critical aspects in the definition of the … and sulphuric acid conference 2009 ... h2so4...

The Southern African Institute of Mining and Metallurgy

Sulphur and Sulphuric Acid Conference 2009

M Verri

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Page 201

CRITICAL ASPECTS IN THE DEFINITION CRITICAL ASPECTS IN THE DEFINITION

OF THE OPTIMUM CONFIGURATION OF A OF THE OPTIMUM CONFIGURATION OF A

SULPHUR BURNING PLANTSULPHUR BURNING PLANT

SUN CITY SUN CITY –– SOUTH AFRICASOUTH AFRICA

May 4May 4thth -- 66thth,, 20092009

BASE DECISIONS FOR THE DEFINITION BASE DECISIONS FOR THE DEFINITION

OF THE CONFIGURATION OF A SULPHUR OF THE CONFIGURATION OF A SULPHUR

BURNING PLANTBURNING PLANT

TYPE OF RAW MATERIALTYPE OF RAW MATERIAL

PRODUCTSPRODUCTS CO CO -- PRODUCTSPRODUCTS

EMISSSIONSEMISSSIONS



M Verri

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02

TYPE OF RAW MATERIALTYPE OF RAW MATERIAL

PRODUCTSPRODUCTS

SULPHUR LIQUID

SOLID

WHICH ?

HOW MUCH ?

QUALITY ?

S.A. 92-99,5% wt

OLEUM 20-25% free SO3

SO2

GASEOUS (CONC.?)

LIQUID

SO3 GASEOUS (CONC.?)

LIQUID

OTHER

SPECIFICATIONS

COCO--PRODUCTS PRODUCTS

STEAM & ELECTRIC POWER REQUIREMENTSSTEAM & ELECTRIC POWER REQUIREMENTS

SUPERHEATED

STEAM

P > 40 barg

T >370 °C

SATURATED OR

SLIGHTLY

SUPERHEATED

Condensing

Turbine

Condensate

L.P. Steam bleeding for site users

(up to 25% of the steam fed flow)

M.P./L.P. Steam for site usersBack

Pressure

Turbine

Second

turbine Condensate

M.P./L.P. Steam for site users

E.P.

E.P.



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Page 203

COCO--PRODUCTS PRODUCTS

STEAM & CONDENSATE CIRCUIT DEFINITIONSTEAM & CONDENSATE CIRCUIT DEFINITION

H2SO4 PLANT STEAM USER

The user does not

consumes all the

steam produced

and/or does not

g i v e b a c k

c o n d e n s a t e

SteamExtra

Steam

Condensate

S T E A M

C O N D E N S E R

I N S T A L L A T IO N

or

RELEASE OF THE

EXCESS STEAM TO

THE ATMOPSHERE

AND SIGNIFICANT

OV E RDE S IGN OF

THE DEMI WATER

UNIT (UP TO 5 TIME

L A R G E R )

T h e u s e r

consumes all the

steam fed and

g i v e s b a c k

c o n d e n s a t e

H2SO4 PLANT

Condensate return

STEAM USER

Steam

PURGE / LOSSES

EMISSIONSEMISSIONS

DCDA

WITHOUT SCRUBBER

DCDA or SCSA

WITH SCRUBBER

STANDARD

CONFIGURATION

EMISSION

MINIMIZATION

SO2: 350-417 PPM

Acid mist + SO3: 80 mg/Nm3

SO2: down to 100 PPM

Acid mist + SO3: up to 30 mg/Nm3

H2O

2

NaOH

Others (Limestone)



M Verri

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Page 204

BASE CONFIGURATIONBASE CONFIGURATION

Sulphur

burningAir drying

W H R B +

ECONOMIZERS

4° pass

3° pass

2° pass

1° pass

CIP/HIP SO3 absorption &

acid circulation

Deareator

AIR SULPHUR DEMI-WATER MAKE-UP PLUS

CONDENSATE RECOVERY (IF ANY)

M.P. STEAM H2SO

498,5%

BASE CONFIGURATIONBASE CONFIGURATION

DEAREATORAIR

DRYING

ACID

CIRCULATION

CONVERSION

CIP/HIP

WHRB + ECO

SULPHUR

BURNING

The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.

L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.

Desmet Ballestra s.p.a.

JOB

Commessa

MILANO - Italy

DRAWING Nr. / Disegno Nr.

We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.

-

CUSTOMER Nr. / Nr. Cliente

PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

SHEET REVISION

Revisione Foglio

SCALE

Scala

SECTION

Sezione

1 / 1

1

-

PRELIMINARY ISSUE0 Frontino 17/02/09

REVISION

Revisione

REVISION HISTORY

Storia delle revisioni

DRAWN

Autore

DATE

Data

Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.

-

-

H2SO4 + OLEUM

-----------

-



M Verri

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Page 205

BASE CONFIGURATION BASE CONFIGURATION

Reference & Performance dataReference & Performance data

PRODUCTS H2SO

4500 TPD 98,5% conc.

STEAM DATA medium pressure steam

(slightly superheated)

30.800 Kg/h 25 bar (g)

245°C

SO2-SO

3CONVERSION 99,7-99.75%

EMISSIONS DATA SO2: 417-350 PPM vol.

