technical cooperation - h2so4 · drying converter iat fat tower ... humidifying tower intermediate...

www.alfalaval.com

Marcelo Gabriel Nov/13

Technical Cooperation

www.alfalaval.com 2

© Alfa Laval

Objectives

•  Outline specific waste heat recovery opportunities within sulphuric acid processing

•  Show how you can profit from waste heat recovery with Alfa Laval solutions

•  Show the improvements in Alfa Laval equipments for Sulphuric acid processing

www.alfalaval.com 3

© Alfa Laval

Content

•  Short about Alfa Laval

•  Alfa Laval products for sulphuric acid processing

•  Waste heat recovery (WHR) opportunities

•  Alfa Laval solutions in WHR

•  Plate material for WHR

•  Heat recovery cases

•  Alfa Laval improvements

•  Summary

www.alfalaval.com 4

© Alfa Laval

We serve most industries

Biofuels

Biotech and pharmaceutical

Chemicals

Engine and transport

Fluid power

Food and beverages

HVAC

Industrial fermentation

Latex

Machinery

Marine and diesel

Metal working

Mining and mineral processing

Oil and gas

Oil refinery

Power

Pulp and paper

Refrigeration and air-conditioning

Steel and coke oven gas

Sulphuric acid

Sugar

Wastewater treatment

www.alfalaval.com 5

© Alfa Laval

Experience counts – over 40 years of industry experience

First unit for sulphuric acid delivered in 1969 to Australia

Thousands of heat exchangers sold since then

across the globe

www.alfalaval.com 6

© Alfa Laval

Content








•  Summary

www.alfalaval.com 7

© Alfa Laval

Sulphuric acid plant

Converter IAT FAT Drying tower

Electrostatic precipitator Washing

Tower (scrubber)

Humidifying tower

Intermediate Absorption Tower

Final Absorption Tower

Weak Acid Cooler (WAC)

Drying tower cooler

IAT cooler FAT cooler

5-20% H2SO4

93-96% H2SO4

98.5% H2SO4

98.5% H2SO4

Hot SO2 gas

SO2

SO2 SO2

Tail gas

SO3

SO2+ SO3

SO2 gas cooler • Oleum Inter- changer (SHE) • Oleum cooler (SHE/PHE)

Sulphur

Air

www.alfalaval.com 8

© Alfa Laval

Content




•  Alfa Laval / Clark-Koch solutions in WHR




•  Summary

www.alfalaval.com 9

© Alfa Laval

Energy demand is increasing International Energy Agency forecasting a 45% rise

until 2030

Source: International Energy Agency, World Energy Outlook 2008

1980 1990 2000 2010 2020 2030 0

1 000

2 000

3 000

4 000

5 000

6 000

Mto

e

Oil Coal Gas Biomass Nuclear Hydro Other renewables

www.alfalaval.com 10

© Alfa Laval

The sulphuric acid power plant

65 MW

1000 tons/day sulphur burning acid plant

1/3

Waste

Steam generation 2/3


© Alfa Laval

Boost profits! Recycle your energy


© Alfa Laval

Heat recovery opportunities In sulphuric acid processing

REDUCE OPEX: Reduced steam / fuel consumption

INCREASE REVENUES: Energy sales / Increase production

REDUCE CAPEX: Installation costs / Utility system / Compact solution

PROFITABILITY

< 1 year

Rapid payback!!!


© Alfa Laval

Heat recovery opportunities In sulphuric acid processing


© Alfa Laval

Heat recovery opportunities Reduced steam / fuel consumption

Ore processing or

chemical plant

Coal fired boiler


10 MW

10 MW

Steam Hot

Water

Example: Boiler Feed Water heating


© Alfa Laval

Heat recovery opportunities Reduced steam / fuel consumption

H2SO4 98% 110 °C

80 °C

P2O5 30% 45 °C

Trim cooler

80 °C

90 °C

50 °C

Water loop

•  Hot water from the acid plant used to pre-heat the P2O5 instead of Low pressure steam.

