critical aspects in the definition of the optimum

CRITICAL ASPECTS IN THE DEFINITION
OF THE OPTIMUM CONFIGURATION OF A
SULPHUR BURNING PLANT
SUN CITY – SOUTH AFRICA
May 4th - 6th, 2009
BASE DECISIONS FOR THE DEFINITION
OF THE CONFIGURATION OF A SULPHUR
BURNING PLANT
TYPE OF RAW MATERIAL
EMISSIONS
PRODUCTS
CO - PRODUCTS
TYPE OF RAW MATERIAL
SULPHUR
LIQUID
SOLID
PRODUCTS
WHICH ?
HOW MUCH ?
S.A. 92-99,5% wt
QUALITY ?
OLEUM 20-25% free SO3
SO2
GASEOUS (CONC.?)
LIQUID
SO3
GASEOUS (CONC.?)
LIQUID
OTHER
SPECIFICATIONS
CO-PRODUCTS
STEAM & ELECTRIC POWER REQUIREMENTS
Condensate
Condensing
Turbine
E.P.
L.P. Steam bleeding for site users
(up to 25% of the steam fed flow)
SUPERHEATED
STEAM
P > 40 barg
T >370 °C
M.P./L.P. Steam for site users
Back
Pressure
Turbine
E.P.
Second
turbine
SATURATED OR
SLIGHTLY
SUPERHEATED
Condensate
M.P./L.P. Steam for site users
CO-PRODUCTS
STEAM & CONDENSATE CIRCUIT DEFINITION
T h e
u s e r
consumes all the
steam fed and
gives back
condensate
Steam
H2SO4 PLANT
STEAM USER
Condensate return
PURGE / LOSSES
The user does not
consumes all the
steam produced
and/or does not
g i v e b a c k
condensate
Extra
Steam
H2SO4 PLANT
S T E A M
CONDENSER
INSTALLATION
Steam
STEAM USER
Condensate
or
R EL E ASE OF THE
EXCESS STEAM TO
THE ATMOPSHERE
A ND SIGNIFICANT
OVERDESIGN OF
THE DEMI WATER
UNIT (UP TO 5 TIME
L A R G E R )
EMISSIONS
DCDA
WITHOUT SCRUBBER
STANDARD
CONFIGURATION
EMISSION
MINIMIZATION
DCDA or SCSA
WITH SCRUBBER
H2O2
NaOH
Others
SO2: 350-417 PPM
Acid mist + SO3: 80 mg/Nm3
SO2: down to 100 PPM
Acid mist + SO3: up to 30 mg/Nm3
BASE CONFIGURATION
H2SO4 98,5%
M.P. STEAM
4° pass
Air drying
Sulphur
burning
WHRB+
ECONOMIZERS
3° pass
CIP/HIP
2° pass
1° pass
Deareator
AIR
SULPHUR
DEMI-WATER MAKE-UP PLUS
CONDENSATE RECOVERY (IF ANY)
SO3 absorption &
acid circulation
BASE CONFIGURATION
WHRB + ECO
CONVERSION
AIR
DEAREATOR
DRYING
CIP/HIP
ACID
CIRCULATION
SULPHUR
BURNING
0
PRELIMINARY ISSUE
REVISION
Revisione
REVISION HISTORY
Storia delle revisioni
Frontino
17/02/09
DRAWN
Autore
DATE
Data
The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.
L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.
DRAWING Nr. / Disegno Nr.
Desmet Ballestra s.p.a.
MILANO - Italy
JOB
Commessa
PLANT
Impianto
TITLE
Titolo
H2SO4 + OLEUM
-----------
CUSTOMER Nr. / Nr. Cliente
-
SHEET
Foglio
SHEET REVISION
Revisione Foglio
SCALE
Scala
SECTION
Sezione
1/ 1
1
-
We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.
Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.
BASE CONFIGURATION
Reference & Performance data
PRODUCTS
STEAM DATA
H2SO4
500 TPD
98,5% conc.
medium pressure steam
(slightly superheated)
30.800 Kg/h
25 bar (g)
245°C
SO2-SO3 CONVERSION
99,7-99.75%
EMISSIONS DATA
SO2: 417-350 PPM vol.
