
the more rapidly the catalyst will be poisoned.
Poisoning shows as a loss of activity leading to a
decreased production, and in serious cases, the
activity loss is so pronounced that the synthesis
Permanent Poisons
The other types of synthesis catalyst poisons are
permanent poisons, of which sulphur compounds are
most notable. The main source of sulphur poisoning
is ingress of compressor lubrication and/or seal oil
into the synthesis loop. Poisoning by sulphur is
irreversible and mainly affects the inlet layer of the
catalyst. To avoid serious sulphur poisoning, compres-
sor lubrication and seal oil should contain a maximum
of 0.15 wt % sulphur. Another permanent poison is
chlorine, which also may be present in compressor
lubrication and seal oils.
KM
KM
Facts and Figures
CATALYST

COMPOSITION

Fe, FeO (WT %)

Fe Oxides (WT %)
K2O, Al2O3, CaO, SiO2 (WT %)
KM1 (UNREDUCED)

-
91 - 95
5-9
KM1R (PREREDUCED)

89 - 93
-
7 - 11

OPERATING TEMPERATURE RANGE 340 - 550°C 340 - 550°C

645 - 1020°F 645 - 1020°F

OPERATING PRESSURE RANGE 90 - 600 kg/cm2 g 90 - 600 kg/cm2 g

1280 - 8530 psig 1280 - 8530 psig

SHAPE Irregular Grains Irregular Grains

DEVELOPMENT IN ACTIVITY WITH SEVERE OXYGEN POISONING

ACTIVITY

POISONING

TIME OF OPERATION
Catalysts for All Services
Technical Service
Topsøe is not only a catalyst manufacturer but also
carries out a very significant research in the field of
catalysis and technology for ammonia plants.
Accordingly, Topsøe’s Catalyst Division with the
back-up of the R&D Department and Engineering
Division is able to provide technical service second-
to-none.
Documentation
Detailed written procedures covering loading,
activation and operation of KM1/KM1R catalysts are
supplied in connection with the catalyst order along
with material safety data sheets and any other
necessary information.
On-site Assistance
Topsøe offers on-site advisory assistance by
experienced engineers for loading and activation of
KM1/KM1R catalysts. Topsøe has developed loading
methods, which increase the loading density of the
catalyst in order to maximise the activity of catalyst
installed.
Follow-up Service
Once the catalyst charge is in operation, Topsøe
provides follow-up service in form of regular
performance checks and catalyst lifetime assessments
based on evaluation of plant operating data using
sophisticated computer programmes. In case of
operating problems, Topsøe also provides
troubleshooting assistance.
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K
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The information and recommendations have been prepared by Topsøe specialists having a thorough Orange, CA 92868
opus

knowledge of catalysts. However, any operation instructions should be considered to be of a general nature and Phone: + 1-714-621-3800
we cannot assume any liability for upsets or damage of the customers’ plants or personnel. Nothing herein is to
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