VK series

Sulphuric acid catalysts

Scanning Electron Micrograph of a typical diatom skeleton.
Selected diatomaceous earths are used as essential raw material for the sulphuric acid catalyst carrier and are crucial for the nal catalyst properties.
VK series
catalysts for today and for the future
The catalytic SO
2
converter is the heart of the sulphuric acid
plant and the quality and characteristics of the selected catalysts
are crucial to a reliable and energy-efcient operation.
The catalyst properties are inuenced by the chemical
composition, the physical properties including the nature of the
support material and the manufacturing process. Topse VK
catalysts are uniquely balanced to combine high and stable
activity, robustness, low pressure drop and a long service life.
Continual improvement of the VK catalysts is achieved through
close cooperation between Topses Catalyst Group, R&D and
the production facilities. Over the years this cooperation has
resulted in major product breakthroughs, providing the industry
with new catalysts for more energy-efcient operation, lower
SO
2
emissions and higher production rates.
Topses VK series comprises four different formulations in a
variety of sizes and shapes, effectively covering all operating
conditions in any sulphuric acid plant.
By combining outstanding activity with low pressure drop and
exceptionally high mechanical strength, the VK catalysts ensure
cost-effective plant operation by providing:
- high SO
2
conversion efciency
- improved energy efciency
- enhanced operating exibility
- low screening losses
- long service life
Product range
VK38
The VK38 formulation provides excellent activity over a wide
range of operating conditions. VK38 is the only catalyst on
the market that can be used effectively in all beds of any SO
2

converter.
For continuous operation VK38 offers a broad temperature
range of 400-630C (750-1170F) and can withstand repeated
temperature spikes up to 650C (1200F).
VK38 is designed to initiate the reaction at a temperature as low
as 360C (680F), ensuring a smooth plant start-up, minimising
pre-heat time due to its superior catalyst activity.
VK48
VK48 is a high-vanadium version of the standard all-round VK38
catalyst.
The catalyst composition is specically formulated for lower
pass service, particularly where the process gas contains
large amounts of SO
3
. The conversion ratio of SO
2
affects the
balance between the active vanadium species in the catalyst.
An optimised ratio of the alkali-metal promoters enables an
increased vanadium content in VK48, resulting in a considerably
enhanced activity.
In high SO
3
gas environments, such as the lower passes of
single absorption plants, or the third pass of a 3:1 double
absorption plant, VK48 offers a signicant performance
advantage.
Caesium catalysts
Incorporating caesium as an additional catalyst promoter
enhances the action of the vanadium and activates the catalyst
at a much lower temperature than conventional non-caesium
catalysts.
Exceptionally high activity
Topses caesium-promoted VK catalysts are up to three times
more active than non-caesium catalysts, depending on the
operating conditions. Topses unique production techniques
result in an optimised silica pore system that combines two
important features: a very uniform distribution of the catalytically
active melt within the pore system and better access for the
process gas to the internal surfaces of the catalyst. This greatly
improves the activity of the caesium-promoted VK catalysts.
Low ignition temperature
VK59 and VK69 have an exceptionally low ignition or strike
temperatures of 320-330C (610-625F) that offer new
possibilities for faster and cleaner start-ups. Autothermal restarts
can be accomplished after a signicantly longer idle time without
the use of pre-heat.
VK59
VK59 is a caesium-promoted catalyst optimised for medium
to high strength SO
2
gasses with continuous operation down
to 370C (700F). A top layer of VK59 in the rst pass makes it
possible to accommodate high strength SO
2
feed gas without
exceeding the maximum outlet temperature of 630C (1165F)
and still maintain high bed conversion efciency.
VK59 installed in the lower pass(es) of single absorption plants
allows for signicant conversion improvement.
Benets
- accommodates strong SO
2
feed gas without excessive rst
pass exit temperatures
- greatly improved operating exibility for rapidly changing
feed gas composition
- low ignition temperature for faster and cleaner start-ups
- signicantly extended idle time for autothermal restarts
- improved overall conversion in single absorption plants
VK69
VK69 is designed specically for the nal pass(es) of double
absorption plants. In the lean SO
2
gas environment after the
inter-pass absorption tower, the unique VK69 formulation
offers unmatched high activity throughout the entire operating
temperature range. This affords existing plants the opportunity
to greatly reduce SO
2
emissions and/or increase production
rates. For new or revamped plants, SO
2
emissions of under
50 ppm are possible.
Using caesium as a promoter, VK69s extremely low ignition or
strike temperature will signicantly reduce pre-heat time and
improve start-up performance.
VK69 is manufactured in a unique 9 mm Daisy-shape. The
high surface area contributes to the high activity in this gas
environment and the high void-fraction ensures a low pressure
drop and good dust tolerance.
Benets
- possibility for over 50% reduction in SO
2
emission from
existing double absorption plants
- possibility for signicantly increased production without
increasing SO
2
emissions
- less than 50 ppm of SO
2
emissions possible from new or
revamped plants
- low ignition temperature for faster and cleaner start-ups
- long lifetime and low screening losses industrially proven
since 1996.
1944 1970 1984 1987 1988
First with Dasiy High vanadium VK48 First with caesium VK58 VK 38 First with rings
Sizes and shapes
25 mm Daisy - dust protection catalyst
For catalyst beds suffering from rapid pressure drop increase
due to dust in the feed gas, a top layer of Topses 25 mm
Daisy-shape catalyst can provide a cost effective remedy. The
extra void fraction and a lower specic surface area allow a
signicantly higher capacity for dust, distributing it throughout
a larger volume of the catalyst bed. The result is a lower rate of
pressure drop increase providing improved energy efciency and
longer intervals between catalyst screenings.
Benets
- 30-50% longer on-stream time compared to existing ring-
shaped dust-protection catalysts
- 100% longer on-stream time compared to 12 mm Daisy
- maintenance cost savings due to less frequent catalyst
screening
- energy cost savings due to lower plant pressure drop
- production increase due to longer time at maximum rate
before pressure drop forces production delay

