commercialization of mecs’ solvrtm regenerative so technology
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Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Commercialization of MECS’
SolvRTM Regenerative SO2 Technology
Presented by: Steve Puricelli
MECS, Inc
USA
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Agenda
• Review of the SolvRTM System
• Evaluation and Selection of SO2 Reduction Technologies
• SolvRTM Key Advantages
• SolvRTM Performance
• Southern States Startup Issues
• Design Improvements
• SolvRTM Opportunities
2
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Safety Contact
SO2 Toxicity
Odor threshold: 0.5 ppm
OSHA Permissible Exposure Limit (PEL) = 5 ppm (weighted, 8 hr avg)
Slight irritation to eyes and throat = 10 ppm
Coughing and eye irritation = 20 ppm
Strong irritation =30 ppm
NIOSH Immediately Dangerous to Life and Health (IDLH) = 100 ppm
Death in a few minutes = 600 to 800 ppm
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
4
Édouard-Léon Scott de Martinville
Born: 25 April 1817
Died: 26 April 1879 (aged 62)
Invented and patented in 1857 the
earliest known sound recording
device, the phonautograph
Hoped to create a form of stenography
that could record the whole of a
conversation without any omissions
Failed to invent a playback mechanism
Phonograph invented by Edison in
1877 revolutionized recording
Phonautograph recordings were
deciphered and played back in 2008
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvRTM Technology
What is SolvRTM?
• A regenerative SO2 recovery system
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvR™ Process
6
Absorber
DynaWave™
Hydrator
Lean/Rich Heat
Exchanger
Stripping
Column
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Why is SolvRTM Different?
• Environmentally friendly, high capacity solvent
• Readily available precursors
• Used in food processing
• Capable of high removal efficiencies
• Generates minimal byproduct
• Lower CAPEX
• Utilizes FRP and Low alloy materials
• Smaller plot space
• Lower OPEX
• Reduced energy usage
– Regeneration done at atmospheric pressure
– Uses low pressure steam
– Energy recovery system further reduces steam usage
• Minimal solvent losses
– Robust and stable solvent
SO2
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Typical Plant Layout
8
Absorber
SO2 Recovery
Column
Solvent Tank
Rectifier Column
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Evaluation and Selection of
SO2 Reduction Technologies
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Comparison of SO2 Abatement Technologies
10
Double Abs Caustic scrub Peroxide scrub NaHSO3 SolvRTM Technology
Equipment HIP
CIP
Converter
FAT
Pumptank
Cooler
Booster fan
Absorber
Oxidizing air
Absorber Absorber
Tail gas scrub
Absorber
Stripper
Interchanger
Reboiler
Trim Cooler
Solvent purification
SO2 Compressor
Effluent None 20 wt% Na2SO4 40% H2SO4 40 wt% NaHSO3 SO2 + Na2SO4
Raw Materials None NaOH @$450/ton H2O2 @ $600/ton NaOH @$450/ton Solvent + NaOH
LP steam
ΔP 80 InWC
(20 kPa)
6-8 InWC
(1.5-2kPa)
6 + 4 InWC
(1.5 + 1 kPa)
8-10 InWC
(2-2.5 kPa)
6 + 2 InWC
(1.5+0.5 kPa)
Attainable Emissions 100 ppm 5 ppm 100 ppm 100 ppm 20 ppm
ReactionsSO2 + ½ O2-> SO2 SO2 + 2 NaOH -> Na2SO3 + H20
Na2SO3 + 1/2 O2 -> Na2SO4
SO2 + H2O2 -> H2SO4 SO2 + NaOH -> NaHSO3 Na2-R + SO2 <-> Na2SO3 + R
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Capital, Operation and Maintenance
Double Absorption
RetrofitCaustic
Scrubber
Hydrogen Peroxide Scrubber
SolvRTM
Technology
Relative Capital Installed Costs 100 25 40 75
Relative Operating Expenses 0.2 0.7 1 0.1*
Relative Maintenance Expenses(As a percentage of capital) 3 0.2 0.4 0.4
* Excludes steam cost
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Net Present Value
Taking Acid Production Recovered into Account
Dual Absorbtion
RetrofitCaustic
Scrubber
Hydrogen Peroxide Scrubber
SolvR Scrubber
Relative Net Present Value (78) (100) (62) (50)
• Using dual absorbtion, hydrogen peroxide scrubbing and
SolvR scrubbing, the sulfur molecule (SO2) is
converted/recovered and used to make product acid.
