Manual for

Topsøe’s sulphuric acid catalysts

Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 2 / 19

Table of contents

1 INTRODUCTION 4

2 APPLICATION 4
2.1 VK series 4
2.2 VK-W series 5

3 CATALYST HANDLING 5
3.1 Colour of VK catalyst 5
3.2 Packing 6
3.3 Handling 7
3.4 Storage 8

4 LOADING 8
4.1 Catalyst support material 9
4.2 Loading of new VK catalyst 9
4.3 Loading of used VK 10
4.4 Pneumatic loading 10
4.5 Top layer separation methods 11

5 START-UP 12

6 OPERATION 12

7 SHUTDOWN 12
7.1 Long duration shutdown 13

8 UNLOADING 13
8.1 Unloading by hand 14
8.2 Unloading by suction 14

9 SCREENING 15
9.1 Screen size 16
9.2 Screening rates 16
9.3 Determination of screening losses 16
9.4 Screening of the 25 mm Daisy dust protection layer 16

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
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2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 3 / 19

10 DISPOSAL OF SPENT CATALYST 17

11 SAFETY 17
11.1 Chemical reactivity 17
11.2 Fire and explosion hazards 17
11.3 Health hazards 17
11.4 Safe handling 18

12 LIABILITY 18

13 CONTACT 19

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 4 / 19

1 Introduction
This “Manual for Topsøe sulphuric acid catalyst” is intended to provide general guidelines for
handling and operation of Haldor Topsøe’s VK Series of catalyst. The guidelines cover:

 handling
 loading
 start-up
 operation
 shutdown
 unloading
 screening
 disposal of spent catalyst
 safety

In case it is necessary to make any deviations from this procedure, it is recommended to

discuss them with Haldor Topsøe.

2 Application
2.1 VK series
Haldor Topsøe’s VK catalyst series is applied in all sulphuric acid plants operating on dry feed
gases.

2.1.1 VK38
VK38 is an all-round catalyst that can be used in any pass of the converter. It is known
throughout the industry for combining high activity with high mechanical strength.

2.1.2 VK48
VK48 is a high vanadium version of standard VK38 and is tailored for maximum activity in a
high SO3/SO2 gas environment, such as the lower passes of single absorption plants or in the
third pass of 3:1 double absorption plants. For this service VK48 offers up to 30% higher activity
than VK38.

2.1.3 VK59
VK59 is a caesium-promoted catalyst developed specially for operation at low temperatures
down to 370°C (700°F). For single-absorption plants conversion can be improved by loading
VK59 in the last passes. In plants in which a low first pass inlet temperature is desirable, a top

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 5 / 19

layer of VK59 can be installed. Faster and cleaner start-ups can also be obtained by adding top
layers of VK59.

2.1.4 VK69
VK69 is a high-vanadium caesium-promoted catalyst optimised for operation in lean SO2 gases
(SO2+SO3 < 1.8 mole %), i.e. for installation in the passes following the intermediate absorption
tower in double absorption plants.

2.2 VK-W series

Haldor Topsøe’s VK-W catalyst series is applied in Topsøe WSA processes, which are
characterised by direct oxidation of SO2 and formation of sulphuric acid in humid process gases.

2.2.1 VK-WSA
VK-WSA is an all-round catalyst that can be used in any pass of the WSA or WSA-DC
converter.

2.2.2 VK-WSX
Haldor Topsøe’s high-activity VK-WSX catalyst has been developed for operation in highly
converted gases (higher than 90% pre-conversion). VK-WSX is a non-caesium catalyst, yet it
permits operation at temperatures down to 370°C (700°F).

2.2.3 VK-WH
VK-WH is a caesium-promoted catalyst for continuous operation down to 370°C (700°F) in
medium to high strength SO2 + SO3 gases.

2.2.4 VK-WL
VK-WL is a caesium-promoted catalyst for continuous operation down to 370°C (700°F) in lean
SO2 + SO3 gases (less than 2 mole % SO2 + SO3).

3 Catalyst handling
3.1 Colour of VK catalyst
VK catalysts as delivered are yellow to light green in colour with white spots on the surface.
VK59, VK69, VK-WH and VK-WL catalysts may furthermore have some grey and black areas.
The variations in colour are related to our manufacturing process. After the catalyst has picked

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 6 / 19

up sulphur oxides during start-up and becomes fully saturated, it will be uniform in colour. The
colour variation on the fresh catalyst has no influence on the activity.

