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SynCOR^TM - a best-in-class technology

Step up your syngas production with what we like to call ‘the workhorse of the future’. SynCOR is a next-generation technology, which is especially well-suited for the production of low-carbon hydrogen and ammonia at very large capacities and with high carbon capture requirements.  

Among all low-carbon technologies, SynCOR is by far the most mature technology in the market. Initially developed in 1958, the technology is supported by 70 years of proven reliability and safe, continuous operation. For that reason, SynCOR exceeds any other in its category.

This is SynCOR^TM!

SynCOR™ is a next-generation autothermal reforming technology (ATR), previously known as A-ATR; advanced autothermal reforming technology. It enables large-scale production of e.g. low-carbon hydrogen and ammonia.

The main reforming process takes place inside a single SynCOR reactor. Process gas enters the SynCOR reactor, and in a combination of steam reforming and partial oxidation transforms hydrocarbon feedstocks, like natural gas, into syngas. This syngas then undergoes further processing to produce low-carbon fuels and chemicals. It is significantly different from any other ATR process, since it operates at a much lower steam-to-carbon ratio.

The SynCOR™ concept which represents a huge leap in syngas process technology and has been in industrial operation since 2002. It is the preferred technology in many of today’s world-scale projects because it enhances economy of scale by maximizing single-line capacity while significantly reducing capital and operating costs.

Topsoe's state-of-the-art equipment includes a process burner that provides safe operation, long lifetime, centered flame, soot-free combustion, and uniform mixing. Topsoe's refractory lining is multi-layered to ensure safety and reliability as well as low surface temperatures on the pressure shell. Our target tiles provide high wear resistance and act as a robust top layer. And last but not least, our autothermal reformer catalysts (RKA-10, RKA-02, RKS-2, and RKS-2-7H) provide long life time, low pressure-drop and high activity as well as other unique attributes that ensure the best possible performance and efficiency of the SynCOR unit. These are placed on a catalyst bed support.

The SynCOR^TM process

The use of SynCOR technology is advantageous because the combustion of feed gas generates heat for the reforming reaction, which eliminates the need for supply or dissipation of thermal energy.

With a SynCOR advanced autothermal reformer, tubular reforming is not necessary – instead, pre-reformed natural gas is sent directly to the autothermal reformer along with oxygen. By eliminating the need for tubular reforming, steam addition can be significantly reduced, and energy efficiency is improved.

Autothermal reforming conditions are typically more challenging than those for a conventional oxygen-fired secondary reformer operating at high S/C ratios, which necessitates very robust hardware and catalysts.

Syngas production for low-carbon fuels and chemicals

Following its installation in many large capacity plants for different applications, including GTL™ (Gas to Liquid), TIGAS™ (natural gas to gasoline), syngas, and so forth, SynCOR has now gained over 300 years of cumulative operational experience. This makes it the most mature technology for low-carbon hydrogen and low-carbon ammonia projects.

SynCOR hydrogen™

Among low-carbon hydrogen technologies, the SynCOR process exhibits the lowest OPEX, since the reactor operates at a steam-to-carbon ratio of 0.6, which is 3–5 times less than that of SMR or less developed conventional ATR systems. This enables refineries to truly capture economy of scale and minimize levelized cost of hydrogen (LCOH). The lower steam throughput also has the benefit of reducing equipment and piping sizes, a benefit that is most pronounced at large scale, since the equipment and piping are kept within standard size ranges – even at very large single-line capacities.

SynCOR is very well suited for use in low-carbon hydrogen production, as, external fuel demand is extremely low. This means a very high carbon-recovery rate (>99%) can be achieved without having to capture the carbon present within the flue gas. 

Due to this low steam-to-carbon ratio, it is economically favorable to employ SynCOR in mega-scale plants. The largest SynCOR reactor in operation today has an equivalent hydrogen production capacity of 455 MMSCFD, while, for comparison, the highest capacity limit for single ATR train is 735 MMSCFD for hydrogen production. The largest SynCOR reactor currently in operation has a hydrogen production capacity of 500 kNm3/hour, and the economical limit for single-train capacity is 825 kNm3/hour. Because of these favorable economics, SynCOR is likely to remain the dominant technology for large-scale hydrogen production.

Dive deeper into low-carbon hydrogen production here

SynCOR Ammonia™

Aim high to secure low-carbon intensity ammonia. With up to 99%+ CO2 removal capabilities, our solutions lead the industry in decarbonization. We collaborate with carbon capture technology providers to ensure seamless integration and industry-leading emission reduction. 

SynCOR Ammonia is not only highly suited for large-scale plants but is also the ammonia process that captures the most CO2 directly from the reforming process without any additional effort. Typically, around 88% of carbon is captured directly from process gas, which is significantly higher than any other ammonia process. From here, carbon capture can easily increase to 99%+ through the process unit.

The SynCOR ammonia solution enables large capacities in single trains and is superior to traditional SMR technology for large-scale plants. The largest SynCOR operating references are producing syngas equivalent to more than 6800 tpd of ammonia. Make use of our proven process and scale up your reforming section in an economically attractive way. Reduce environmental impacts by cutting water consumption, NOX, and CO2 emissions and prioritize safety with an automated reforming section.

Dive deeper into low-carbon ammonia production here

The main benefits of SynCOR^TM

•    Superior to traditional SMR technology for large size plants
•    Large capacities in single trains
•    Great economy of scale
•    Lower OPEX
•    Minimal gas consumption
•    Low steam to carbon ratio
•    Very low water consumption
•    Reduced environmental impact through lower emissions
•    Exceeding 99% availability
•    Easy and safe operation

Invest with confidence

When you partner with us, you benefit from unparalleled knowledge. We provide a complete range of catalysts, proprietary equipment, spare parts, and consumables designed and manufactured to work optimally.

Watch our video to explore the applications and benefits of the SynCOR  process.