• When using caustic scrubbing, the sulfur molecule leaves with
the effluent.
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Other ConsiderationsSO2 capability, Reagent and Effluent Stream
Double AbsCaustic
Scrubber
Peroxide
Scrubber
SolvR
Scrubber
Outlet SO2 (ppm) 100 5 20 10
Reagent n/a NaOH H2O2 NaOH(pH control)
New Effluent Stream None Yes Maybe Small
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvRTM Key Advantages
• Lowest overall cost of ownership
• Recovers SO2 as product acid
• Capable of low SO2 emissions
• No byproducts to market
• Uses waste energy
• Robust process
• Small footprint
• Modular design
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvRTM Performance
At
Southern States Chemicals
• SO2 emissions
• Steam consumption
• Sulfate generation and solvent losses
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Actual vs. Capability
• Stack emissions controlled at 700 ppm
• Performance limited by solvent flow over absorber
• SO2 in lean solvent measured at 30 - 70 ppm
• Predicted stack emissions with higher absorber solvent flow
• <10 ppm
16
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Steam Consumption
(Based on a fixed flow of steam to the stripper)
• Estimated steam flow = 500 lb/hr
• SO2 processed = 1,200 ppm -> 700 ppm
• Lb steam / Lb SO2 recovered = 9
• Extrapolated to <10 ppm conditions
• Lb steam / Lb SO2 recovered = 3.5
18
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Sulfate Generation
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SO2
Sulfate Generation
• Prior to chimney tray failure
• 0.5% of throughput was converted to Na2SO4
– (Na2-R + SO4 -> Na2SO4 + R)
• After rerouting of SO2 laden saturator stream to stripping tower
• 50% increase in Na2SO4 production
• Minimal stack losses due to extremely low volatility
SO2
SO2
O2 O2
O2
H2SO4H2SO4
Na2SO4
or
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Solvent Performance
21
• Controlling sulfate
concentration in the
solvent is important
• Some accumulation of
chlorides and metal ions
in solvent occurred, but
no affect on performance
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvRTM Startup Issues
• Chimney Tray Leakage
• Solvent in Steam Lines
• Stack Opacity
• Mist Generation
• SO3 Slip
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Chimney Tray Leak
23
Solvent mixed with quench water
• Dilution water contaminated
• Reduced steam consumption to
achieve neutral water balance
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Chimney Tray Leak
24
Possible Causes:• Peripheral seal leak
• Damaged riser
• Overflow
Temporary Solution• Discontinued use as dilution water
• Used live steam only to replace
evaporation losses
• Controlled level by routing saturator
effluent to the solvent tank
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Solvent in Stripping Steam Line
25
SLOT LENGTH
DISTRIBUTOR LENGTH (INSIDE
VESSEL)
DIS
TR
IBU
TO
R
DIA
ME
TE
R
SANDWICH ENDPLATE
BETWEEN FLANGES
DISTRIBUTOR
(316L STAINLESS STEEL SCH 10 PIPE)
NOZZLE
PROJECTION VESSEL WALL
Return flow from the
reboiler was entering the
LP steam inlet nozzle.
Corrected by use of a
gas injection nozzle
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Stack Opacity After Initial Operation
26
Possible Causes:
• Mist
• SO3 slip
Plant #2
with SolvR
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Stack After Adjusting Absorbing Tower Parameters
27
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Design Improvements
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Eliminate the SO2 Blower
29
Operating the
stripper under
pressure can
eliminate the
SO2 blower
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Eliminate Stages in the Rectification Column
30
Interim operation showed
that water saturated with
SO2 did not have a
significant impact on
stripper performance.
