MECS SULFOX High Energy Efficient Sulfuric Acid Process Technology for cleaning up Lean & Wet Sulfurous Off-gasses

Transcription

1 MECS SULFOX High Energy Efficient Sulfuric Acid Process Technology for cleaning up Lean & Wet Sulfurous Off-gasses Sulphuric Acid Conference 4 6 MAY 2009 SUN CITY, SOUTH AFRICA

2 day s Topics MECS Introduction Overview Processes around the sulfur molecule SULFOX description & it applications Benefits

3 CS Intro The leading EXPERT for dealing with SULFUROUS GASSES Sulfuric Acid Plants Process Technologie Sulfur Recovery Tail gas cleanup Know-How People Products & Engineered Equipment

4 SO 2 removal SO 2 in Gas stream (% Vol) Alkaline scrubbers Regenerative Absorption Wet gas process (Sulfox) Conventional Sulfuric Process

5 SO 2 removal MECS has created a unique offering One consolidated approach: Conventional acid plant Wet Process SO 2 regenerative system DynaWave scrubbers

6 t Process Chemistry Evaporation is required to make concentrated aci Catalyst (SO 2 + 1/2 O 2 ) y y. SO 3 y. H 2 SO 4 + x(h 2 O) + x(h 2 O) + (x-y) (H 2 O)

7 at is SULFOX? A Technology for: cleaning up wet sulfur containing offgas with production of a valuable product as Sulfuric Acid Applications (anywhere SO 2, H 2 S, CS 2, is present): Petrochemical (gasification) Refinery Natural Gas production Waste Management (gasification or burning) Mining & Roasting industry Viscose industry

8 LFOX Basic Flow Diagram SO 2 ~370 C Catalyst V 2 O 5 Square Reactor (Converter) Condensation column ~70 C -200 C WESP + A.C. Clean Stack (incl. excess water) D w V 2 O C H 2 SO 4 (g) ~250 C H 2 SO 4 (l)

9 LFOX A Process Technology (know-how), including equipment & layo design, for converting sulfurous gas components into Sulfuric Acid, via a sequence of following main equipment, or parts of: 1. Square reactor (=converter): using Pt and vanadium based catalyst & with internal heat exchangers using molten salt, to convert the sulfurous components to SO 3 2. Condenser: with special lining, with horizontal glass HEX tube for acid condensation, and an acid concentration section (packed section) 3. WESP: to capture the acid mist and partly oxidize the remaini SO 2 4. Activated Carbon Bed Filter: to partly oxidize the remaining S and wash out the SO 3 as weak acid.

10 LFOX Applications - Basic Flow Scheme Application: Combustion Required Dirty Feed Streams Always Included As Required Step 1 Combustion / Steam Equipment Step 2 Gas Cleaning System Step 3 SULFOX Step 4 Tailgas Scrubber MECS: Know-How DynaWave Catalyst D-205 Cooler DynaWave 1. Liquid feeds and large H 2 S gas feeds 2. Dirty liquid or gas feeds 3. All applications (converter, heat exchanger, condenser, WESP, activated carbon) 4. As required to meet low SO 2 emissions (>99.5% conversion)

11 ndard typical flow scheme lean SO 2 DRY GAS FROM AIR ESP FURNACE INLEAKAGE (BY OTHERS ) GAS TO BLOWER FC PC ELECTROSTATIC MIST PRECIPITATOR FC MAKE-UP WATER PC PC SAFETY SEAL LC PRIMARY REVERSE JET SCRUBBER WEAK ACID COOLERS LC GAS COOLING TOWER LC FINAL REVERSE JET SCRUBBER EFFLUENT TO NEUTRALIZATION SYSTEM GAS COOLING TOWER PUMPS FINAL REVERSE JET SCRUBBER PUMPS PRIMARY REVERSE JET SCRUBBER PUMPS COOLING WATER SUPPLY COOLING WATER SUPPLY TC FUEL GAS COMBUSTION AIR 127 COMBUSTION CHAMBER AND STARTUP BURNER REACTOR (CONVERTER ) 28 TAIL GAS COMBUSTION AIR FAN ACTIVATED CARBON FILTER 128 DEMIN WATER AMBIENT AIR 1 TO 3 ATMOSPHERE AIR FAN WITH VFD ELECTROSTATIC MIST PRECIPITATOR WEAK ACID TANK LC GAS PREHEATER TC MOLTEN SALT COOLER 27 WEAK ACID (10%) PUMP GAS COOLER TC FROM WESP (AFTER GAS CLEANING) 11 MAIN BLOWER DILUTE ACID (50%) PUMP 123 CONDENSATION COLUMN, WITH GLASS TUBE HEAT EXCHANGER MOLTEN SALT PUMP MOLTEN SALT TANK 26 PRODUCT ACID COOLER 121 LC PRODUCT ACID TANK 122 PRODUCT ACID

12 LFOX pictures

13 LFOX pictures

14 LFOX pictures

15 LFOX pictures

16 nefits of SULFOX wet gas process SULFOX benefits: 1. No liquid effluent, but a saleable product (Sulfuric Acid) 2. Very Low Acid Mist Emission WESP 3. High SO 2 conversion, so low SO 2 emissions Activated Carbon Bed 4. Reliability: Robust Mechanical Condenser Design Horizontal short tubes (w/ interim supports)

17 LFOX Condenser advantage ~3m ROBUST DESIGN!

18 nefits of SULFOX wet gas process SULFOX benefits: 1. No liquid effluent, but a saleable product (Sulfuric Acid) 2. Very Low Acid Mist Emission WESP 3. High SO 2 conversion, so low SO 2 emissions Activated Carbon Bed 4. Reliability: Robust Mechanical Condenser Design Horizontal short tubes (w/ interim supports) 5. Reliable DynaWave TM Gas cleaning 6. Proven Catalyst: Use of different types of catalyst (Pt) 7. MECS know-how, reputation & service in acid plants 8. Very compact: low CAPEX & OPEX (low pressure drop)