•  More steam is then available for electricity generation in the turbine

•  Less fuel is consumed in the boilers


© Alfa Laval

Copper electrolyte heating Heating electrolyte from 50°C à 70°C

Stripping

Washing

Extraction Leaching

PLS PLS Copper

ore

Grinding

Raffinate

Rich electrolyte

Spent electrolyte Spent electrolyte

Rich electrolyte

Raffinate

Copper cathodes

Electro- winning Steam or

hot water

- +


© Alfa Laval

Zinc sulphate solution heating Heating from 50°C à 85°C

Zinc ore

Spent electrolyte

Zinc cathodes

Electro- winning

- +

Leaching

Grinding

Rotation

SO2 to sulphuric acid

production

Roasting

Purification

Zinc dust

Cu, CD, Ni removal

Hot acid leaching

Purification

Ag, Fe, As, Pb removal

Steam or hot water

Steam or hot water

Steam or hot water

Spent electrolyte

Ammonia Or NaOH

Spent acid


© Alfa Laval

Heat recovery opportunities Reduced electricity cost

•  Low pressure steam in the process (Copper / Nickel / Zinc / P2O5 / etc) is replaced with hot water from the acid plant

•  More steam is then available for electricity generation in the turbine

Steam

Turbine

50 bar

steam

0.1 bar steam

5 bar steam


© Alfa Laval

Heat recovery opportunities Energy sales – district heating

Kemira Sulphuric acid plant

22 MW

Industry Park of Sweden Power company

22 MW

City of Helsingborg Gas fired

boiler 22 MW

•  Replace district heating boilers with acid plant heat

•  Sulphuric acid plants are perfect heat sources

•  Profitable for both city and acid plant


© Alfa Laval

Content








•  Summary


© Alfa Laval

Heat integration network


Heat recovery applications Heat integration network

Sulphuric acid cooler

Back-up steam heater

Heater

Trim cooler

Boiler feed water

heating

Copper electrolyte

heating

Zinc sulphate solution heating

EXAMPLES

District heating

Absorption tower


© Alfa Laval

Why use an intermediate circuit?

Sulphuric acid cooler

Back-up steam heater

Heater

Trim cooler

•  Acts as a safety barrier – prevents mixing

•  If long distances needs to be covered

•  Flexibility and reduced interdependence

•  Multiple heat sources can connect to circuit


© Alfa Laval

Energy Integration H2SO4 98,5% -Boiler Feed Water Heating

Hast D205

AISI 316

Absoption Tower

S&T Anodic protection

BFW Out / 100 °C

BFW In / 50 °C


© Alfa Laval

Energy Integration H2SO4 98,5% -Boiler Feed Water Heating

BW In // 50 °C

BW Out // 100 °C

110 °C

Absorption Tower Hast D205 AISI 316

Expansion tank


© Alfa Laval

Rapid payback For waste heat recovery investments

<1 year


© Alfa Laval

Pay back calculation EXAMPLE


© Alfa Laval

Proven plate technology Plate Heat Exchangers enables superior heat recovery – at profitability

Thermal efficiency Crossing temperatures

Advanced alloys used

5x 47 40

90 87

Lower investment cost

Higher grade energy


© Alfa Laval

Proven plate technology Five times more thermally efficient than competing technology

Thermal efficiency

5x High turbulence

High heat transfer coefficient

Minimized fouling

Compact solution!

Less material required!

Less space!


© Alfa Laval

Proven plate technology Crossing temperatures possible thanks to the true counter current flow

47 40

90 87

Plate heat exchanger

47 40

90

47

Shell & tube

True counter current flow Cross flow


© Alfa Laval

Discover hidden assets How Alfa Laval can help in waste heat recovery •  Alfa Laval Energy Review – helps you identify

your heat recovery potential

•  Standard WHR Skid – Package for heat integration system (Clark – Koch)

•  Supply of semi-welded D-205 plate heat exchangers

•  Service of heat exchangers


© Alfa Laval

Content








•  Summary


© Alfa Laval

Plate materials for sulphuric acid duties

Diabon

254 SMO

Alloy G-30

AISI 316 AISI 316

150

100

50

0

°C

150

100

50

0

°C

0 10 20 30 40 50 60 70 90 80 100%

D205

C276

Iso corrosion diagram (0.1 mm/year)


© Alfa Laval

High acid temperatures possible with Hastelloy D-205 material

130°C Enabling maximum

usage of low grade heat!

0.4

0.3

0.2

0.1

0 90 105 110 130 150 95

Cor

rosi

on r

ate

(mm

/yea

r)

Acid temperature (°C)

Alloy C-276

Hastelloy D-205

Corrosion curve 98.5% H2SO4


© Alfa Laval

Resistance against chlorides

0

50

100

Tem

pera

ture

(°C

)

No corrosion 316

C-276

254 SMO

Crevice corrosion

D-205

pH = min 7.0

10 102 103 104 105 ppm chlorides


© Alfa Laval

D-205 for strong acid cooling The semi-welded heat exchanger

Gasketed channel for cooling medium

Welded channel for aggressive fluid

Weld Gasket

Flow pattern in a welded plate heat exchanger

Gasket exposure to aggressive fluid virtually eliminated

Peripheral weld


© Alfa Laval

Why D205 can take high acid temperatures

C-276 D-205

Passivating layer

D205’s passivating film SiOx is:

•  Thicker

•  Stronger

•  Not as sensitive to velocity

•  Rebuilds faster

SiOx CrOx


© Alfa Laval

Material composition (%) Key difference between D-205 and C-276

D-205

C-276

Material Ni

64.5

58

Cr

20

15.5

Mo

2.5

16

Cu

2

0

Fe

6

5

W

0

4

Stabilizes material

Chloride resistance

Acid resistance

H2SO4 resistance

Si

5

0

!


© Alfa Laval

Content








•  Summary


© Alfa Laval

Heat recovery cases Extract from reference list

China

Country Company

Sweden Kemira, Helsingborg Sweden Boliden, Skellefteå Finland Yara, Silinjärvi Finland Boliden, Harjavalta

UK Courtalds Germany Capro Leuna Germany Sachtleben

India Varinder Agro

Wuxin Copper


© Alfa Laval

MARKET CASE

Kemira Helsingborg, Sweden Start-up:1999

•  22 MW recovered using Alfa Laval plate heat exchangers in D-205 / FKMS gaskets

•  3 semi-welded PHEs replaced 5 anodically protected S&T

•  Sale to municipal district heating system

•  Recovered heat corresponding to 22,000 m3 of oil saved every year Payback <12 months


© Alfa Laval

MARKET CASE

Kemira Helsingborg, Sweden


© Alfa Laval

MARKET CASE

Kemira Helsingborg, Sweden •  Initial direct cooling system before 1999

•  Absorption towers: 2 x 2 anodically protected S&T

•  Drying tower: Anodically protected S&T

•  Replaced with three PHE-SW in D205 / FKMS

•  Three tanks acid tanks replaced with one common tank

•  Plant capacity: 1000 tons/day

•  Recovered: 530 MWh/day (22 MW), 240 GWh corresponding to 22,000 m3 of oil

•  Payback less than a year

•  Eliminated need for cooling water


© Alfa Laval

Boliden Harjavalta, Finland Start-up:1995

•  40 MW of heat recovered with Alfa Laval plate heat exchangers in D-205

•  Sale to municipal district heating system (20MW)

•  Use in Nickel production plant (12MW)

•  Use in Copper production plant (8MW)

MARKET CASE


© Alfa Laval

Wuxin Copper, China Start-up:2013

MARKET CASE

•  Original •  Total 5 Waste Heat Boiler generate 74.7 t/h steam

•  Consumption summer: 38.2 t/h

•  Consumption winter: 78.5 t/h

•  Heat recovery •  Distance between plants: ca 500m

•  Temperature program

–  Acid side (98% H2SO4): 112°C à 85°C

–  Water loop: ~100°C

•  Alfa Laval equipment: 2 x MA30-W in D205/FKMS with portfilters

Payback <12 months


© Alfa Laval

Wuxin Copper WHR set-up


Heat recovery applications Heat integration network

Sulphuric acid coolers

Heater

Trim cooler (S&T)

Boiler feed water

heating

Copper electrolyte

heating

EXAMPLES

District Heating for the plant

Intermediate Absorption

Tower


© Alfa Laval

17.4 MW

Heat recovered in various applications

IAT heat load

79%

Summer time heat applications

Cu electrolyte heating

9.2 MW

BFW heating 4.5 MW

100% Recovery rate:

Winter time heat applications

Cu electrolyte heating

12.2 MW

Plant heating 5.2 MW


© Alfa Laval

Substantial savings achieved

Increased heat recovery 14-17 MW

Reduced cooling need / freed cooling capacity 14-17 MW

Reduced steam consumption 150 ktons/year


© Alfa Laval

•  Hot acid external leakage Environmental, capital and human danger.

•  Micro leakage may give secondary corrosion. Results in rapid general corrosion!

Hot acid leaking by droplets to the leak chamber

Humidity

Diluted acid!

The sealing is important


© Alfa Laval

Gasket selection

0

10

20

30

40

50

60

70

1 2 3

% S

wel

ling

Viton G FKMS

The gaskets were placed in 98% acid at 110°C (1 for 14 days, 2-3 for additional 7 days respectively) and then subjected to water for one day. This was repeated 3 times. After each test the swelling was measured.


© Alfa Laval

Viton Gaskets Resistance in Sulphuric Acid

•  Viton A 65 Dissolved •  Viton B 67 48 •  Viton G 69 10 •  FKMS >70 ?

Swelling due to high acid temperature 98% acid at 110°C during 60 days

Rubber Type % Fluor % swelling


© Alfa Laval

Alfa Laval Port Filter Design

Guiding ring

Port filter inserted through

pressure plate

Frame plate

Pressure plate

Inlet port


© Alfa Laval

Alfa Laval Port Filter Design

•  A simple solution without a separate filter

•  Cylindrical perforated tube

•  Protects at the inlet port

•  Mounted and dismantled from pressure plate

•  Requires –  Hole in the pressure plate

–  Lining

–  Inspection cover


© Alfa Laval

For predictable operations & total peace of mind

•  Extends normal Performance Agreements

•  Guaranteed results

•  Commitment to an agreed outcome, such as uptime

•  We analyze, plan and perform all required services

•  Total tailored solution

–  Example of content: Uptime Commitment, Total Care Agreement, 24/7 Support Service, Lead Time Guarantee – Services and Spare Parts, Extended Warranty

Performance Agreements with Extended Commitments

Description Alfa Laval Performance Agreements

Performance Agreements


© Alfa Laval

An Italian Ferry Co. Performance Agreement based on preventive maintenance on 7 ferries and 49 high speed separators

Benefits •  Fixed maintenance cost

• Optimized maintenance

•  24/7 support

Cargill Cargill in Netherlands signed a Performance Agreement with extended commitments to get maximum benefits from their new equipment

Benefits • Maximized uptime • Lowered total cost of ownership • Optimized maintenance

Stockholm vatten Stockholm’s municipal water company signed a Performance Agreement covering 15 decanters at three different sites

Benefits •  Fixed annual service cost

•  Lowered total cost of ownership

• More reliable operation

Boliden This smelter signed a Performance Agreement with condition monitoring, Cleaning-in-place, recond-itioning and optimization

Benefits • Reduced energy cost

•  Improved environmental performance

• Maximized uptime

PROCESS INDUSTRY ENVIRONMENT FOOD TECHNOLOGY MARINE

Customer stories


© Alfa Laval

Summary

•  Importance of efficient energy usage will increase

•  Many opportunities exist in waste heat recovery

•  Heat recovery means increased profits – here and now! Payback below 1 year.

•  Proven technology and solutions are available from Alfa Laval / Clark-Koch.

technical cooperation - h2so4 · drying converter iat fat tower ... humidifying tower intermediate...

Documents