12 mm Daisy
The 12 mm Daisy has become the most widely used catalyst
shape on the market since introduced by Topse in 1984.
The high void fraction results in improved energy efciency
throughout the operating cycle due to low initial pressure drop
and increased capacity for dust.
Topses 12 mm Daisy-shape has proven to be robust as well,
with reported screening losses typically well below 10%.
Topses VK38, VK48, and VK59 formulations are all available in
the 12 mm Daisy-shape.
Benets
- low initial pressure drop
- high dust capacity yielding in a lower rate of pressure
drop increase
- high activity
- low screening losses
9 mm Daisy
VK69 is produced in the unique 9 mm Daisy-shape. In the low
SO
2
environment, after the intermediate absorption tower, the
9 mm size and Daisy-shape combination gives 30% extra
activity compared to a 12 mm Daisy-shape, in part due to the
higher surface area. Also, the Daisy-shape ensures remarkably
low pressure drop.
10 mm rings and 6 mm cylinders
VK catalysts in the form of 10 mm rings and 6 mm cylinders
remain available for plants that desire or require their continued
use.

1996 1998 2007
2nd caesium generation
VK69 VK59 25 mm Daisy 25 mm Daisy
0
0
100
200
300
400
500
6 12 18 24 30
Operating time (months)
No dust guard
10 cm top layer of 20 mm rings
10 cm top layer of 25 mm Daisy
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Pressure drop development across various catalyst loadings in a dust laden feed gas.
Installation of a 10-15 cm (4-6 inches) top layer of the 25 mm Daisy results in
30-35% longer production campaigns compared to the 20 mm rings or a doubling
when compared to the 12 mm Daisy.
ISO
Catalyst manufacturing facilities are located in Denmark and
in Houston, Texas, USA. Both plants are certied to the ISO
9001: 2008 and ISO 14001: 2004 standards. Topses quality
management system includes continuous improvement to
achieve the highest quality.
Topse recognises its responsibility towards the local and
global community in all its activities. We protect the external
environment through responsible behaviour and are dedicated
to a continual improvement of personal safety and internal work
processes.
Packaging and storage
The standard packagings for VK catalysts are supersacks and
200 litre bre drums. A polyethylene liner protects the catalyst
from moisture. VK catalysts are very durable and can be stored
for years without loss in activity or strength when kept dry and in
the original packaging.
Single absorption Plant
VK59 - ignition layer
VK38
VK38
VK48
VK48 VK69
VK38
VK38
VK48
VK38 VK59 - for high conversion -
and/or
increased production rates
Double absorption plant
3+1 layout
VK38 - dust protection layer
Optional
VK38 VK48
Type Potassium-promoted Potassium-promoted
Ignition temperature 360C/680F 360C/680F
Continuous operating
temperature range
400-630C
750-1165F
410-550C
770-1020F
Thermostability 650C/1200F 650C/1200F
Size and shape 12 mm Daisy
25 mm Daisy
10 mm rings
6 mm cylinders
12 mm Daisy
10 mm rings
6 mm cylinders
Opportunities Excellent activity in the full range of operating conditions.
Suitable for use in all passes of all converters.
High-vanadium catalyst with enhanced activity for lower pass
service, particularly where the process gas contains signicant
amounts of SO
3
.
Tailored catalyst loadings
Topses range of VK catalyst formulations and shapes allow tailored loadings for each plants requirements.
Topses catalyst experts will assist in selecting the optimum catalyst type and shape for each pass in any
converter design, keeping the clients objectives in mind.
Technical service
Based on experience over more than half a century, Topse has
established an extensive technical service programme available
to our VK catalyst users. In addition to frequent contact, the
service programme includes activity testing of catalyst samples,
evaluations of catalyst performance, plant optimisation, trouble
shooting and management of catalyst replacement.
Activity testing of catalyst samples represents a valuable source
of information, which combined with computer evaluations
of the plant performance enables Topse to optimise future
catalyst management.
Topses Portable Gas Analysis Unit, TOPGUN enables
a thorough analysis of a sulphuric acid converter system.
TOPGUN is a fully portable, infrared gas-analysis unit for
SO
2
and O
2
analyses. The gas analyses are used as input to
Topses proprietary computer programs, which can accurately
simulate the converter performance. TOPGUN has proven a
very efcient tool for troubleshooting and optimising the plant
performance.
VK69
VK38
Low temperature
caesium catalysts
open a larger
equilibrium window
Temperature
Converter temperature - conversion profile
SO2 conversion
Equilibrium conversion
after interpass absorber
Equilibrium conversion
VK59 VK69
Type Caesium-promoted Caesium-promoted
Ignition temperature 320C/610F 320C/610F
Continuous operating
temperature range
370-500C
700-930F
370-500C
700-930F
Thermostability 650C/1200F 650C/1200F
Size and shape 12 mm Daisy 9 mm Daisy
Opportunities Optimised for medium to high-strength SO
2
gases.
Use as an ignition layer in any bed. Improved
conversion in single absorption plants.
Double absorption plants only - optimised for use in the pass(es)
after the intermediate absorption tower. Extremely high activity
throughout the entire temperature range.

Haldor Topse A/S - Nymllevej 55 - 2800 Kgs. Lyngby - Denmark
Tel. +45 4527 2000 - Fax. +45 4527 2999 - www.topsoe.com
The information and recommendations have been prepared by Topse specialists having a
thorough knowledge of the catalysts. However, any operation instructions should be considered to
be of a general nature and we cannot assume any liability for upsets or damage of 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.
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