The catalytic reaction cycle involves a shift in the valence of vanadium between the penta- and
tetravalent state.

The ratio V5+/V4+ depends on temperature and partial pressures of the gas components. This
means that the colour of used catalyst can vary widely, depending on the conditions to which it
is exposed. Unsulphated vanadium is almost white, whereas pentavalent vanadium (V5+) which
has been sulphated will appear yellow with various light brown or red tints. Tetravalent (V4+) will
be green, light grey or blue.

VK catalysts are pre-activated but they are not 100% saturated with SO3 when delivered. The
advantage of supplying VK catalyst less than 100% saturated is that the catalyst is less
sensitive towards humidity.

3.2 Packing

VK catalysts are delivered in fibre drums or big bags on pallets:

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 7 / 19

Fibre drums are sealed with a polyethylene lining and are fitted with a full removable lid.

Big bags are sealed with a polyethylene liner and equipped with lifting lugs (four straps, one at
each upper corner). Discharge of the catalyst must be done through the discharge chute in the
bottom of the big bag.

3.3 Handling
VK catalysts are classified as non-hazardous, i.e. no special safety measures are required for
transportation and storage.

During catalyst handling local regulations must be strictly observed.

It is important that the catalyst containers are handled carefully without bumping and that the
containers are never rolled to avoid breakage of the catalyst.

Handling methods creating excessive dust should be avoided and mechanical ventilation should
be used when appropriate. Use good housekeeping and personal hygiene practice. Do not eat,
drink or smoke when handling the catalyst. Hands should be washed thoroughly after handling.

Respiratory protection Minimum dust mask recommended.

Use approved respirator when exposure may exceed
recommended limits.

Hand protection Minimum gloves recommended.

Eye protection Minimum goggles recommended.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 8 / 19

Other protection Change work clothing daily.

For further information see Safety (Section 11).

3.4 Storage
Before storage the fibre drum or big bags must be inspected for possible transport damage. If
any holes are found these must be mended, e.g. by means of tape. This is highly important in
order to prevent the catalyst from breathing and humidity and water being absorbed by the
catalyst.

The drums should preferably be transported in upright position and must never be rolled. Big
bags should be handled as gentle as possible and due care must be exercised during
transportation.

The drums or big bags must be stored on pallets in a well-ventilated dry warehouse, preferably
with a floor of concrete, tiles or wood. The catalyst must at all times be protected against
moisture and water and we propose that the drums or big bags are inspected at regular
intervals. Big bags must be placed in single layers (no stacking).

Outdoor storage is only acceptable for short periods and the drums or big bags must be
absolutely protected against rain and moisture from the ground. The lower drums should be
placed on logs or pallets and the stack should be covered by plastic or canvas sheets. The
pallets should be placed on a concrete skid or similar in order to protect them from getting
flooded.

VK catalyst in fibre drums has a long “shelf life” when kept dry and in original packing. In a
warehouse, the catalyst may be stored for years.

Storage of VK catalyst in big bags for extended period of time is not recommended. Generally,
big bags should not be stored for more than a couple of years.

4 Loading
The most important thing about loading any converter is to ensure a uniform packing of the
catalyst and supporting material in order to ensure a uniform flow distribution and avoid
channelling.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 9 / 19

Before the loading takes place, the converter must be cleaned and inspected. The division plate
under the grids must be cleaned thoroughly as any dust left on the division plate will end up in
the next layer of catalyst. Grids should be inspected and if the grid slots are plugged by pieces
of support material or catalyst, these must be cleaned in order not to cause an increased
pressure drop.

Adequate rain protection is important in the areas in which the drums are opened and reloaded
into the metal bin as well as in the manhole area.

Remember good record keeping

When loading the catalyst, it is important to calculate the depth of the catalyst and supporting
material for each bed and to mark the converter wall plainly.

When reloading used, screened catalyst, it is NOT sufficient to determine the catalyst volume by
counting the number of screened bags. This has resulted in either significant over-loaded or
under-loaded beds.

Upon completion of the catalyst loading activities the converter should be sealed and a small
over-pressure in the converter using dried (instrument) air should be kept.

4.1 Catalyst support material

The support material may be exposed to the pyrosulphate melt and must therefore be resistant
to this. This requirement is fulfilled by natural quartz stones or shaped bodies of stoneware. The
use of alumina support should be avoided.

The top support shall stabilise the pass and prevent the incoming gas from moving the catalyst.
A 50-100 mm layer on the top of the catalyst is recommended.

