Sulphuric Acid PlantConverter Replacement Projects - Chemetics - COBRAS 2015

Title of Presentation

Sulphuric Acid PlantConverter Replacement Projects

Copyright 2015, Chemetics Inc. All rights reserved.

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19/10/2015Slide 2Grigory Lwow1942 2014In Memory of

Copyright 2015, Chemetics Inc. All rights reserved.Presentation OutlineMain Factors to ConsiderTechnology changeFabrication Strategy3 Case StudiesProject 1 CanadaProject 2 USAProject 3 BrazilConclusions

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement Projects in GeneralLargest piece of process equipment in acid plantTraditional discussions when replacing a ConverterSpace constraintsNew foundation vs. existing foundationTechnology changeMaterials of constructionInternal heat exchangers and/or superheaterFabrication Strategy modular Converter approachOpportunity for capacity increaseReplace aging equipmentPreheater evaluationNew ductingCatalystShutdown time for tie-in

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Copyright 2015, Chemetics Inc. All rights reserved.Technology Change19/10/2015

Bed # 1Bed # 2Bed # 3Bed # 4

Carbon Steel bricklined ConverterStainless Steel ConverterStainless Steel Converter with Internal Exchangers


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Copyright 2015, Chemetics Inc. All rights reserved.Technology Change

Enthusiasts

Visionaries

Pragmatists

Conservatives

Skeptics

Diffusion of Innovation Principle19/10/2015Slide 6

Copyright 2015, Chemetics Inc. All rights reserved.Technology Change Stainless Steel Converters with Internal Exhangers

Enthusiasts

Visionaries

Pragmatists

Conservatives

Skeptics

Diffusion of Innovation Principle19/10/2015Slide 7

Copyright 2015, Chemetics Inc. All rights reserved.Fabrication StrategyConverters rarely can be shipped in 1 piece3 options:On site stick build fabrication (raw plate supply 100% on site fabrication)On site knock-down fabrication (cut, rolled, bevelled pieces done in shop and supplied to field > 75% on site fabrication)Modularize fabrication (> 80% shop fabrication & < 20% on site fabrication)

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsRecent Case Studies2011 Project 1 Canada 2013 Project 2 USA2014 Project 3 Brazil

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 1 Canada 1100 mtpd metallurgical acid plantConverter Diagnostic+25 year old carbon steel brick-lined ConverterEquipment reaching end of service lifeStructural integrity of Converter compromised shell thinningExtended plant shutdowns for major repairsProjectTechnology upgrade to SS Converter on new foundationInternal exchanger to reduce ducting costs and reduce footprintReplace cold and inter gas/gas heat exchangersConstruct new Converter next to operating plantTie-in during 28 day general maintenance shutdownRe-use old catalyst and combine with new catalyst19/10/2015Slide 10

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 1 Canada Chemetics Scope of WorkEPSEngineeringComplete basic and detailed engineeringAll disciplinesProcurementModular Converter supply13.3m diameter Converter (3+1 configuration)14 months (12 months fabrication w/5 months installation overlap)Gas/gas exchanger supplyAll materials supply Field ServicesConstruction advisory servicesMechanical check-outCommissioning advisory services19/10/2015Slide 11

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 1 Canada

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 1 Canada 19/10/2015Slide 14








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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsXstrata Nickel19/10/2015Slide 25




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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 2 USA 1800 mtpd sulphur burning acid plantConverter Diagnostic+30 year old carbon steel brick-lined ConverterEquipment reached end of service lifeFrequent gas leaksPlant shutdowns for repairsProjectTechnology upgrade to SS Converter on new foundationInternal gas exchangers to reduce ducting costsConstruct new Converter next to operating plantSupply Converter in modules to reduce construction costs and overall project scheduleTie-in during 19 day general maintenance shutdownAll new catalyst 19/10/2015Slide 29

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 2 USA Chemetics Scope of WorkEPSEngineeringComplete basic and detailed engineeringAll disciplinesProcurementModular Converter supply11.7m diameter Converter (3+1 configuration)Accelerated schedule14 months (12 months fabrication w/3 months installation)Site ServicesConstruction advisory servicesMechanical check-outCommissioning advisory services19/10/2015Slide 30

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 2 USA19/10/2015Slide 31


Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 2 USA

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 3 Brazil 1400 mtpd sulphur burning acid plantConverter Diagnostic+30 year old carbon steel brick-lined ConverterEquipment reaching end of service lifeFrequent ducting gas leaksFrequent plant shutdowns for repairs ProjectTechnology upgrade to SS Converter on new foundationNew Internal exchanger and Superheater to reduce ducting costsReplace Inter and Final economizersReplace almost all plant ductingSize converter for increased plant capacity 1600 mtpdConstruct new (knock down) Converter next to operating plantTie-in during general maintenance shutdownRe-use old catalyst and combine with new catalyst19/10/2015Slide 48

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 3 Brazil Chemetics Scope of WorkE+SEngineeringBasic engineering all disciplinesDetailed engineering proprietary equipment and ductingField ServicesConstruction advisory servicesMechanical check-outCommissioning advisory servicesProject11.85m diameter Converter (3+1 configuration)Built on-site some large pieces shipped to site12 months (7 months pre-fabrication w/5 months installation)

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Copyright 2015, Chemetics Inc. All rights reserved.Chemetics Sulphur Burning Acid Plant Converter19/10/2015Slide 50


Copyright 2015, Chemetics Inc. All rights reserved.19/10/2015Slide 51


SuperheaterInter Reheat Exchanger

SO2 from Boiler

SO2/SO3 to IAT

SO3 to Econ. / FAT

SO2 from Cold Reheat Exch.

Steam

Chemetics Sulphur Burning Acid Plant ConverterFlow Path

Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 3 Brazil

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsProject 3 Brazil 19/10/2015Slide 54


Novo Conversor 3:1 (11.85 m x 21.45 m H) Super Aquecedor Interno Tocador Inter Reheat Interno

Novo Economizador Final

Novo Inter Economizador

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Converter Replacement ProjectsProject 3 Brazil 19/10/2015Slide 56






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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsRetrofit References Last 20 yearsStartupCountryBedsSS ConverterInternal Heat ExchangersNew FoundationModular2015Confidential4YesYes (2)YesYes2014Canada4YesYes (2)YesYes2014Brazil4YesYes (2)YesNo2013USA4YesYes (1)YesYes2012Canada4YesYes (1)YesYes2010UK4YesNoYesNo2006USA4YesYes (1)YesNo2006Canada4YesNoYesNo2000Sweden5YesYes (1)YesNo1999RSA4YesNoNoNo1999Netherlands1YesYes (1)YesNo1995USA4YesYesNoNo

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Copyright 2015, Chemetics Inc. All rights reserved.Converter Replacement ProjectsConclusionsMost common solutions in Converter replacement projectsNew SS converter on new foundationInternal exchangers for space limitations and ducting costsInstall Converter while plant is operating and then tie-in new ducting during a general maintenance shutdown (