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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
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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