the bayqik® technology - cobras 2015

Introduction and typical applicationsThe BAYQIK® Technology

Torsten Weber

Forward-Looking StatementsThis presentation may contain forward-looking statements based on current assumptions and forecasts made by Bayer Group or subgroup management.

Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Bayer’s public reports which are available on the Bayer website at www.bayer.com.

The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

BAYQIK®

Sulfuric Acid Technology

Introduction of Bayer Technology Services GmbH (BTS)

Introduction of the BAYQIK® Technology

Examples of applications

SulfO2Bay

Summary

• 118,900 employees

• Full year sales: EUR 42.2 billion

• 302 subsidiaries

• R&D expenditures: EUR 3.6 billion

As of December 31, 2014

Bayer Group

Bayer Technology Services – A Leading Technology CompanyTechnology solutions, services, know-how – our core competencies for your success.

Competent service partner for value-generating, holistic solutions along the entire life cycle of chemical/pharmaceutical products, processes and plants – we initiate, implement and support technological innovations over the long term from development through engineering and construction to process optimization. Complete technology packages go beyond our spectrum of services.

Technology Development

Project Management & Engineering

Operation Support & Safety

Bayer Technology Services –Full Year 2014

Employees 2,300*

Full Year Sales EUR 480 millionGlobal network 21 offices in 10 countries

* as permanent or fixed-term contracts, in FTE

Global Network & Local Offices

Leverkusen (global headquarters)Bergkamen, Berlin, Dormagen,

Krefeld, Wuppertal, WendelsheimMexico-City

Berkeley

Baytown

Pittsburgh

New Martinsville

Belford Roxo

Antwerp

Mumbai

Singapore

ShanghaiBeijing

Moscow

Saskatoon

Vapi

Sulfuric Acid Technology competence of BAYER

Why choosing BAYER as Sulfuric Acid Technology Provider?

Why choosing BAYER as Sulfuric Acid Technology Provider?

• Deep knowledge in Sulfuric Acid Technology with more than 100 years of experience• Bayer has a long track record as innovator in Sulfuric Acid Technology• Inventor of the Double Absorption Process, Fluidized Bed Technology and BAYQIK®

• Strong Materials Technology competence in Sulfuric Acid Applications• Unique combination of experience in design and operation of Sulfuric Acid Plants• Strong experience in in chemical and petrochemical processes• Familiar with safety procedures and standards being mandatory in the chemical and

petrochemical industry• Provision of customized added value solutions• High reputation

BAYQIK®

Technology

Superior process to treat

gases from any source ofSO2 at any concentration

Challenges in SO2-Gas ProcessingInitiator for Invetion – Primary off gas treatment from Nonferrous Metal Production

RoastingSmelting

Converting

Heat RemovalSteam generation Dust removal

QuenchingScrubbingSulfidic ore

Air

SteamMetal Slag

Wet-ESPHg-Removal

ExistingSulfuric acid

plant

Stack

Sulphuric Acid

High strength SO2-process gasOxygen enriched air

Cd-, As-RemovalGas drying

Bottleneck

Equilibrium CurveSO2-c

onve

rsio

n [%

]

bed exit temperature [°C]400 450 500 550 600 650 700 750

10

20

30

40

50

60

70

80

90

100

0

Operation temperature of catalyst

Catalytic Processes using V2O5Adiabatic SO2-conversion

Bed 2

Bed 1

Bed 3

Adiabatic Process of SO2-conversion

Equilibrium CurveSO2-c

onve

rsio

n [%

]


10

20

30

40

50

60

70

80

90

100

0


Limits of the adiabatic process

Catalytic Processes using V2O5Adiabatic SO2-conversion (Limits)

14% SO2

16% SO2

18% SO2

12% SO2

Page 14

SO2-concentrations above 13 Vol.% lead to temperatures that exceed the thermal stability limits of the catalyst

SO2-c

onve

rsio

n [%

]


10

20

30

40

50

60

70

80

90

100

0


Catalytic Processes using V2O5Isothermal SO2-conversion

No limitation in

SO2 concentration

Continuous removal of the heat of reaction to keep the temperature within the operation limits of the catalyst at any time

Isothermal Processing

Equilibrium Curve

What is BAYQIK®?

• BAYQIK is a Technology for the treatment of SO2 containing process gases from any sources with the intention to produce sulfuric acid, Oleum or SO3 (gaseous or liquid).

• Basic idea is an isothermal tubular converter for the conversion of SO2 to SO3.

• Due to the unique design of converter and process the limits of existing dry and wet sulfuric acid production technologies are eliminated.

• Standard commercially available Vanadium Pentoxide or cesium promoted Vanadium Pentoxide Catalyst is used in the process.

Modular SO2-converter

Bringing the Converter…

…into the Heat Exchanger!

BAYQIK® – Converter

• Tubes are filled with conventional V2O5-catalyst

• Reaction SO2 + ½ O2 SO3 takes place inside the tubes

• Heat of reaction is removed continuously by cooling medium

Cooling media In

Process gas

Cooling medium

Cooling medium

Process gasProcess gas

Temperature Profile

Tube length x

Tem

pera

ture

t

Hot Spot with maximum temperature difference

Temperature curve of process gas

Temperature curve of cooling medium

Temperature Process gas outlet

Temperatur Process gas inlet

Xm

tmax

Temperature Cooling medium outlet

Temperature Cooling medium inlet

Catalyst filling procedure

Funnel with orifice

Support for catalyst

• Choosing right catalyst type (clients preferred catalyst possible)