The bottom support shall prevent the catalyst from blocking the slots or falling through the slots
in the grids. A 50-100 mm layer below the catalyst is recommended.

4.2 Loading of new VK catalyst

VK catalyst is normally loaded by emptying the drums into a metal bin and hoisting the bin to a
belt conveyer that transports the catalyst into the converter.

If the catalyst is supplied in Big Bags, these can be hoisted by their top straps, kept steady over
a belt conveyer and emptied via the bottom chute.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 10 / 19

If a hose is used to transfer the catalyst into the reactor it is recommended that the inner
diameter is minimum 150 mm (6") when loading 12 mm Daisy and minimum 200 mm (8") when
loading the 25 mm Daisy. This will allow the catalyst to flow easily through the hose and prevent
the catalyst from bridging inside the hose.

The catalyst is manually distributed over the cross section of the converter. The catalyst should
not be dumped more than 1.5 m (5 feet). Normally, the distribution of the catalyst begins in the
part of the bed opposite the manhole up to the desired level and then distribution continues
towards the manhole in order to minimise walk upon the catalyst. The catalyst can be walked
upon if protected by boards, plates or panels of plywood.

Special attention when loading dust protection catalyst

When loading a dust protection catalyst layer in the shape of 25 mm Daisy, special attention
should be paid not to walk directly on the catalyst. Due to the large size, the big Daisy rings are
easy to break when stepping on them.

The same special attention should be paid for a possible top support installed on top of the dust
protection layer. The edges of the much harder natural quartz stone or shaped bodies of
stoneware will exert an increased force on the 25 mm Daisy particles if walked upon and
thereby increase risk of breakage. The inert material can be walked upon if protected by boards,
plates or panels of plywood.

Screening of new VK is normally not necessary unless the drums have been handled roughly
during transport; should this be the case, any fines are retained in about the bottom 10 litres of
the drums. This portion may then be screened before loading.

4.3 Loading of used VK

In general, used VK catalyst is stronger than unused catalyst, except for catalyst that is worn
down significantly from multiple pervious screenings. The same precautions and procedures
should be taken as for fresh catalyst.

For the first pass, it is important to reload the used catalyst layers at its original location in the
bed. (See Unloading). When new VK is added as make-up to used catalyst, it should, however,
be added to the top of the catalyst bed.

4.4 Pneumatic loading

If using a pneumatic means of loading it is important that the vessel pressure is adjusted to the
minimum required level where the catalyst flows continuously. Using the minimum pressure

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
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Manual for Topsøe’s sulphuric acid catalysts 11 / 19

helps reducing the risk of catalyst breakage. A significantly higher pressure is typically required
when initiating the flow from the vessel. It is therefore important that the pressure is then
adjusted down to the minimum needed for continuous flow immediately after this initiation phase
has passed.

The 25 mm Daisy used for dust protection should not be loaded using pneumatic means.

4.5 Top layer separation methods

For plants using a top layer of caesium catalyst, a good separation of the more expensive
caesium catalyst from the lower lying conventional catalyst is recommended during loading in
order to facilitate unloading and screening. This is also the case when new fresh make-up
catalyst is loaded on the top of old layers of screened catalyst.

The easiest way requires no physical means of separation in the converter, just some good
record keeping:

 The caesium catalyst or new top layer catalyst should simply be installed on a well-
levelled catalyst bed and the exact depth of the top layer should be recorded.

Another possibility is to install a physical boundary layer; however, they each have their
drawbacks:

 Pebbles/Ceramics boundary layer: This makes a nice visual marker for the screening
crew. However, it adds significant time to the loading, unloading and screening process.
It also tends to increase the screening losses. Also the pebbles/ceramics add weight to
the converter and take up space in the converter that might be better used for catalyst.
 A better way to ease the separation by using pebbles/ceramics without being time
consuming and increasing the screening losses is to distribute a few ceramics (3-5
pieces/m2) as indicator for the border between the two catalyst types.
 Wire mesh: Effective separation, however, time consuming. The mesh will be exposed
to the pyrosulphate melt and must therefore be resistant to this. In some cases pressure
drop build-up due to blocking of the mesh openings by corrosion products has been
experienced.