SO3 + acid mist: 80 mg/Nm3 (as H2SO4)
INVESTMENT FACTOR *
100
* For process plant engineering and procurement cost
CASE STUDY 1:
H2SO4 concentration/dilution & OLEUM production
0
PRELIMINARY ISSUE
REVISION
Revisione
REVISION HISTORY
Storia delle revisioni
Frontino
17/02/09
DRAWN
Autore
DATE
Data
The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.
L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.
DRAWING Nr. / Disegno Nr.
Desmet Ballestra s.p.a.
MILANO - Italy
-----------
CUSTOMER Nr. / Nr. Cliente
-
JOB
Commessa
-
SHEET
Foglio
PLANT
Impianto
TITLE
Titolo
H2SO4 + OLEUM
SHEET REVISION
Revisione Foglio
SCALE
Scala
SECTION
Sezione
1/1
1
-
We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.
Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.
CASE STUDY 1:
H2SO4 concentration/dilution & OLEUM production
Reference & performance data
H2SO4
400 TPD
(as 100% H2SO4)
98,5 %
OLEUM
100 TPD
(as 100% H2SO4)
105,5% (25% free SO3)
medium pressure steam
(slightly superheated)
30.400 Kg/h
25 bar (g)
245°C
PRODUCTS
STEAM DATA
SO2-SO3 CONVERSION
99,7-99.75%
EMISSIONS DATA
SO2: 417-350 PPM vol.
SO3 + acid mist: 80 mg/Nm3 (as H2SO4)
INVESTMENT FACTOR
104
CASE STUDY 2:
H2SO4 and SO2 gas production
0
PRELIMINARY ISSUE
REVISION
Revisione
REVISION HISTORY
Storia delle revisioni
Giacalone
17/02/09
DRAWN
Autore
DATE
Data
The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.
L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.
DRAWING Nr. / Disegno Nr.
Desmet Ballestra s.p.a.
-----------
MILANO - Italy
CUSTOMER Nr. / Nr. Cliente
-
JOB
Commessa
-
SHEET
Foglio
PLANT
Impianto
H2SO4 + SO2 GAS
SHEET REVISION
Revisione Foglio
1
SCALE
Scala
-
TITLE
Titolo
SECTION
Sezione
1/2
-
We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.
Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.
CASE STUDY 2:
H2SO4 and SO2 gas production
0
P R E LIM IN A R Y IS S U E
RE V IS IO N
R evis ione
R E V IS IO N HIS T O RY
S toria delle revisioni
G ia ca lone
1 7/02 /09
D RA W N
A utore
D ATE
Data
T he m aste r ve rsion of this d ocum e n t is stored as a digita l file in a data b ase . A p prova l proce ss is digita lly m ana g ed and n o sign atu re is visible on the docum e nt.
L 'o rigina le d el presen te do cu m en to risied e in u n data b ase d igita le.Il p ro ce sso di a pp ro va zio n e è ge stito via so ftware e le firm e n on so no visib ili sul do cu m ento .
D R A W ING N r. / D isegno Nr.
D esm et Ba llestra s.p.a.
M ILA N O - Italy
JOB
C om m essa
P LA NT
Im pianto
T IT LE
T itolo
H 2S O 4 + S O 2 G A S
-----------
C U S T O M E R N r. / N r. Cliente
S H EE T
F o glio
S H E ET R E V ISIO N
R ev is ion e Foglio
S C ALE
S ca la
S E CT IO N
S ez ione
2 /2
1
-
W e res e rv e the o wne rsh ip un de r the la w o f this d raw ing w ith proh ibition o f e ven p artial rep rod uc tion a nd to m a ke it kn ow n it th ird perso ns with out our w ritten auth orization.
C i rise rvia m o la prop rietà a te rm ini di le g ge di que sto d is eg no co n div ieto di rip ro du rlo a nc he in pa rte o d i re nde rlo n oto a te rz i s en za nos tra au torizz az ione sc ritta.