• Installation of catalyst support

• Filling via orifice with specified diameter

• Pressure drop measurements

• Adjusting and documentation of pressure drop

• Discharge of catalyst from the bottom by removing support or

• from top with pressurized air lance and vacuum device

BAYQIK®

GAS / GAS –HX

Start-upHeater

COOLING AIRBLOWER

HEAT REMOVALBAYQIK® CONVERTER

RICH SO2

PROCESS GAS

LEAN SO2

PROCESS GAS

BAYQIK® Add-on configuration

Example – Primary off gas treatment from Nonferrous Metal ProductionInstallation of BAYQIK® eliminates bottlenecks in existing sulphuric acid plants and improves SO2-capture

RoastingSmelting

Converting

Heat RemovalSteam generation Dust removal

QuenchingScrubbingSulfidic ore

Air

SteamMetal Slag

Wet-ESPHg-Removal

ExistingSulfuric acid

plant

Stack

Sulphuric Acid

High strength SO2-process gasOxygen enriched air

Cd-, As-RemovalGas drying

Bottleneck

BAYQIK®

HighSO2-concentration

LowSO2-concentration

SO2-concentrationat Design value

of Sulfuric Acid plant

BAYQIK® Add-onTypical Plant Configuration

Start-upheater

COOLING AIRBLOWERHEAT REMOVALBAYQIK® CONVERTER

GAS-GASHEAT EXCHANGER

SO2-BLOWER

BAYQIK®

ADD-ON PLANT

DRYINGTOWER

MAINBLOWER

HX III HX I HX II INTERMEDIATEABSORPTION

FINALABSORPTION STACK

AMBIENTAIR

HX IV

WHB

Bed 1

Bed 2

Bed 3

Bed 4

INTERMEDIATEABSORPTION

H2SO4

EXISTING DOUBLEABSORPTION PLANT

BAYQIK® Add-onControl Mode

HX Converter Pass 1

BAYQIK

HX Absorber

QIC

M

SO2

SO2 > 8 Vol%

n

t

Blower Speed

Volume FlowV

t

c

t

SO2 Concentration

Set Point = 8 Vol% SO2

BAYQIK® Add-onControl Mode

HX Converter Pass 1

BAYQIK

HX Absorber

QIC

M

SO2

Set Point = 8 Vol% SO2

c

t

SO2 Concentration

n

t

Blower Speed

V

t

Volume Flow

c

t

8 Vol%c

t

BAYQIK® Add-onProject Example

Natural gas

Ambient air

Combustion airblower

Start-upheater

Cooling airblowerHeat removalBAYQIK® Converter

Gas-GasHeat Exchanger

SO2-Blower

DryingMain

Blower HX HX HXSteamsuperheater

IntermediateAbsorber

FinalAbsorber Stack

BAYQIK®

Add-on Unit

Ambientair

SO2-Gas

HX

IntermediateAbsorber

Steam 45 bar

Water injection

QSO2

BAYQIK® Add-onProject Example

Customer: Berzelius Stolberg, GermanySO2-Gas source: Metallurgical Plant

SO2-concentration: 18 Vol% (peaking up to 23 Vol%)

Total Capacity: 450 metric tons H2SO4 per day

BAYQIK® Add-onDealing with fluctuating process conditions

DATA FROM PROCESS CONTROL SYSTEM

Extended Catalyst Lifetime SO2 inlet concentration

18,2 Vol% SO2 outlet concentration 3,0 Vol%

Temperature curve over tube length

CAPEX Comparison

BAYQIK Technology shows lowest CAPEX Cost compared to alternative conventional options

Cooling airblower

BAYQIK®

ConverterHX

Blower

Pass 5

Pass 4

Pass 3

Pass 1

Pass 2

BAYQIK Add-on

WHB

Gas fromS-Burner

Superheater

SO2-conc. ≤ 10 Vol%

EconomizerInterpass-HX

Gas toIAT

Gas fomIAT

Economizer

Gas toFAT

BAYQIK® Add-on configurationElemental Sulfur Burning Plant (1)

30

WHB,Superheater. or Eco

Existing Plant

Cooling airblower

BAYQIK®

Converter

Pass 5

Pass 4

Pass 3

Pass 1

Pass 2


Existing Plant

WHB

Gas fromS-Burner

Superheater

Flowrate reduced by ~ 25%


Gas toIAT

Gas fomIAT

Economizer

Gas toFAT



31

BAYQIK Add-on

Cooling airblower

BAYQIK®

ConverterHX

Blower

Pass 5

Pass 4

Pass 3

Pass 1

Pass 2

AbsorptionTower

Existing Plant

WHB

Gas fromS-Burner

Superheater

SO2-conc. ≤ 10 Vol%


Gas toIAT

Gas fomIAT

Economizer

Gas toFAT


Sulfuric Acid

Make-upwater

32

Flow reduced by 7%


BAYQIK Add-on

Regenerable SO2 Scrubbing + BAYQIK® Plant configuration

DryingTower

HX AbsorbtionTower

Stack

Ambient Air(or Oxygen)

RegenerableSO2 Scrubbing

SO2 - Gas

Clean GasWet SO2-Gas (95 – 98 Vol% of SO2)

Start-upheater

Cooling airblower

EnergyRecoveryBAYQIK® Converter

H2SO4

98,5%

DeminWater

SULFO2BAY®

Technology

SulfO2Bay®

HP Steam 47 t/h

TGSV=200Nm3/h

Sulphur 10t/hOxygen

BAYQIK®

Absorber

Burner

Boiler

HTSCoolingsystem

LP steam 9 t/h

Sulfuric Acid 31 t/h

Overall Conversion99,99%

SummaryBAYQIK® – Process

No limitation in SO2-concentration

Has an operating range from 0 – 100% load Deals with fluctuating process conditions of input streams Low CAPEX and OPEX Improves on-stream time of upstream processes Easy implementation / Short time for Tie in Operates fully automated Has lowest catalyst demand & increased catalyst lifetime Is proven technology, safe and reliable

Thank you!