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Practical Application of SolvRTM
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
SolvR™ Generates New Opportunities
SolvR™
TechnologySolvR™ after Claus
Hybrid Plants
New Low Capital
Sulfuric Acid
Process
Gas Plants
High Energy RecoverySulfuric Acid Plants
Innovating our core technologies
Improving adjacent technologies
RefineriesLow Capital Sulfuric
Acid Plants
Debottlenecking of
existing Sulfuric
Acid Plants
New High Energy
Recovery Acid
Process Maxene™
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
• Advantages
• Low capital investment
• Low SO2 emissions
• Disadvantages
• Lower specific steam production
33
SolvRTM Sulfuric Acid Debottlenecking
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
34
12.2%
1,500 ppm
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Hybrid Sulfuric Acid Plants
(High Energy Recovery)
35
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
PRODUCT
ACID
AIR
THIS DRAWING IS THE PROPERTY OF
MECS, INC.
INFORMATION AND KNOW HOW HEREON ARE CONFIDENTIAL
AND MAY NOT BE USED, REPRODUCED, OR REVEALED TO
OTHERS EXCEPT IN ACCORD WITH CONTRACT OR OTHER
WRITTEN PERMISSION OF MECS INC. ANY REPRODUCTIONS IN
WHOLE OR IN PART INCLUDING SHOP DRAWINGS SHALL BEAR
OR REFER TO THIS STAMP.
DEMIN
H2O
SULFUR
STEAM
INJECTION
VESSEL
INLET
AIR
FILTER
DRYING TOWER
MESH PAD
DRYING
TOWER
MAIN
COMPRESSOR
HEAT
RECOVERY
TOWER
LP
STEAM
IMPORT
COMBINATION PUMP TANK
HRS
HEATER
HRS
PREHEATER
HRS
DILUTER
COMMON ACID
COOLER
PRODUCT ACID
COOLER
HRS
DILUTION
WATER
BFW BFW
BFW BFW
HEAT
RECOVERY
TOWER MIST
ELIMINATORS
1 2
3
12
8
SULFUR BURNER
9
13
50
20
19
15
81
51
61
69
72
6667
80
52
5453
55
56
70
68
71
57
SUPERHEATER
SH0A
COMMON
ACID
PUMP
HRS ACID
CIRCULATING
PUMP
WASTE HEAT
BOILER #2
WHB4
58
64
MECS, INC.
ST. LOUIS, MISSOURI
750 MTPD , 3 PASS SINGLE ABS,
HRS FOLLOWED BY SURE SCRUBBER
05X178
REVMEN
CHECKED
DRAWN RCF
BY
31 AUG
11
DATE APP'D DATE
HRS HEATER
ECHRSA
119
17
WASTE HEAT
BOILER #1
WHB0
HRS BOILER
62
18
65
CONVERTER
4
3
2
1
SUPERHEATER
SH1B
10
11
ECONOMIZER
EC2C
ECONOMIZER
EC3B
14
16
7
4
60
TO
PEROXIDE
SCRUBBER
59
63
AIR
HEATER
5
Hybrid Sulfuric Acid Flow Scheme
To
SOLVR
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Relative Overall Order of Magnitude Savings
2,400 MTPD
Conventional Conventional SolvR + NPV Δ
with HRS HRS Conventional
Overall TIC 1.0 1.2 1.1 ($8 MM)
Parasitic power (MW) 4.3 4.3 3.5 $3.5 MM
Power generation (MW) 33 39 42 $38 MM
SolvR steam (MW) (1.6) ($7 MM)
Total NPV $26.5 MM
Notes: 1. Discount rate = 9% for 30 years
2. Electricity = $$0.05/kWH
3. LP steam = $8/MT
4. SolvR steam = 16 T/hr at 5 T/T
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Claus + SolvRTM
38
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Advantages of SolvR in Claus Tail Gas Applications
No reducing gas
generator required
No reactor
required
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
40
Future Claus Configuration Using SolvRTM
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
Original Edison Tin Foil
PhonographPhonautograph
Southern States Chemicals
SolvRTM Unit
Copyright © 2012 MECS. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles
of science™, and MECS® are registered trademarks or trademarks of DuPont or its affiliates.
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