Loading (Section 4) (as well as Unloading (Section 8) and Screening (Section 9)) should take
place in such a way that the period during which the catalyst is exposed to the atmosphere is
minimised. The reason for this being that sulphuric acid catalyst is hygroscopic which is why it
should also be protected against moisture and precipitation.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 12 / 19

5 Start-up
The catalyst must be heated above the dew point of the heating fuel/air mixture to prevent
condensation in the catalyst bed during start-up. Heat up the converter by dried hot air until
minimum 150°C (300°F) before the heating fuel/air mixture is applied. Once the outlet
temperature from each bed is minimum 150°C (300°F), the catalyst can be heated by a direct
fire through the plant. The heating oil, natural gas etc. can be burned and the “wet gases” from
their combustion can be passed directly through the converter without the fear of condensation
in the catalyst bed.

VK catalysts are not affected by rapid heating. Thus, the heat-up rate may be the maximum
permissible to the converter, heat exchangers and ducting. When the first pass catalyst is
heated to an outlet temperature of not less than 380°C (715°F) for VK38 and VK-WSA and
350°C (660°F) for VK59, VK69, VK-WH and VK-WL, process gas can normally be introduced to
the catalyst. Depending on environmental regulations, it may be necessary to heat every
catalyst bed to these temperatures.

The reaction starts immediately in 1st pass giving a temperature rise. As VK is presulphated
when delivered, the additional heat formation is modest. Therefore, also for the first start-up of a
converter loaded with new VK in all passes, the initial SO2 concentration can be 5-7%. A few
hours after the switch to process gas, the operation is adjusted to normal operating conditions.

6 Operation
VK should not be operated continuously at bed exit temperatures above 630°C (1170°F). Inlet
temperatures lower than 400°C (750°F) for VK38 and VK-WSA, 410°C (770°F) for VK48 and
370°C (700°F) for VK59, VK69, VK-WH, VK-WL and VK-WSX are not recommended for
continuous operation.

7 Shutdown
The catalyst should not be exposed to humidity and every effort should be made to protect the
catalyst from any kind of condensation or precipitation.

After having been in operation, the catalyst is more sensitive to air humidity at ambient
temperature than the fresh catalyst, which is the reason for minimising the time the catalyst is
exposed to ambient air. Draught of humid air through the catalyst should be prevented.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 13 / 19

7.1 Long duration shutdown

Purge out the catalyst with dried (hot) air while the catalyst is still warm. The catalyst
temperatures should be kept above 400°C (750°F) while purging by using by-passes around
boilers, superheaters, gas to gas heat exchangers etc. Purging must continue until no SO2/SO3
– no “white smoke” is present in the gas from the sample lines after the final catalyst pass. If the
catalyst is not maintained above 400°C (750°F) until the SO2/SO3 is purged from the plant,
SO2/SO3 will be trapped in the catalyst, making the catalyst more hygroscopic. This will be seen
as green spots on the catalyst when it is exposed to humid air. This will also be evident when
heating the plant back up; once the catalyst reaches 350-370°C (660-700°C) “blue smoke” will
be seen in the stack.

If access to the converter is needed during the shutdown, cool down the catalyst and converter
with dry air until the temperatures are low enough to allow for safe human entry.

Converter manways should be left on as long as possible and replaced as soon as possible
after inspection/repairs are made. While the converter manway covers are removed, the
manways should be covered with plastic when not in use in order to keep out any form of
precipitation. Manways on the top of the converter should be covered with a piece of plywood
cut to the size of the manway and then covered with plastic to keep out precipitation. Without
the plywood, plastic applied to cover top manways will eventually collapse under the weight of
accumulated precipitation and allow moisture to enter the converter directly.

If no access to the converter is needed, the converter should be sealed. Keep a small over-
pressure in the converter using dried (instrument) air.

8 Unloading
Prior to the unloading of catalyst from the converter, read Safety (Section 11) and further make
sure that the atmosphere in the converter is safe for entry.

Walking directly on the catalyst or the pebbles/ceramics is not permitted. Panels of e.g. plywood
must be used as working platform inside the converter.

Study old loading records and keep focus on separation of catalyst layers of different age and/or
type. Consider possible catalyst sampling strategy in each bed from various catalyst layers
and/or depth.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
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Manual for Topsøe’s sulphuric acid catalysts 14 / 19

In order to separate layers of different age and/or type require good communication with the
screening contractor and the labourers doing the work.

1. It is recommended to draw a line with chalk inside the converter indicating the present
level of catalyst (see Screening (Section 9)).

