CRITICAL ASPECTS IN THE DEFINITION OF THE OPTIMUM CONFIGURATION OF A SULPHUR BURNING PLANT

Transcription

1 The Southern African Institute of Mining and Metallurgy CRITICAL ASPECTS IN THE DEFINITION OF THE OPTIMUM CONFIGURATION OF A SULPHUR BURNING SUN CITY SOUTH AFRICA May 4 th 6 th, 2009 BASE DECISIONS FOR THE DEFINITION OF THE CONFIGURATION OF A SULPHUR BURNING TYPE OF RAW MATERIAL EMISSSIONS PRODUCTS CO PRODUCTS Page 20

2 The Southern African Institute of Mining and Metallurgy TYPE OF RAW MATERIAL SULPHUR LIQUID SOLID WHICH? HOW MUCH? QUALITY? PRODUCTS S.A. 9299,5% wt OLEUM 2025% free SO 3 SO 3 GASEOUS (CONC.?) LIQUID GASEOUS (CONC.?) LIQUID OTHER SPECIFICATIONS COPRODUCTS STEAM & ELECTRIC POWER REQUIREMENTS Condensate SUPERHEATED STEAM P > 40 barg T >370 C Condensing Turbine Back Pressure Turbine E.P. E.P. L.P. Steam bleeding for site users (up to 25% of the steam fed flow) M.P./L.P. Steam for site users Second turbine Condensate SATURATED OR SLIGHTLY SUPERHEATED M.P./L.P. Steam for site users Page 202

3 The Southern African Institute of Mining and Metallurgy COPRODUCTS STEAM & CONDENSATE CIRCUIT DEFINITION T h e u s e r consumes all the steam fed and gives back condensate Steam H2SO4 STEAM USER Condensate return PURGE / LOSSES The user does not consumes all the steam produced and/or does not give back condensate Extra Steam H2SO4 Steam STEAM USER Condensate S T E A M CONDENSER INSTALLATION or RELEASE OF THE EXCESS STEAM TO THE ATMOPSHERE AND SIGNIFICANT OVERDESIGN OF THE DEMI WATER UNIT (UP TO 5 TIME L A R G E R ) EMISSIONS DCDA WITHOUT SCRUBBER STANDARD CONFIGURATION : PPM Acid mist + SO 3 : 80 mg/nm 3 EMISSION MINIMIZATION : down to 00 PPM Acid mist + SO 3 : up to 30 mg/nm 3 DCDA or SCSA WITH SCRUBBER H 2 O 2 NaOH Others (Limestone) Page 203

4 0 PRELIMINARY ISSUE Frontino 7/02/09 MILANO Italy Commessa / Impianto H2SO4 + OLEUM The Southern African Institute of Mining and Metallurgy BASE CONFIGURATION M.P. STEAM H 2 98,5% 4 pass Air drying Sulphur burning W H R B + ECONOMIZERS 3 pass 2 pass CIP/HIP SO3 absorption & acid circulation pass Deareator AIR SULPHUR DEMIWATER MAKEUP PLUS CONDENSATE RECOVERY (IF ANY) BASE CONFIGURATION WHRB + ECO CONVERSION AIR DRYING DEAREATOR SULPHUR BURNING CIP/HIP ACID CIRCULATION Page 204

5 0 PRELIMINARY ISSUE Frontino 7/02/09 MILANO Italy Commessa / Impianto H2SO4 + OLEUM The Southern African Institute of Mining and Metallurgy BASE CONFIGURATION Reference & Performance data PRODUCTS H TPD 98,5% conc. STEAM DATA medium pressure steam (slightly superheated) Kg/h 25 bar (g) 245 C SO 3 CONVERSION 99,799.75% EMISSIONS DATA : PPM vol. SO 3 + acid mist: 80 mg/nm 3 (as H 2 ) INVESTMENT FACTOR * 00 * For process plant engineering and procurement cost CASE STUDY : H 2 concentration/dilution & OLEUM production Page 205

