clark mutually increasing safety and the recovery - h2so4
TRANSCRIPT
MUTUALLY INCREASING SAFETY AND HEAT RECOVERY IN SULFURIC ACID PLANTS
UPDATEPRESENTED AT THE
COBRAS – CONGRESSO BRASILEIRO DE ÁCIDO SULFÚRICOFOZ DO IGUAÇÚ - BRASIL
OCTOBER 17TH , 2019
®
COMPANY
SOME PRODUCTSMANUFACTURING
Dry SealDevice
Modular PlantsSulfuric Acid
Mist Eliminators
FiberBed® MaxiMesh®
Liquid distributors
MaxiFlow®
Random Packing
MaxiSaddle® BPC
CSXTM
High Silicon Sulfuric AcidStainless Steel
ALWAYS INNOVATING
SUMMARY
SUMMARY
THE CHALLENGE
LEAK SITUATION
Leaks eventually happen.
Auto-catalytic effect
Once a leak starts, acid and water start mixing, dilution and heating take place, acceleration the corrosion and leakageHydrogen Release
Metal corrosion releases hydrogen. The longer the leak is undetected, the
more hydrogen is released.
Water Contamination
Cooling and BFW Water contamination add to costs
and shut down period
Plant Shutdown
Depending on seriousness, plant can be down for days or weeks.
Besides production loss, major equipment may need repairs.
NORMAL OPERATION
SUMMARY
SUMMARY
HYDROGEN SAFETY
Hydrogen Safety is a major concern in the modern sulfuric acid industry
* Courtesy Sulfuric Acid Today, Kathy Hayward
HYDROGEN SAFETY
Autralia (2)
Brazil (3)
Holland (1)
India (2)
Italy (1)
UK (1)
US (6)
Chile (2)
Some reported hydrogen incidents with collateral damages…
Data as of 2015
2014USA
InterPass Absorption Tower Hydrogen Incident
* Source: Sulfur Conference 2011/2014 – Hydrogen Safety in the Sulfuric Acid Industry
HYDROGEN SAFETY
MAJOR HYDROGEN INCIDENTS CAUSES
CAUSESMAJOR HYDROGEN INCIDENTS
Chemical cleaningof acid coolers (1x)
Tower acid strengthout of control (2x)
Economizer leak (5x)
Heat Recovery Boiler leak (2x)
Acid cooler leak (7x)
SUMMARY
SUMMARY
INDIRECT COOLING OF SULFURIC ACID
BASIC ARRANGEMENTINDIRECT COOLING OF SULFURIC ACID
WHAT HAPPENS ON A FAILURE SITUATION?
How to measure the corrosion rate at the dynamic leak area? Device to measure corrosion rate at dynamic conditions.
INDIRECT COOLING OF SULFURIC ACID
FAILURE SITUATIONINDIRECT COOLING OF SULFURIC ACID
Process Fluidcompartment
Glasscontainers
Thinplate
Cooling Fluidcompartment
Leakhole
INDIRECT COOLING OF SULFURIC ACID
INDIRECT COOLING OF SULFURIC ACID
INDIRECT COOLING OF SULFURIC ACID
INDIRECT COOLING OF SULFURIC ACID
Time:0 min
Time:40 min
Time:120 min
SS 316L
Table 1Sulfuric Acid Corrosion Progression on Leaking Hole
(tests realized at ambient temperatures)
Fluid Pair Conditions Results Images
Water98% Sulfuric Acid
2mm hole120 min test
Start at ambient temperaturePeak temperature 66 °C
316L Stainless steel
Corrosion rate >145 mm/year
INDIRECT COOLING OF SULFURIC ACID
SUMMARY
SUMMARY
INERT FLUID
Inert to acid and water
Non-flammable
Non-Toxic
Low Vapor Pressures Safe to handleSubstantial density
difference between fluid and water/acid
Good heat transfer properties
Stability
CHARACTERISTICSSAFEHR® INERT FLUID FAMILY
INERT FLUID
Sulfuric acid + Inert fluid
Inert fluid+ Water
Sulfuric acid + Inert fluid + Water
“D” FAMILY ACID/WATER IMMISCIBILITYSAFEHR® INERT FLUID FAMILY
INERT FLUID
“D” FAMILY SAFETY, FLAMABILITY, TOXICITYSAFEHR® INERT FLUID FAMILY
