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MESA REDONDA 2010Latest Developments in
Sulphuric Acid Technology by
MESA REDONDA 20102
Extract of Developments in last years
Outotec Acid Technology in brief OTOVentTMTM – Venturi Quench System Energy Recovery HEROSHEROSTM TM ProcessProcess Drying & Absorption Towers
- FiDiTM TM System – Film Distributer- Vertical Wire MeshTMTM
- Candle Filter Plate Support SystemTMTM
in Presentation Noracid Sulphur Combustion – New LURO2TMTM Sacrificial Heat Exchanger
MESA REDONDA 2010
3
Outotec in briefOutotec in brief
4
Operational model
© Outotec
Technology Management
Market Operations (incl. Market Areas)
Supply
Business Infrastructure
Strategy
Finance & Control
Legal Affairs
Human Capital
ServicesServices
Sh
ared
Su
pp
ort
Fu
nct
ion
s
Business Areas
CustomersCustomers
Energy, Light
Metals & Environ-mental
Solutions
Energy, Light
Metals & Environ-mental
Solutions
Ferrous Solutions
Ferrous Solutions
Non-ferrous
Solutions
Non-ferrous
Solutions
2010
4
Services
5 2010 © Outotec
Lifecycle service solutions and a global network of service centers for Outotec’s customersServices from spare parts support and delivery, site and equipment maintenance and plant audits to optimization and upgrades, project management and training.
Recent acquisitions 2010 Millteam maintenance services for mining
companies and special expertise in grinding mill service
Ausmelt complements our smelting technology portfolio
Larox filtration technologies and services enable us to offer solutions for the whole value chain from mine to metal
Edmeston
Specializing in engineering and supply of process equipment for sulfuric acid plants.
Unique know-how of special stainless steel grades suitable for use in highly corrosive environment.
© Outotec6 2010
MESA REDONDA 2010
7
OTOVent
Quench Venturi System
Traditional Areas of Concern withQuench Towers or Quench Venturis
Nozzle Area of Quench VenturiGas Inlet of Quench Tower
Areas where Hot & Dry and subsequent Cold & Wet Conditions are manifest
MESA REDONDA 2010
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Requirements for Improvementrealized by OTOVent
hot/dry conditionand
wet/cold condition
1. Defined Areas for only Hot / Dry and only Cold / Wet Conditions AND
2. Avoidance of Dust / Partical Deposits at Wall and In / On Acid Overflow
MESA REDONDA 2010
9
Developement of Design Features
1. Separation of Hot & Dry and Cold & Wet Areas
Creation of an Overall Localized Even Acid Film at Wall / Bricklining above Acid Spray Nozzle Level
2. Avoid Dust & Partical Deposits on Wall
Wall / Bricklining above Acid Spray Nozzle Level is in the Shadow of the Gas Inlet ( larger inside diameter )
3. Avoid Dust & Partical Deposits In & On Acid Overflow
Acid Overflow Channel is Conical
- to Avoid Partical Deposits in Channel by Higher Acid Velocity at the Bottom - to Create an equal Film at the Overflow by Lower Velocity at Top
MESA REDONDA 2010
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Thickness of Film (m)
MESA REDONDA 2010
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Temperature of Film (K)
Flow Analysis by Fluent Wall by Loadcase 380 / 70
Temperature ( K ) Analysis by Fluent for Loadcase 380 / 70
MESA REDONDA 2010
12
of Droplets of Gas
MESA REDONDA 2010
13
Types of Application
Retrofit to OptimizeExisting Quench Tower
Green Field Application
MESA REDONDA 2010
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MESA REDONDA 2010
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Energy Recovery Energy Recovery
HEROSHEROSTM TM ProcessProcess
MESA REDONDA 2010
16
product aciddrying tower
main blower
air
sulphur
waste heatboiler
combustionfurnace
converter
superheater
evaporator
intermediate absorption tower
intermediateheatexchanger
economizerfinal absorption tower
stack
atmosphere
HP STEAM GENERATION
LOW TEMPERATURE HEAT RECOVERY
Excess Energy RemovalExcess Energy Removal
04/12/2317
LP-Steam
Boiler Feed Water
Feed WaterPreheating
Dilution Water
gas in outAcid Cross-flow
c/w
Outotec HEROS System Outotec HEROS System Recent advances - Enhanced HEROSRecent advances - Enhanced HEROSTMTM
IIN COMPARISON TO N COMPARISON TO HHEROSEROSTMTM WITH WITH EARLIER EARLIER DDESIGNESIGN
18
Outotec HEROS SystemOutotec HEROS System – Design Philosophy – Design Philosophy
Aspect Description Related HEROS feature Advantages
Operational Flexibiity • Ability to vary the amount of LP steam production without altering the production of the Acid plant
• Controlled bypass of the venturi absorber system• IAT designed for 100% capacity
• LP Steam can be easily adjusted in HEROS and absorption of SO3 in IAT is ensured
Safety • Minimize corrosion in case of normal operation and off-set conditions
• Material selection (alloy 3033)• New boiler concept• Enhanced safety concept (leak detection)
• Plant operation in a range of 97.5 – 99.5 % • Fast isolation of boiler• Early detection of leaks in water/steam circuit
Overall Plant Availability • Failure of hot circuit must not lead to plant shutdown
• Seperation of hot acid circuit from system by gravity• IAT design for 100 % capacity
• Acid and HP steam production at nominal capacity possible.
