MESA REDONDA 2010MESA REDONDA 2010Latest Developments in

Sulphuric Acid Technology by

MESA REDONDA 20102

Extract of Developments in last yearsOutotec Acid Technology in briefOTOVentTMTM – Venturi Quench SystemQ yEnergy Recovery HEROSHEROSTM TM ProcessProcessDrying & Absorption TowersDrying & Absorption Towers- FiDiTM TM System – Film Distributer

Vertical Wire MeshTMTM- Vertical Wire MeshTMTM

- Candle Filter Plate Support SystemTMTM

in Presentation Noracid Sulphur Combustion – New LURO2TMTMSulphur Combustion – New LURO2Sacrificial Heat Exchanger

MESA REDONDA 2010

3

Outotec in briefOutotec in brief

Operational model2010

Operational modelCustomers

Market Operations (incl. Market Areas)

SupplySupply

Business Infrastructure Services

ctio

ns

Energy, Light

Metals & Environ-

Ferrous Solutions

Non-ferrous

Solutions

Technology Management

Strategy

port

Fun

c mental Solutions

Solutions

Finance & Control

Legal Affairs

ared

Sup

p

Human CapitalSha

Business Areas

4© Outotec4

Services5 2010 © Outotec

ServicesLifecycle service solutions and a global network of service centers forglobal network of service centers for Outotec’s customersServices from spare parts support

d d li it d i tand delivery, site and equipment maintenance and plant audits to optimization and upgrades, project

Expertise Solutions for

management and training.

Expertise Solutions forComponent servicesExpert servicesE i t d

PlantsProcessesE i tEquipment upgrades

Operation and maintenance

Equipment

Recent acquisitions 2010

© Outotec6 2010

Recent acquisitions 2010Millteam maintenance services for mining companies and special expertise in grinding millcompanies and special expertise in grinding mill service

Ausmelt complements our smelting technology p g gyportfolio

Larox filtration technologies and services enable ff l i f h h l l h i fus to offer solutions for the whole value chain from

mine to metal

EdmestonEdmeston

Specializing in engineering and supply of process equipment for sulfuric acid plants. p q p p

Unique know-how of special stainless steel grades suitable for use in highly corrosive

i tenvironment.

MESA REDONDA 2010

7

OTOVentOTOVent

Q h V t i S tQuench Venturi System

Traditional Areas of Concern ithMESA

REDONDA 20108

Traditional Areas of Concern withQuench Towers or Quench Venturis

Areas where Hot & Dry and subsequent Cold & Wet Conditions are manifest

Nozzle Area of Quench VenturiGas Inlet of Quench Tower

Req irements for Impro ementMESA

REDONDA 20109

Requirements for Improvementrealized by OTOVenty

1. Defined Areas for only Hot / Dry and only Cold / Wet Conditions ANDy

2. Avoidance of Dust / Partical Deposits at Wall and In / On Acid Overflow

hot/dry conditionandand

wet/cold condition

De elopement of Design Feat resMESA

REDONDA 201010

Developement of Design Features

1. Separation of Hot & Dry and Cold & Wet AreasCreation of an Overall Localized Even Acid Film at Wall / Bricklining above Acid Spray Nozzle Level

2. Avoid Dust & Partical Deposits on WallpWall / Bricklining above Acid Spray Nozzle Level is in the Shadow of the Gas Inlet ( larger inside diameter )

3. Avoid Dust & Partical Deposits In & On Acid Overflow Acid Overflow Channel is Conical

- to Avoid Partical Deposits in Channel by Higher Acid Velocity at the Bottom

to Create an equal Film at the Overflow by Lower Velocity at- to Create an equal Film at the Overflow by Lower Velocity at Top

MESA REDONDA 2010

11

Fl A l i b Fl tFlow Analysis by Fluent Wall by Loadcase 380 / 70

Thickness of Film (m) Temperature of Film (K)