Table 2Sulfuric Acid Corrosion Progression on Leaking Hole
(tests realized at ambient temperatures)
Fluid Pair Conditions Results Images
Water98% Sulfuric Acid
2mm holeStart at ambient temperature
Peak temperature 66 °C316L Stainless steel
Corrosion rate >145 mm/year
D-20 Inert Fluid98% Sulfuric Acid
2mm hole72 hours test duration
Start at ambient temperature316L Stainless steel
Corrosion rate: nilMass lost: nil
INDIRECT COOLING OF SULFURIC ACID
SUMMARY
SUMMARY
DIRECT COOLING OF SULFURIC ACID
2013 PATENTDIRECT COOLING OF SULFURIC ACID
DIRECT COOLING OF SULFURIC ACID
2013 PATENT DRAWBACKSDIRECT COOLING OF SULFURIC ACID
TECHNOLOGY FOUND FEASIBLE BUT:
AVERAGE FLUID TEMPERATURE
BUILD UP OF FLUID IN ACID SIDE
LARGE VOLUME OF FLUID
Increases heat transfer equipment size
Reduces heat recovery possibility
Coalescer efficiency Large equipment and vessels
SUMMARY
SUMMARY
INDIRECT COOLING OF SULFURIC ACID
*These and next numbers based on approximate to 1000 MTPD Acid Plant
BASIC ARRANGMENTINDIRECT COOLING OF SULFURIC ACID
IN ERT FLU ID
INDIRECT COOLING OF SULFURIC ACID
SETUP FOR HTC (U) ESTIMATIONINDIRECT COOLING OF SULFURIC ACID
IN ERT FLU ID
INDIRECT COOLING OF SULFURIC ACID
SETUP FOR HTC (U) ESTIMATIONINDIRECT COOLING OF SULFURIC ACID
SAFEHR® APPROACHAPPLICATION AREAS
Increase Steam Generation Reduce Safety Risks
STANDARD SYSTEMS
RECOVERING HEAT OF HOT ACID
Commom pump tank
SAFEHR® APPROACHCOMMON PUMP TANK
STANDARD SYSTEMS
SAFEHR® APPROACHBOILER FEED WATER HEATERSafehr® can increase safety while maintaining/improving heat recovery.
STANDARD SYSTEMS
SAFEHR® APPROACHHEAT RECOVERY SYSTEMS
HEAT RECOVERY TOWERDouble deck absorption tower.
Benefits
Heat Recovery≈ 50GJ/hCooling Water M/U Reduction≈ <90%
Risks
• Boiler Corrosion/Failure• H2 Generation/Explosion• Site Shutdown• Acid / Energy Production Loss• Equipment damage
BFW5-10 bar
Sulfuric Acid99.0% & 225° C
Sulfuric Acid99.0% & 180° C
LP/MP Steam5-10 bar
Sulfuric Acid98.0% & 80° C
From FAT
SO3 Laden Gas
SO3 Free Gas
STANDARD SYSTEMS
HEAT RECOVERY SYSTEMS
Venturi absorber followed by conventional tower.
Benefits
Heat Recovery≈ 50GJ/hCooling Water M/U Reduction≈ <90%
Risks
• Heat Exchanger Corrosion/Failure• H2 Generation/Explosion• Energy Production Loss• Equipment damage
VENTURI ABSORBER
Sulfuric Acid98.0% & 180° C
SO3 Laden Gas
SO3 Free Gas
Sulfuric Acid98.5% & 220° C
Sulfuric Acid98.0% & 80° C
Sulfuric Acid98.5% & 80° C
BFW5-10 bar
LP/MP Steam5-10 bar
SAFEHR® APPROACH
STANDARD SYSTEMS
SAFEHR can be used in replacement to a heat recovery boiler...to inscrease safety...
Acid/FluidCooler
Fluid/WaterCoolerSO3 Laden Gas
SO3 Free Gas
Sulfuric Acid98.0% & 80° C
From FAT
BFW5-10 bar
LP/MP Steam5-10 bar
HEAT RECOVERY SYSTEMS
Safehr® eliminates acid/water Pressure boiler
HEAT RECOVERY TOWER
SAFEHR® APPROACH
STANDARD SYSTEMS
With Safehr® most of the energy recovered...can be shifted to HP steam!
Acid/FluidCooler
Fluid/WaterCoolerSO3 Laden Gas
SO3 Free Gas
Sulfuric Acid98.0% & 80° C
From FAT
BFW5-10 bar
LP/MP Steam5-10 bar
While a direct boiler limits heat recovery to LP/MP Steam generation...
HEAT RECOVERY SYSTEMSSAFEHR® APPROACH
STANDARD SYSTEMS
Up to 70% of Energy shifted to HP Steam...
