reduce emission and increase production with new …reduce emission and increase production with new...

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Reduce emission and increase productionwith new LEAP5™ catalyst

1

Presented by Eliana Revelli

2

Air pollutionTighter regulation is expected in the future

Beijing

Sao Paulo

Source:GB269332, ELVIK BREF 2007, EPA

New Delhi

London

Los Angeles

Mexico City

3

Reduction is a worldwide trend

SO2 emission

16%Further reductions

during start-up

37%Further reductions during

daily operation

47%No further reductions and other

Future regulations on SO2 emission+ 50%

Expect further reduction

Perú

Current: 200-400 ppm

Brazil

Current: 400 ppm

Chile

Current: 400 – 600 ppm

4

Common ways to reduce your SO2 emissionWithout reducing plant output

Cs catalyst in last bed

+ Easy installation

+ Normal operation & handling

+ Cleaner start-up

+ Slightly higher production

÷ Extra CAPEX

• May require lower inlet temperature

Adding an extra bed

+ Normal operation and handling

+ Similar start-up

+ Slightly higher production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra CAPEX and extra OPEX

Cut capacity

+ No installation

+ No requirements

+ Normal operation and handling

+ Similar start-up

÷ Lower production

Tail-gas scrubber

+ Cleaner start-up

+ Normal production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra handling of scrubber products

÷ Extra CAPEX and extra OPEX

61%Catalyst Solution

26%Scrubber solution

13%Revamp or

replace de plant

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The sulphuric acid catalystSupported liquid phase

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The sulphuric acid catalystSupported liquid phase

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Ambient temperature

Active phase is present as crystals

The sulphuric acid catalystSupported liquid phase

Operating conditions

Vanadium is dissolved in a pyrosulphate melt

The active phase is a liquid

8

Mechanism for SO2 oxidationVanadium (V) makes the catalyst active

(VVO)2O(SO4)4

(VVO)2O(SO4)4O2

(VVO)2O(SO4)4O

(VVO)2O(SO4)4SO3

-4

-4 -4

-4

SO3

SO2

SO2

SO3

O2

2VIVO(SO4)2 2VIVOSO4 (s)

2SO4SO2 SO3-2Main reaction

mechanism

Equilibrium reaction to VIV

9

Vanadium (V) contentTraditional catalyst technologies

0

10

20

30

40

50

60

70

80

380 390 400 410 420 430 440

Re

lati

ve

co

nte

nt

of

va

na

diu

m (

V)

[%]

Temperature [°C]Conditions: 10% SO2, 10% O2, high conversion

Traditional catalyst technologies

VK-711 LEAP5™

Why not utilize this potential?

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Nano-scale Vanadium melt dynamicsTEM in situ recordings - Physical properties analyzed

F. Cavalca, P. Beato, J. Hyldtoft, K. Christensen, and S. Helveg (2017). Phys. Chem. C, 121, 3350−3364.

Vanadium (V)

Vanadium (IV)

Vanadium (IV)

Through optimizing the carrier structure and formulation, the Vanadium (V) content is

maximised.

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New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

SO2 feed

SO3 rich gas

VK48

VK38

VK69

VK38

Equilibrium curve before intermediate

absorption

0

2

4

6

8

10

SO

2co

nce

ntr

ati

on

[%

]

Equilibrium curve after intermediate

absorption

350 400 450 500 550 600 650

Temperature [°C]

Bed 1

Bed 2

Bed 3

Bed 4

Inte

rme

dia

te

ab

sorp

tio

n

12

0

0.5

1.0

1.5

2.0

SO

2co

nce

ntr

ati

on

[%

]

380 400 420 440 460 480 500

Temperature [°C]

Bed 3 Equilibrium curve before intermediate

absorptionBed 3

Equilibrium curve after intermediate

absorptionBed 4Bed 4

SO2 feed

SO3 rich gas

VK48

VK38

VK69

VK38

Inte

rme

dia

te

ab

sorp

tio

n

+100% activity?

New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

13

0

50

100

150

200

SO

2co

nce

ntr

ati

on

[p

pm

]

380 390 400 410 420 430 440

Temperature [°C]

Bed 4

Bed 4

Equilibrium curve before intermediate

absorption

Equilibrium curve after intermediate

absorption

37% emission reduction

SO2 feed

SO3 rich gas

VK38

VK69

VK38

Inte

rme

dia

te

ab

sorp

tio

n

+100% activity?LEAP5™

New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

14

Optimizing performance at lower operating temperaturesNew VK-711 LEAP5™

1

10

100

1000

370 380 390 400 410 420 430 440 450 460 470 480 490

Re

lati

ve

act

ivit

y

Temperature [°C]

VK48

VK-701 LEAP5TM

VK59

VK-711 LEAP5TM

15

Optimised Vanadium (V) contentIntroducing LEAP5™

0

10

20

30

40

50

60

70

80

380 390 400 410 420 430 440

Re

lati

ve

co

nte

nt

of

va

na

diu

m (

V)

[%]

Temperature [°C]Conditions: 10% SO2, 10% O2, high conversion

LEAP5™

Traditional catalyst technologies

16

How does LEAP5 fit in?Without reducing plant output

Adding an extra bed

+ Normal operation and handling

+ Similar start-up

+ Slightly higher production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra CAPEX and extra OPEX

LEAP5 catalyst

+ Easy installation

+ Normal operation

+ Cleaner start-up

+ Slightly higher production

+ Reduce OPEX of any future scrubber

÷ May require lower inlet temperature

÷ Extra CAPEX

Cut capacity

+ No installation

+ No requirements

+ Normal operation and handling

+ Similar start-up

÷ Lower production

Tail-gas scrubber

+ Cleaner start-up

+ Normal production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra handling of scrubber products

÷ Extra CAPEX and extra OPEX

17

LEAP5 – Worldwide references

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LEAP5™ can do more than reduce emissionFive advantages for acid plant operators

Reduced SO2

emissionIncreased sulfuric

acid capacityReduce scrubber

chemical consumption

Reduced plant pressure drop

Thank You