2. To the extent possible, pebbles/ceramic topping material and catalyst should be

removed carefully as a separate layer, preferably by hand. This helps to reduce the
breakage of the catalyst. The support material is much heavier than the catalyst and
has a ball-mill effect on the catalyst on the trip through the hose, cyclone and screening
rig.

3. For the first pass, it is recommended to take out the catalyst in at least two separate
layers and to keep these fractions separated during the subsequent screening and
storage period, and to reload the catalyst in the same order. In this way, the catalyst will
be operating at practically the same temperatures for most of its operational life. For
plants with a deep 1st bed, we recommend taking out the catalyst in three separate
layers: top, middle and bottom.

4. If two types of catalysts are installed in one bed, it is important to discuss the unloading
and screening strategy with the people directly involved. If the caesium layer is installed
without any physical boundary layers, this should be scalped by carefully measuring the
depth at the time unloading was initiated (see Loading (Section 4)).

For catalyst beds that are not to be unloaded and screened, it is advisable to do whatever
possible to eliminate the flow of atmospheric air drawn through the catalyst beds. If a catalyst
bed has a dust layer build-up within the catalyst, it is possible that the moisture from the air
going through the bed will react with the sulphurous compounds contained in the dust and result
in a crust being formed.

8.1 Unloading by hand

Manual unloading in general is gentler to the catalyst but also more time consuming. Often, the
crew shovels the different layers into bins while standing on boards. The bins are then hoisted
to the ground level where subsequent treatment of the catalyst takes place.

8.2 Unloading by suction

Unloading of catalyst by means of suction is a time- and labour-saving method. Provided the
equipment is properly designed and carefully operated, the screening losses of VK will be low.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
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Manual for Topsøe’s sulphuric acid catalysts 15 / 19

Vacuum removal is often carried out by companies specialising in this field. Normally, the
unloading and screening are a combined package and it is important from the point of view of
the plant to specify the work needed when asking for bids.

It is highly recommended that someone knowledgeable from the plant is present to coach the
person operating the vacuum hose:

 At the beginning of the pebbles/ceramic material removal phase to ensure little or no

catalyst is taken up in the vacuum hose along with the inert material. The vacuum hose
is to be kept parallel to the surface to minimise carryover of the catalyst.
 And again at the beginning of the top catalyst layer removal phase to ensure that the
correct depth or “cut” is established from the start.

The air velocity should be controlled at the lowest rate sufficient for lifting the catalyst (about
30 m/sec) and the length of the hoses and tubes with downward movement of air and catalyst
should be as short as possible. This may be achieved by elevating the cyclone to the level of
the pass in question. If the height of the converter and the placement of the screening
equipment allow it, the angle of the hose leading to the cyclone should ideally be no steeper
than 45°. This will reduce the velocity at which the catalyst travels down the hose.

The catalyst entering the cyclone must not hit a striker plate. The catalyst must flow freely into
the cyclone without obstruction before it starts to spiral.

The lengths of the vacuum hoses are to be minimised and sharp bends should be avoided. To
keep the losses low, non-metal hoses should be used. The hose must be constructed of smooth
soft material.

Obviously, high air velocities will be needed when scalping off the pebbles/ceramics topping
material. The vacuum should then be reduced when unloading of the catalyst commences. Also
remember to adjust the air velocity when unloading different catalyst types with different bulk
densities.

9 Screening
It is highly recommended that someone knowledgeable from the plant is supervising the initial
screening. In case of high screening losses, the screening operation must be evaluated and
optimised in order to minimise screening losses.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
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Manual for Topsøe’s sulphuric acid catalysts 16 / 19

Catalyst screening cannot be conducted when it is raining. Adequate rain protection is required.

9.1 Screen size

It is recommended to screen the catalyst on a tilted, vibrating or rotating screen with rectangular
openings.

Guidelines for selection of screen sizes can be found in the below table:

Screening Screen Size, mm

Ceramics 22-25 x 25-40
25 mm Daisy 15-18 x 30-35
20 mm rings 12-15 x 25-30
12 mm Daisy 6-7 x 10-20
10 mm rings 6-7 x 10-20
9 mm Daisy 4-5 x 8-10
6 mm cylinders 4 x 8-15

For a converter having a history of rapid high pressure drop build-up, a slightly larger size is
usually selected as it weeds out more broken and worn rings from previous screenings.

During set-up of the screening rig an inspection of the screens should be done to verify the
specified screen sizes and to make sure that no degraded screens are being used.

Full, screened bags must be stored as specified in Packing, Handling and Storage (Sections
3.2-3.4).