HEAT RECOVERY SYSTEMSSAFEHR® APPROACH
CHARG
E TANK
RECEIVING
TAN
K
IP Boiler
HP BFW Preheater(after deaerator)
HP BFW Preheater(before deaerator)
SAFE
HR®
INER
T FL
UID
CIR
CUIT
≈ 200°C
≈ 180°C
≈ 180°C
≈ 115°C
SUMMARY
SUMMARY
SAFEHR HEAT RECOVERY SYSTEMSchematic diagram of first plant designed with SAFEHR Heat Recovery System…
Drying Tower
BlowerAir
Sulphur
Waste HeatBoiler
SulphurBurner
ConverterBoilers
Superheaters Economizer
ProductAcid
Stack
Atmosphere
Heat Recovery Tower
H2O2 ScrubberSafehr® SystemBFW
10 bar Steam
180°C225°C
180°C
215°C
170°C 105°C
Temperatures on a Heat Recovery application may vary according to steam pressure levels
Heat Recovery Towertower
SAFEHRcircuit
Cooling WaterSystem
Hot Acid Inert Fluid Water/Steam
Heat Exchangers typical temperature approach for SAFEHR®
ON A
HEAT RECOVERY SYSTEM
SAFEHR® HEAT RECOVERY SYSTEM
SAFEHR® HEAT RECOVERY SYSTEM
3D of SAFEHR Heat Recovery System
THE FIRST PLANT
Round Production Numbers for 150 MTPD Capacity
ConsumptionSulphur (ton/day) 50
Energy (kW) 450Dilution Water (m3/h) 0.9Cooling water (m3/h) 70
Production
Sulfuric Acid (ton/day) 150Steam Generation Ratio (ton/ton) 1.9-2.0 @ 10 bar
SUMMARY
SUMMARY
SAFEHR HEAT RECOVERY SYSTEMSingle absorption with Heat Recovery and Tail Gas Scrubbing will push energy generation limits…
SAFEHR PERFORMANCE
Rejected heat
70
High pressure steam
180
225
Low Pressure Steam
45
Rejected heat25
High pressure steam
155
Rejected heat25
LP Steam20
Total Generation heat StandardDA Plant
Heat Recovery DA Plant
SAFEHR®DA Plant
90%
65%
100%
Energy breakdown in different plant configurations (all values in GJ/h)
* Pro-rated figures for sulphur burning plant, 3/1 IPA, 1000 MTDP
Single Absorption Plants with Tail Gas Scrubber and Safehr produce even more steam..
High pressure steam
195
Rejected heat 10LP Steam
15
95%
SAFEHR®SA Plant w/TGS
SUMMARY
SUMMARY
STANDARD SYSTEMS
EQUIPMENT AND INSTRUMENTATIONINDIRECT COOLING OF SULFURIC ACID
PT
00
CooledInert Fluid
Strong Hot Acid
Strong Cooled Acid
HeatedInert Fluid
CooledInert Fluid
HeatedInert Fluid
TIC
00
LIC
00
PIC
00
PSV
00
AICCON D
00
TIC
00PT
00
TIC
00
SAFETY HEAT EXCHANGERpatent pending
CASCO
HOT FLUID BUNDLE(S)
COULD FLUID BUNDLE(S)
SAFETY FLUID
SAFETY HEAT EXCHANGERpatent pending
CONDENSING SAFETY FLUID
BOILING SAFETY FLUID
HOT FLUID
COLD FLUID(HP BFW)
COLD FLUID(LP BFW)
STANDARD SYSTEMS
SAFEHX® HEAT EXCHANGERSAFE HEAT RECOVERY SYSTEMS
HEAT RECOVERY TOWERDouble deck absorption tower.
Benefits
Heat Recovery≈ 50GJ/hCooling Water M/U Reduction≈ <90%
Reduced Risks
• Boiler Corrosion/Failure• H2 Generation/Explosion• Site Shutdown• Acid / Energy Production Loss• Equipment damage
SUMMARY
WHAT’S NEXT?
SUMMARY
CONCLUSION
Failure Safe
Leaks no longer cause emergency shut-down
No auto-catalytic effect
No auto-catalytic effect caused by leaks guarantee long life to equipment.
Energy
35+% lost energy recovered
Cooling water
Reduced cooling water circulationEnergy can be shifted elsewhere
Make-up water
Reduced cooling water make-up and treatment
SAFEHR®
Enables safer operation and environment
BRASIL
Av. Moema, 281 Planalto Paulista - MoemaSão Paulo - SP - CEP 04077-020
Av. D.Joaninha, 91Jardim Mimas – Embú das ArtesSP - CEP 06807-690
[email protected].: +55 11 3472-3333
CHILE
Volcan Lascar 801,2 HPudahuel – Santiago - Chile
(Representante)E.P.A.S ING LTDA Rancagua NO 396Los Andes – Chile
T: +56-034-2 403090
COLÔMBIA
(Representante)Cra 88 No.6-46 - Cali – Colombia
T: (57-2) 3865130 ext 107http://www.impolama.com
EUA
411 SE Mizner BLVD #72Boca Raton FL [email protected]
CHINA
Room B1407-38,Tian An Chuangxin Technology Plaza,Futian District, [email protected]
WHERE WE ARE