6 0 PRELIMINARY ISSUE Giacalone 7/02/09 MILANO Italy Commessa / 2 Impianto H2SO4 + SO2 GAS The Southern African Institute of Mining and Metallurgy CASE STUDY : H2SO4 concentration/dilution & OLEUM production Reference & performance data PRODUCTS H TPD (as 00% H 2 ) OLEUM STEAM DATA medium pressure steam (slightly superheated) SO 3 CONVERSION 99,799.75% 00 TPD (as 00% H 2 ) 98,5 % 05,5% (25% free SO 3 ) Kg/h 25 bar (g) 245 C EMISSIONS DATA : PPM vol. SO 3 + acid mist: 80 mg/nm 3 (as H 2 ) INVESTMENT FACTOR 04 CASE STUDY 2: H2SO4 and SO2 gas production Page 206

7 0 PRELIMINARY ISSUE Giacalone 7/02/09 MILANO Italy Commessa Impianto H2SO4 + SO2 GAS R ev isione 2 / 2 The Southern African Institute of Mining and Metallurgy CASE STUDY 2: H2SO4 and SO2 gas production CASE STUDY 2: H 2 and gas production Reference & performance data PRODUCTS H2SO4 350 TPD (as 00% H2SO4) SO2 GAS STEAM DATA medium pressure steam (slightly superheated) SO 3 CONVERSION 99,7% 00 TPD (as 00% SO2) 98,5% conc. 0% conc. 2 bar (g) ; 00 C kg/h 25 bar (g) 245 C EMISSIONS DATA : PPM vol. SO 3 + acid mist: 80 mg/nm 3 INVESTMENT FACTOR 25 Page 207

8 SUPERHEATED STEAM FROM H2SO4 BOILER 42 Barg / 400 C H2O (LIQUID) 90 C TURBINE ELECTRIC POWER FOR H2SO4 OPERATION /h K g.0 0 CONDENSER Commessa Impianto 0 PRELIMINARY ISSUE Frontino 7/02/09 MILANO Italy HIGH PRE4SSURE STEAM (ELECTRIC POWER PRODUCTION) 2 / 2 0 PRELIMINARY ISSUE Frontino 7/02/09 MILANO Italy Commessa / 2 Impianto HIGH PRE4SSURE STEAM (ELECTRIC POWER PRODUCTION) The Southern African Institute of Mining and Metallurgy CASE STUDY 3: HIGH PRESSURE STEAM configuration for ELECTRIC POWER generation CASE STUDY 3: HIGH PRESSURE STEAM configuration for ELECTRIC POWER generation Page 208

9 0 PRELIMINARY ISSUE Frontino 8/02/09 MILANO Italy Commessa / Impianto EMISSION MINIMIZATION The Southern African Institute of Mining and Metallurgy CASE STUDY 3: HIGH PRESSURE STEAM configuration for ELECTRIC POWER generation Reference & performance data PRODUCTS H TPD 98,5% conc. STEAM DATA High pressure steam (superheated) Kg/h 42 bar (g) 400 C ELECTRIC POWER 5,5 MWh/h PRODUCTION SO 3 CONVERSION 99,799.75% EMISSIONS DATA : PPM vol. SO 3 + acid mist: 80 mg/nm 3 INVESTMENT FACTOR 32 CASE STUDY 4: EMISSIONS MINIMIZATION Page 209

10 The Southern African Institute of Mining and Metallurgy CASE STUDY 4: EMISSIONS MINIMIZATION Reference & performance data PRODUCTS H TPD 98,5% conc. STEAM DATA medium pressure steam (slightly superheated) kg/h 25 bar (g) 245 C SO 3 CONVERSION 99,90% EMISSIONS DATA : 00 PPM vol. SO 3 + acid mist: 35 mg/nm 3 INVESTMENT FACTOR 0 Page 20

11 The Southern African Institute of Mining and Metallurgy The Author Maurizio VERRI, Desmet Ballestra SpA (Italy), Deputy Process Manager 983 : MS degree in Chemical Engineering 984 : Started working as Process Engineer for Offshore Installation for TECNOMARE S.p.A. 988 : Joined Ballestra S.p.A Process Engineer for Sulfonation, Spray Drying and Detergent Plants 992 : Deputy Process Manager 2002 : Technical Coordinator of Chemical Plants Division (DIC) of DBI. Technologies covered: Dodecyl Benzene Production (UOP Licence) Sulfuric Acid Plants (MECS Licence and Inhouse technology for small plants). Fertilizers (SSP / NPK production) Zeolite 4A (detergent grade) Sodium Silicate Working experience includes Process Design, Commissioning and Startup for all the technologies outlined. Page 2

12 The Southern African Institute of Mining and Metallurgy Page 22