SO3

+ acid mist: 80 mg/Nm3 (as H2SO

4)

INVESTMENT FACTOR * 100

* For process plant engineering and procurement cost

CASE STUDY 1: CASE STUDY 1:

HH22SOSO44 concentration/dilution & OLEUM productionconcentration/dilution & OLEUM production




JOB

Commessa

MILANO - Italy



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PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

SHEET REVISION

Revisione Foglio

SCALE

Scala

SECTION

Sezione

1 / 1

1

-


REVISION

Revisione

REVISION HISTORY


DRAWN

Autore

DATE

Data


-

-

H2SO4 + OLEUM

-----------

-



M Verri

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Page 206


H2SO4 concentration/dilution & OLEUM production H2SO4 concentration/dilution & OLEUM production

Reference & performance dataReference & performance data

PRODUCTS H2SO

4400 TPD

(as 100% H2SO

4)

98,5 %

OLEUM 100 TPD

(as 100% H2SO

4)

105,5% (25% free SO3)



30.400 Kg/h 25 bar (g)

245°C

SO2-SO



SO3

+ acid mist: 80 mg/Nm3 (as H2SO

4)

INVESTMENT FACTOR 104


H2SO4 and SO2 gas productionH2SO4 and SO2 gas production




JOB

Commessa

MILANO - Italy



-


PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

SHEET REVISION

Revisione Foglio

SCALE

Scala

SECTION

Sezione

1 / 2

1

-

PRELIMINARY ISSUE0 Giacalone 17/02/09

REVISION

Revisione

REVISION HISTORY


DRAWN

Autore

DATE

Data


-

-

H2SO4 + SO2 GAS

-----------

-



M Verri

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Page 207


H2SO4 and SO2 gas productionH2SO4 and SO2 gas production

Giacalone

H2SO4 + SO2 GAS

The maste r v ersion of th is do cument is stored as a d ig ita l file in a database. A pprov al process is d ig ita lly managed and no signa ture is v isible on the document.

L 'orig ina le del p rese nte documento risied e in un database d ig ita le .Il pro cesso d i approv az ione è gestito v ia softw are e le firme non sono v isibili su l documento.


JOB

Commessa

M ILANO - Italy

D RA WING Nr. / D isegno Nr.

We rese rv e the o wnership under the law of th is drawing with prohib itio n o f ev en partia l reproduction an d to make it kn own it th ird persons w ithout our written authorization.

-

C U STOM ER N r. / Nr. Cliente

PLANT

Impianto

TITLE

Tito lo

S HE ET

Foglio

S HE ET R EV ISION

R ev isione Foglio

S CA LE

S cala

S EC TION

S ezione

2 / 2

1

-

PRELIMINARY ISSUE0 17/02/09

RE VIS ION

R ev isione

REV IS ION HISTORY

S toria delle rev ision i

DRA WN

A utore

D ATE

Data

C i riserv iamo la proprietà a termin i d i legge d i questo d iseg no con d iv ie to d i riprodurlo anche in parte o di re nde rlo no to a terz i senza nostra autorizzaz ione scritta .

-

-

-----------

-


HH22SOSO44 and SOand SO

22 gas production gas production


PRODUCTS H2SO4 350 TPD

(as 100% H2SO4)

98,5% conc.

SO2 GAS 100 TPD

(as 100% SO2)

10% conc.

2 bar (g) ; 100°C



29.000 kg/h 25 bar (g)

245°C

SO2-SO

3 CONVERSION 99,7%


SO3

+ acid mist: 80 mg/Nm3




M Verri

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Page 208


HIGH PRESSURE STEAM configuration for ELECTRIC HIGH PRESSURE STEAM configuration for ELECTRIC

POWER generation POWER generation




JOB

Commessa

MILANO - Italy



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PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

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Revisione Foglio

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DRAWN

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Data


-

-

HIGH PRE4SSURE STEAM

-----------

-(ELECTRIC POWER PRODUCTION)




CONDENSER

TURBINE

SUPERHEATED STEAM FROM H2SO4 BOILER 42 Barg / 400°C

H2O (LIQUID) 90°C

0.0 Kg/h

ELECTRIC POWER

FOR H2SO4

PLANT OPERATION




JOB

Commessa

MILANO - Italy



-


PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

SHEET REVISION

Revisione Foglio

SCALE

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SECTION

Sezione

2 / 2

1

-


REVISION

Revisione

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DRAWN

Autore

DATE

Data


-

-

HIGH PRE4SSURE STEAM

-----------

-(ELECTRIC POWER PRODUCTION)



M Verri

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Page 209





PRODUCTS H2SO

4500 TPD 98,5% conc.

STEAM DATA High pressure steam

(superheated)

27.000 Kg/h 42 bar (g)

400°C

ELECTRIC POWER

PRODUCTION

5,5 MWh/h

SO2-SO



SO3




EMISSIONS MINIMIZATIONEMISSIONS MINIMIZATION




JOB

Commessa

MILANO - Italy



-


PLANT

Impianto

TITLE

Titolo

SHEET

Foglio

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Revisione Foglio

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SECTION

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1 / 1

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DRAWN

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-

-

EMISSION MINIMIZATION

-----------

-



M Verri

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Page 210


EMISSIONS MINIMIZATION EMISSIONS MINIMIZATION


PRODUCTS H2SO

4500 TPD 98,5% conc.



30.600 kg/h 25 bar (g)

245°C

SO2-SO

3CONVERSION 99,90%

EMISSIONS DATA SO2: 100 PPM vol.

SO3





M Verri

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Page 211

The Author

Maurizio VERRI, Desmet Ballestra SpA (Italy), Deputy Process Manager

1983 : MS degree in Chemical Engineering

1984 : Started working as Process Engineer for Offshore Installation for TECNOMARE S.p.A.

1988 : Joined Ballestra S.p.A – Process Engineer for Sulfonation, Spray Drying and Detergent

Plants

1992 : 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 In-house technology for small plants).

- Fertilizers (SSP / NPK production)

- Zeolite 4A (detergent grade)

- Sodium Silicate

Working experience includes Process Design, Commissioning and Start-up for all the

technologies outlined.



M Verri

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Page 212

critical aspects in the definition of the … and sulphuric acid conference 2009 ... h2so4...

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