9.2 Screening rates

Screening rates should not exceed 3,000 litres of catalyst per hour in order to keep the losses
low.

9.3 Determination of screening losses

It is recommended that a line is drawn inside the converter indicating the level of the catalyst
prior to unloading. This is useful to assure proper level of reloading as well as to accurately
determine screening losses. (Determining screening losses based on screened bags of catalyst
and chips/fines are inaccurate).

9.4 Screening of the 25 mm Daisy dust protection layer

The screening of the 25 mm Daisy used for dust protection should be conducted as described
above. The layer should, however, be regarded as a sacrificial layer, as the catalyst becomes

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
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Manual for Topsøe’s sulphuric acid catalysts 17 / 19

less sticky after dust exposure, whereby the effect of the dust protection is reduced. It is
therefore recommended to:

 Replace 50% of the installed 25 mm Daisy with fresh make-up catalyst during
screenings.
 Full replacement of the dust protection layer for every second screening.

10 Disposal of spent catalyst

Haldor Topsøe does not reclaim spent catalyst. However, we should be pleased to provide you
with a list of companies that can arrange reclamation of spent vanadium catalyst.

11 Safety
11.1 Chemical reactivity
Vanadium pentoxide catalysts are oxidation catalysts capable of oxidising SO2 to SO3 at
temperatures above 330°C (630°F).

When in contact with water, soluble salts may dissolve from the catalyst and the material as
such may disintegrate. Water exposed to the catalyst will show an acidic reaction.

11.2 Fire and explosion hazards

Vanadium pentoxide catalysts are not combustible. At elevated temperatures, SO2 and SO3
may evolve (400°C/750°F) and vanadium pentoxide may vaporise (650°C/1200°F).

Any normal fire-fighting techniques may be employed and breathing apparatus is

recommended.

11.3 Health hazards

Due to the content of vanadium pentoxide, the sulphuric acid catalyst has the following
classification in accordance to the directive 1999/45/EC:

Xn: Harmful.

 Harmful: danger of serious damage to health by prolonged exposure through inhalation.

 Possible risk of harm to the unborn child.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 18 / 19

 Possible risk of irreversible effects.

 Harmful to aquatic organisms may cause long-term adverse effects in the aquatic
environment.

In case of exposure of dust from the catalyst, the following symptoms may be observed:

Inhalation of excessive amounts of dust may cause irritation of the respiratory system;
symptoms may include coughing and difficulty in breathing. May cause physical irritation of
eyes. May irritate skin. Dust and fumes from vanadium compounds can irritate the respiratory
system; symptoms may include nose bleeding, sore throat, cough, bronchitis, expectoration,
chest pain; serious exposure may cause pneumonia and pulmonary oedema. The symptoms of
pulmonary oedema often do not become manifest until several hours have passed and they are
aggravated by physical effort. Rest and medical observation is therefore essential. Vanadium
compounds may cause green discoloration of tongue.

11.4 Safe handling

Handling the product demands proper precautions to be taken in order to reduce risk of
exposure. Handling methods that avoid excessive dust formation should be chosen. If
necessary, use mechanical ventilation. Use good housekeeping and personal hygiene
practices. Do not eat, drink or smoke when handling materials. Wash hands thoroughly after
handling.

It is recommended to use approved respirator with particle filter type P3 (EU-standard)/P100

(US-standard), when exposure may exceed recommended limits. Gloves are recommended. In
cases of excessive dust formation safety goggles are recommended.

For further information, see Material Safety Data Sheet for the catalysts.

12 Liability
The above recommendations have been prepared by Haldor Topsøe specialists having a
thorough knowledge of the catalysts. However, any recommendation should be considered to
be of a general nature given without any liability to Haldor Topsøe for upsets or damages to 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.

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.
Haldor Topsøe A/S - Nymøllevej 55
2800 Kgs. Lyngby - Denmark

Manual for Topsøe’s sulphuric acid catalysts 19 / 19

We wish to underline the importance of recommendations issued by Haldor Topsøe being

carefully reviewed by the plant personnel. Unclear points (if any) should be discussed and
clarified with Haldor Topsøe.

13 Contact
For contact information, please visit our website on www.topsoe.com.

December 2010 MAVO/MSHJ

Information contained herein is confidential; it may not be used for any

purpose other than for which it has been issued, and may not be used by
or disclosed to third parties without written approval of Haldor Topsøe A/S.