Temperature ( K ) Analysis by Fluent

MESA REDONDA 2010

12

Temperature ( K ) Analysis by Fluent for Loadcase 380 / 70

f G of Droplets of Gas

MESA REDONDA 2010

13

T pes of Application

MESA REDONDA 2010

14

Types of Application

Retrofit to Optimize GRetrofit to OptimizeExisting Quench Tower

Green Field Application

MESA REDONDA 2010

15

Energy RecoveryEnergy RecoveryEnergy Recovery Energy Recovery

HEROSHEROSTM TM ProcessProcess

MESA REDONDA 2010

16

Excess Energy RemovalExcess Energy Removalmain blower

atmosphere

HP STEAM GENERATION

Excess Energy RemovalExcess Energy Removal

air

sulphur

HP STEAM GENERATION

LOW TEMPERATURE HEAT RECOVERY

sulphur

waste heatcombustionstack

product aciddrying tower

waste heatboiler

combustionfurnace

converter

superheater

evaporatorintermediate absorption

intermediateheateconomizer

final absorption evaporator p

towerexchangerp

tower

10/26/201017

Outotec HEROS System Outotec HEROS System

Feed Water

yyRecent advances Recent advances -- Enhanced HEROSEnhanced HEROSTMTM

IIN COMPARISON TO N COMPARISON TO HHEROSEROSTMTM WITH WITH EARLIER EARLIER DDESIGNESIGNFeed WaterPreheating

Dilution Water

gas in out

LP-Steam

gAcid Cross-flow

c/w

Boiler Feed Water

18

Outotec HEROS SystemOutotec HEROS System Design PhilosophyDesign PhilosophyOutotec HEROS SystemOutotec HEROS System –– Design PhilosophyDesign Philosophy

Aspect Description Related HEROS feature AdvantagesAspect Description Related HEROS feature Advantages

Operational Flexibiity • Ability to vary the amount of LP steam

d ti ith t

• Controlled bypass of the venturi absorber

t

• LP Steam can be easily adjusted in HEROS and

b ti f SO3 i IATproduction without altering the production of the Acid plant

system• IAT designed for 100% capacity

absorption of SO3 in IAT is ensured

Safety • Minimize corrosion in case of normal operation

d ff t diti

• Material selection (alloy 3033)

N b il t

• Plant operation in a range of 97.5 – 99.5 %

F t i l ti f b iland off-set conditions • New boiler concept• Enhanced safety concept (leak detection)

• Fast isolation of boiler• Early detection of leaks in water/steam circuit

Overall Plant Availability • Failure of hot circuit must not lead to plant shutdown

• Seperation of hot acid circuit from system by gravity• IAT design for 100 %

• Acid and HP steam production at nominal capacity possible.

gcapacity

19

Outotec HEROS SystemOutotec HEROS SystemOutotec HEROS System Outotec HEROS System Recent advances Recent advances -- Enhanced HEROSEnhanced HEROSTMTM

Sulphuric AcidLP-Steam Process Gas

BFW

withSO2 & SO3

SO2 gas

Process water

1

62

35

4

Shell and tube type heat exchanger (3)

Horizontal arrangement above pump tank

Mixer with water injection at inlet at (8)

Tube side boiling

6Separate steam drum (1)

Forced circulation (2)

10/26/201020

Insert: Glass / PTFECover: 3033

Flange: 316L HHEROSEROSTMTM: Application of Material: Application of Material

Cover: 3033

Piping: 3033

CS / Bricks 40 2 x 65

p g

CS / Bricks 40, 2 x 65

Sleeve

Bricklined Venturi 1 maximum reliability1. maximum reliability2. 100% acid production even in case of boiler failure!

MESA REDONDA 2010

21

HEROS™HEROS™ Material SelectionMaterial SelectionNicrofer 3033 - Excellent weldability, high ductility

300

HEROS™ HEROS™ –– Material SelectionMaterial Selection

250

300

Nicrofer 3033

200

Super Ferrite

150

empe

ratu

re °C

Sandvik SX

100

Te

Sandvik SX

310 SS

HEROSTypical range of operation

50310 SS

096.5 97.0 97.5 98.0 98.5 99.0 99.5 100.0

Acid Concentration % H2SO4

10/26/201022

Ri k Miti tiRi k Miti ti

LEAKAGE / FAILURE

Risk MitigationRisk Mitigation

15

20

25

30

w in

m³/h BFW

Process water

Fast detection vital Supervision ofAcid ConcentrationBoiler Water Contamination

0

5

10

40 60 80 100

Flow

Process- and BFW-ManagementEnergy Balance

Plant load in %

45.0050.00

Loss preventionSeparate drains for acid and water: fast and safely 10 00

15.0020.0025.0030.0035.0040.00

Flow

in m

³/h

BFW

Process water

fast and safely

Summary

-5.00

10.00

0 1 2 3 4 5 6 7 8 9 10 11 12

Leak size in mm

Can operate 97.5 – 99.5 % H2SO4 (98.5 ± 1.0 %)