CASE STUDY 2:
H2SO4 and SO2 gas production
Reference & performance data
H2SO4
350 TPD
(as 100% H2SO4)
98,5% conc.
SO2 GAS
100 TPD
(as 100% SO2)
10% conc.
2 bar (g) ; 100°C
medium pressure steam
(slightly superheated)
29.000 kg/h
25 bar (g)
245°C
PRODUCTS
STEAM DATA
SO2-SO3 CONVERSION
99,7%
EMISSIONS DATA
SO2: 417-350 PPM vol.
SO3 + acid mist: 80 mg/Nm3
INVESTMENT FACTOR
125
CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation
0
PRELIMINARY ISSUE
REVISION
Revisione
REVISION HISTORY
Storia delle revisioni
Frontino
17/02/09
DRAWN
Autore
DATE
Data
The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.
L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.
DRAWING Nr. / Disegno Nr.
Desmet Ballestra s.p.a.
MILANO - Italy
JOB
Commessa
PLANT
Impianto
TITLE
Titolo
HIGH PRE4SSURE STEAM
(ELECTRIC POWER PRODUCTION)
-----------
CUSTOMER Nr. / Nr. Cliente
-
SHEET
Foglio
SHEET REVISION
Revisione Foglio
SCALE
Scala
SECTION
Sezione
1/2
1
-
We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.
Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.
CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation
H.P. DEMI WATER
SUPERHEATED
STEAM SUPPLY
STEAM
TURBINE
G
ELECTRIC POWER
PRODUCED
LOW PRESSURE STEAM
TO CONSUMERS
C.W.
CONDENSATE
RECOVERY
STEAM
CONDENSER
CONDENSATE
RECOVERY PUMP
CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation
Reference & performance data
PRODUCTS
STEAM DATA
H2SO4
500 TPD
98,5% conc.
High pressure steam
(superheated)
27.000 Kg/h
42 bar (g)
400°C
ELECTRIC POWER
PRODUCTION
5,5 MWh/h
SO2-SO3 CONVERSION
99,7-99.75%
EMISSIONS DATA
SO2: 417-350 PPM vol.
SO3 + acid mist: 80 mg/Nm3
INVESTMENT FACTOR
132
CASE STUDY 4:
EMISSIONS MINIMIZATION
0
PRELIMINARY ISSUE
REVISION
Revisione
REVISION HISTORY
Storia delle revisioni
Frontino
18/02/09
DRAWN
Autore
DATE
Data
The master version of this document is stored as a digital file in a database. Approval process is digitally managed and no signature is visible on the document.
L'originale del presente documento risiede in un database digitale.Il processo di approvazione è gestito via software e le firme non sono visibili sul documento.
DRAWING Nr. / Disegno Nr.
Desmet Ballestra s.p.a.
-----------
MILANO - Italy
CUSTOMER Nr. / Nr. Cliente
-
JOB
Commessa
-
SHEET
Foglio
PLANT
Impianto
EMISSION MINIMIZATION
SHEET REVISION
Revisione Foglio
1
SCALE
Scala
-
TITLE
Titolo
SECTION
Sezione
1/1
-
We reserve the ownership under the law of this drawing with prohibition of even partial reproduction and to make it known it third persons without our written authorization.
Ci riserviamo la proprietà a termini di legge di questo disegno con divieto di riprodurlo anche in parte o di renderlo noto a terzi senza nostra autorizzazione scritta.
CASE STUDY 4:
EMISSIONS MINIMIZATION
Reference & performance data
PRODUCTS
STEAM DATA
H2SO4
500 TPD
98,5% conc.
medium pressure steam
(slightly superheated)
30.600 kg/h
25 bar (g)
245°C
SO2-SO3 CONVERSION
99,90%
EMISSIONS DATA
SO2: 100 PPM vol.
SO3 + acid mist: 30 mg/Nm3
INVESTMENT FACTOR
110