Strong Acid Equipment Review and Developments. COBRAS 2017 Frans Kodeda /26

Transcription

1 Strong Acid Equipment Review and Developments COBRAS 2017 Frans Kodeda /26

2 Outotec a process technology company Outotec provides leading technologies and services for the sustainable use of Earth s natural resources. With over 650 sulfuric acid plant installations worldwide, Outotec is the leader in sulfuric acid plant design and delivery The Outotec Edmeston Product Center specializes in the design and supply of strong acid equipment, mainly manufactured from the proprietary alloy Edmeston SX. introduced to the market in

3 Outotec-Edmeston history Engineering Company established 1984 as part of the Sandvik Group. Part of Outotec since 2010 as exclusive supplier of original Edmeston SX material, piping and equipment. EDMESTON PRODUCT CENTER 3

4 Sulphuric Acid Production Contact process, mature and well established Double contact process since 1964 Drivers for change: Energy efficiency Environmental issues Price-performance ratio 4

5 Sulphuric Acid Production Energy efficiency Low grade heat -> steam, preheating, external use Environmental issues Air & Water emissions, Water availability Price-performance ratio Equipment efficiency, reliability & availability vs cost 5

6 Edmeston SX Sulphuric Acid Steel An austenitic stainless steel developed by Swedish steel manufacturer Sandvik in the 70 s, Introduced by Edmeston in 1984, now Outotec Edmeston Product Center. Chemical Composition: Cr % Mo % Ni % Cu % C 0.07 % Si % Mn 2.0 % 6

7 Edmeston SX Sulphuric Acid Steel Isocorrosion diagram, reference line indicating 0.1 mm/year. Confirmed properties for dynamic conditions Suitable for all parts of the acid circuits 7

8 Material choice increasingly important For best plant performance and availability - No compromise in material choice - Well proven materials 8

9 Edmeston SX Sulphuric Acid Steel Throughs in Edmeston SX not affected Downcomers in cost effective material damaged from corrosion 9

10 Sulphuric Acid Piping 10

11 Edmeston SX Piping Conditions moving towards -> faster & hotter Traditional materials sensitive to - increased temperature - increased velocity Edmeston SX piping - Excellent temp/conc corrosion properties - confirmed properties for dynamic conditions - Typical design velocity m/s - 0,0 mm/year, corrosion expectancy 11

12 Edmeston SX Piping Fig 1. Piece by piece DN 400 Fig 2. Re-designed to DN 300 relative V relative dp

13 Edmeston SX Piping Cost Comparison Replacement Replacement piece by piece, re-designed to DN400 DN300 Straight Pipe Elbows Reducers Stub Ends Loose Flanges 150# Gaskets, bolts & nuts Welds SUM

14 Edmeston SX flow control valves Delaminated plastic valve lining Edmeston SX valve 14

15 Acid irrigation systems 15

16 Acid irrigation systems Trough type Pipe type 16

17 Acid irrigation systems Lurgi pipe type Edmeston Pipe type Edmeston Trough type 17

18 Acid irrigation systems faster & hotter limiting factor for distributor design Minimise carryover and mist formation Provide large free area for gas flow Accommodate large acid flow Traditional irrigation systems causing congestion 18

19 Edmeston SX FiDi Distributor 19

20 Edmeston SX FiDi Distributor Benefits: Generous free gas flow area Homogenous acid distribution Minimizing mist formation and carryover Long lifetime, manufactured from Edmeston SX Simple and reliable design Reduced investment costs compared to trough type 20

21 Edmeston SX FiDi Distributor High efficiency towers Proven performance 40+ distributors supplied 21

22 Acid Cooling Cooling with water Evaporative cooling tower loop! - water availability, pollution Cooling with sea water! - water availability, pollution, corrosion Cooling by intermediary loop to low grade heat recipient! availability, suitable recipient 22

23 Acid Cooling Water loop fin-fan air coolers + Edmeston SX Shell & tube acid cooler 23

24 Acid Coolers Plate Coolers & Shell & Tube coolers Shell & Tube with Anodic protection dominating Acid side corrosion resistance rely on anodic protection 24

25 Edmeston SX Acid Coolers Without anodic protection Rely on material properties for corrosion resistance 25

26 Direct acid-air coolers Direct acid cooling in fin-fan air coolers No cooling water Edmeston SX provides reliable and safe operation 26

27 Absorption Towers Brick lined or Alloy tower depending on project conditions 27

28 Absorption Towers Alloy towers The Devil is in the details material knowledge and experience in detail design imperative. Brick lined towers Proper design, materials and labour 28

29 Absorption Towers 3 plants each 5000 mtpd Largest singel train acid plants ever built Economy of scale will demand even larger Conventional towers suitable up to ~ 6000 mtpd 29

30 Radial Flow Towers Uniform gas distribution Mechanical stability Suitable for large plant capacities Venturi, pre-absorber Packed bed, post absorber 30

31 Thank You! author contact: