3ER SEMINARIO FUNDICIÓN Y REFINERÍA 26/04/2018 LOGO ... · Rene Dijkstra Acid Technology Manager...

www.congreso.expomin.cl

INNOVACIÓN PARA EL DESARROLLO MINEROINNOVATION FOR MINING DEVELOPMENT

23 – 27 ABRIL/APRIL 2018

Santiago, Chile

ORGANIZA Y PRODUCEORGANIZED AND PRODUCED BY

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3ER SEMINARIO FUNDICIÓN Y REFINERÍA

26/04/2018

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

Rene Dijkstra

Acid Technology Manager

Chemetics Inc.

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• Equipment Fabricator

• Design and Supply of Sulfuric Acid plants

Chemetics Head Office in Vancouver

Chemetics Fabrication Facility (Toronto)

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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Local representatives in:• Morocco• Tunisia• Russia• Chile

• Peru• Brazil• China• India

1. INTRODUCTION

• The smelting of non-ferrous metals produces off-gases containing SO2

which typically are converted to Sulfuric Acid.

• Recent innovations in smelter technologies have increased theconcentration of SO2 in the off-gases.

• Smelter Off-gases require additional oxygen before entering the acid plant

• Current acid plant technologies require addition dilution of the smelter offgases to limit the SO2 concentration to ~12.5 vol%

• This presentation will briefly discuss existing technologies and then focuson an Innovative approach to dealing with higher SO2 concentrations usingthe Chemetics CORE™ System

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• Conventional Sulfuric Acid Plant

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• Dilution Air used to control SO2 concentration below ~12.5 vol%• Results in very large acid plants to cope with diluted gas flows• Plant size increases as smelter Off-gas concentration is higher

Smelter Off-Gas

Dilution Air

1st Contact3-pass

2nd Contact1-pass

• Chemetics High Strength (CHS™) / MECS Pre-converter System

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• All dilution air is mixed with a portion of smelter off-gas to create ~12.5 vol% gas• After the CHS converter all remaining smelter gas is added• Additional Equipment is required

• Air/SO2 Blower• Second Drying Tower• CHS Converter with single catalyst bed

• Not suitable for all Smelter Off-gas• Possible to retro-fit to existing plant• Proven and reliable equipment• Can be operated as conventional plant at reduced rate

1st Contact3-pass

2nd Contact1-pass

CHS ConverterSmelter Off-Gas

Dilution Air

• Outotec Lurec System

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• Recycle of process gas after bed 3• Increased gas flow and SO3 presence reduces peak bed temperature• Additional Equipment is required

• SO3 recycle Blower – Tough duty!• Larger Converter• 5th Catalyst Bed

• Typically not possible to retro-fit to existing plant• SO3 Recycle Blower failure is immediate risk to plant due to overheating• Can be operated as conventional plant at reduced rate

1st Contact3-pass

Hot SO3 recycle

2nd Contact2-pass

Dilution Air

Smelter Off-Gas

• Chemetics CORE™ System

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• SO2 conversion in special cooled reactor • Air/Oxygen only required to maintain desired O2:SO2 ratio• Less equipment compared to conventional plant• Highest energy recovery

1st Contact1-pass CORE™

2nd Contact1 or 2-pass

Smelter Off-Gas

Air or Oxygen

1st Contact1-pass CORE™

Smelter Off-Gas

Air or Oxygen

RegenerativeTGTU

High purity SO2

• Comparison of Plant Size (Gas to Converter)

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• Plant size dependent on both SO2 and O2 concentrations in smelter off-gas• CORE™ design allows use of Oxygen to reduce plant size further

0

50

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70

Rel

ativ

e G

as f

low

SO2 Concentration [vol%]

Conventional

CORE™

• CORETM (Cooled Oxidation Reactor)

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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1.

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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Start-up Heater

COOLANT

CIRCULATIONHEAT REMOVALCORE® REACTOR

RICH SO2

PROCESS GAS

LEAN SO2

PROCESS GAS

• CORETM (Cooled Oxidation Reaction)

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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• The Chemetics CORETM Converter is the only commercially available isothermal converter system for SO2 oxidation.

• Continuous removal of the reaction heat allows the process temperature to be controlled within the operating limit of the catalyst.

• Highly stable and easy to control (coolant control only)

• Standby mode keeps reactor hot during smelter interruptions

• Demonstration unit has over 8 yr operating record

• Smelter upgrades – Acid Plant in good condition– Use CORE System in Add-On configuration

– CORE System handles additional SO2

– Existing acid plant continues to operate as before

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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CORE™Add-On

Existing Acid Plant

Smelter Off-Gas

Dilution Air

• Smelter upgrades – Acid Plant in good condition– Use CORE™ System in Add-On configuration

– CORE System handles additional SO2

– Existing acid plant continues to operate as before

– Small additional investment

– Additional benefit: High Purity Acid & Steam

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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DryingMain

Blower HX HXHXSteam

Boiler

Intermediate

Absorber

Final

Absorber Stack

Ambient

air

SO2-Gas

HXSO2

Fuel (start-up)

Start-up

heater

Coolant

circulationCORE™ ConverterGas-Gas

Heat Exchanger

SO2-Blower

CORE®

Add-on UnitIntermediate

Absorber

Existing Double absorption Acid Plant

• Smelter upgrades – Acid Plant in Bad condition

New Smelter / Acid Plant installation

– Use CORE™ System with in-line configuration• Double Absorption configuration

• Single Absorption with Regenerative tail gas scrubber

– CORE System handles all smelter Off-gas

– Highest Energy Recovery using single boiler

– Smallest plant size

– Highest reliability

– Lowest investment cost

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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OR

• CORE In-line configuration (Double Absorption)

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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HIGH SO2 GAS

FROM DRY TOWER

ABSORPTION

SO2

BLOWER

TO STACK

GAS / GAS

EXCHANGER

COOLANT

PUMP

HEAT REMOVAL

CORE® REACTOR

& HOT EXCHANGER

COOLANT

TANK & HEATER

ABSORPTIONGAS / GAS

EXCHANGER

FINAL

CONVERTER

• CORE In-line configuration

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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ABSORPTION

TOWER

SO2

BLOWER

GAS / GAS

EXCHANGER

COOLANT

PUMP

HEAT REMOVAL

CORE® REACTOR

& HOT EXCHANGER

MOLTEN SALT

TANK & HEATER

DRYING

TOWER

STACK

RegenerableSO2 Scrubbing

(e.g. CANSOLV©)

Dilute SO2 Gas (<2vol%)

Clean Gas

LP Steam

Strong SO2 Gas

Ambient Air

(or Oxygen)

High Purity SO2

Conventional CHS™ Lurec™ CORE™

SO2 < 12.5% PP P P PP

SO2 > 12.5% O P P PP

New Plant Design PP PP PP PP

Expansion/Retrofit O P O PP

Equipment Size O P P PP

Equipment count O O P PP

Oxygen Enrichment O O/P O/P PP

Smelter interruptions O/P O/P O/P PP

Energy Efficiency O P P PP

Operability P P P PP

Reliability P P O PP

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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Conclusions

• The CORE System allows for direct processing of high strength smelter gases without unnecessary dilution

• If Oxygen is available then a CORE system becomes much smaller and even more attractive

• Combining CORE with Regenerative Scrubbing further reduces CAPEX and improves operational flexibility and emissions

• Once a regenerative scrubber is installed it can easily be adapted to capture other SO2 emissions

“Innovative Sulphuric Acid Production for high strength smelter off-gases using the CORE™ System”

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www.congreso.expomin.cl

INNOVACIÓN PARA EL DESARROLLO MINEROINNOVATION FOR MINING DEVELOPMENT

23 – 27 ABRIL/APRIL 2018

Santiago, Chile

ORGANIZA Y PRODUCEORGANIZED AND PRODUCED BY

LOGOTo Insert “Company’s logo”

3ER SEMINARIO FUNDICIÓN Y REFINERÍA

26/04/2018

Questions?....

Contact:

Claudia Araya Bravo

Business development manager for Chemetics in LatinAmerica

claudia.araya@jacobs.com