19
Outotec HEROS System Outotec HEROS System Recent advances - Enhanced HEROSRecent advances - Enhanced HEROSTMTM
6
Sulphuric Acid
BFW
LP-Steam Process Gaswith
SO2 & SO3
SO2 gas
Process
water
1
2
3
4
5
6
Shell and tube type heat exchanger (3)
Horizontal arrangement above pump tank
Mixer with water injection at inlet at (8)
Tube side boiling
Separate steam drum (1)
Forced circulation (2)
Bricklined Venturi 1. maximum reliability2. 100% acid production even in case of boiler failure!
04/12/2320
CS / Bricks 40, 2 x 65
Insert: Glass / PTFECover: 3033
Sleeve
Flange: 316L
Piping: 3033
HHEROSEROSTMTM: Application of Material: Application of Material
MESA REDONDA 2010
21
Nicrofer 3033 - Excellent weldability, high ductility
0
50
100
150
200
250
300
96.5 97.0 97.5 98.0 98.5 99.0 99.5 100.0
Acid Concentration % H2SO4
Tem
pera
ture
°C
Sandvik SX
Nicrofer 3033
Super Ferrite
310 SS
HEROS™ – Material SelectionHEROS™ – Material Selection
HEROSTypical range of operation
04/12/2322
LEAKAGE / FAILURE Fast detection vital Supervision of
Acid Concentration Boiler Water Contamination Process- and BFW-Management Energy Balance
Loss prevention Separate drains for acid and water:
fast and safely
Summary
Can operate 97.5 – 99.5 % H2SO4 (98.5 ± 1.0 %)
Employs proven equipment and materials of construction
For piping and evaporator, special material 3033
Is easy to install as a plant upgrade, revamps
Risk MitigationRisk Mitigation
0
5
10
15
20
25
30
40 60 80 100
Plant load in %
Flo
w in
m³/
h BFW
Process water
-5.00
10.0015.0020.0025.0030.0035.0040.0045.0050.00
0 1 2 3 4 5 6 7 8 9 10 11 12
Leak size in mm
Flo
w in
m³/
h
BFW
Process water
MESA REDONDA 2010
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HEROS™ – LayoutHEROS™ – Layout
MESA REDONDA 2010
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HEROS™ – SectionHEROS™ – Section
MESA REDONDA 2010
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Drying &Drying &
Absorption TowersAbsorption Towers
MESA REDONDA 2010
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Tower - OptionsTower - Options
Self-supporting dome Acid exit at side Process water addition
Conventionaltower design
Combinedventuri +
packed bed
Integratedtop heat
exchanger
Integratedventuri for
large plants
MESA REDONDA 2010
27
CONVENTIONAL TOWER DESIGN
with special attention to:
-multi-layer bricklining
- self-supporting domes
-distribution system of SX
- adequate acid mist and
droplet removal
MESA REDONDA 2010
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Outotec Edmeston TOWER DESIGN
with special attention to:
-SX Stainless Steel
-one-layer bricklining up to dome
- self-supporting domes
-distribution system of SX
- adequate acid mist and
droplet removal with shell of 316L
MESA REDONDA 201029
SS Towers of SX and Top of 316L
MESA REDONDA 201030
SX Material by Outotec Edmeston
For
• Towers
• Pump Tanks
• Irrigation System
• Acid Coolers
• Piping
MESA REDONDA 2010
31
p a c k i n g
nozzle
deflector plateliquidtrajectory
Conventional Acid DistributionConventional Acid Distribution
MESA REDONDA 2010
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Modern Acid DistributionModern Acid Distribution
Stainless Steel Tower SX3,000 t/d S-burning Plant
FiDiTMTM system Elemants
MESA REDONDA 201033
Optimization of Acid Distributionby Fluid Dynamic Analysis
Standard configuration without orifices
Orifice of 80% at arm 4, orifice of 60% of radius at arm 5
MESA REDONDA 201034
Comparison of Irrigation Systems
Free Gas Flow Areathrough Irrigation System
45 to 55 %
Trough System LURGI System Outotec FiDiTMTM System
Free Gas Flow Areathrough Irrigation System
55 to 60 %
Free Gas Flow Areathrough Irrigation System
65 to 75 % %
MESA REDONDA 201035
LAB Test - FIDITMTM
Sulphur Burning Plants
36
Fluid Dynamic Analysis Vertical Wire MeshTMTM
Sulphur Burning Plants
37
Pictures of Vertical Wire MeshTMTM
MESA REDONDA 201038
Outotec Support TM TM of Candle Filter Plate
Dia 5.4 m - Dead weight & 250 kg / candle
Old Design New
Deflection ( mm 170 Center 3 170 Maximum 16
Main Benefit: Due to Less in Deflection nearly no Bending at Flange / Gasket
MESA REDONDA 201039
Not mentioned Developments today
Propriety Equipment New Design of SS Converter Outotec Edmeston SX Tower without Bricks 2 New Designs of High Efficiency Scrubber Enhanced Design of Wet ESP
Process Applications LuRec Concentration Expand Etc.
MESA REDONDA 2010
40
40 | 12 April 2023 | TAK-S Meeting Worms40 | 12 April 2023 | BHP – Olympic Dam
www.outotec.com
Thank you forThank you foryour attention !your attention !
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