Employs proven equipment and materials of construction

For piping and evaporator, special material 3033

Is easy to install as a plant upgrade, revamps

MESA REDONDA 2010

23

HEROS™HEROS™ LayoutLayoutHEROS™ HEROS™ –– LayoutLayout

MESA REDONDA 2010

24

HEROS™ HEROS™ –– SectionSection

MESA REDONDA 2010

25

Drying &Drying &Drying &Drying &

Absorption TowersAbsorption Towers

MESA REDONDA 2010

26

TowerTower OptionsOptionsTower Tower -- OptionsOptions

Integrated IntegratedConventionaltower design

Combinedventuri +

packed bed

top heatexchanger

venturi forlarge plants

Self-supporting dome Acid exit at side Process water addition

MESA REDONDA 2010

27

CONVENTIONAL TOWER DESIGNCONVENTIONAL TOWER DESIGN

with special attention to:

-multi-layer bricklining

- self-supporting domes

-distribution system of SX

- adequate acid mist and

droplet removal

MESA REDONDA 2010

28

Outotec Edmeston TOWER DESIGN

with special attention to:

-SX Stainless Steel

-one-layer bricklining up to dome-one-layer bricklining up to dome

- self-supporting domes

distribution system of SX-distribution system of SX

- adequate acid mist and

droplet removal with shell of 316Ldroplet removal with shell of 316L

MESA REDONDA 201029

SS T f SX d T f 316LSS Towers of SX and Top of 316L

MESA REDONDA 201030

SX Material by Outotec Edmeston

For

Towers• Towers

• Pump Tanks

• Irrigation System

• Acid Coolers• Acid Coolers

• Piping

MESA REDONDA 2010

31

Conventional Acid DistributionConventional Acid Distribution

nozzle

deflector plateliquid

Conventional Acid DistributionConventional Acid Distribution

nozzle trajectory

p a c k i n g

MESA REDONDA 2010

32

Modern Acid DistributionModern Acid Distribution

FiDiTMTM system Elemants

Stainless Steel Tower SX3 000 t/d S burning Plant3,000 t/d S-burning Plant

MESA REDONDA 201033

Optimization of Acid DistributionOptimization of Acid Distributionby Fluid Dynamic Analysis

Standard configuration without orifices

Orifice of 80% at arm 4, orifice of 60% of radius at arm 5

MESA REDONDA 201034

Comparison of Irrigation SystemsTrough System LURGI System Outotec FiDiTMTM SystemTrough System LURGI System Outotec FiDi System

Free Gas Flow Area Free Gas Flow Area Free Gas Flow Areathrough Irrigation System

45 to 55 %

Free Gas Flow Areathrough Irrigation System

55 to 60 %through Irrigation System

65 to 75 % %

MESA REDONDA 201035

LAB Test - FIDITMTM

Sulphur Burning Plants

36

Fluid Dynamic Analysis Vertical Wire MeshTMTM

Sulphur Burning Plants

37

Pictures of Vertical Wire MeshTMTM

MESA REDONDA 201038

Outotec Support TMTM of Candle Filter PlateOld Design New

D fl ti (Deflection ( mm

170 Center 3170 Maximum 16

Dia 5.4 m - Dead weight & 250 kg / candle

Main Benefit: Due to Less in Deflection nearly no Bending at Flange / Gasket

MESA REDONDA 201039

Not mentioned Developments todayPropriety Equipment

New Design of SS Converter Outotec Edmeston SX Tower without Bricks2 New Designs of High Efficiency Scrubberg g yEnhanced Design of Wet ESP

Process ApplicationsLuRecLuRecConcentration ExpandEtcEtc.

MESA REDONDA 2010

40

Thank you forThank you foryour attention !your attention !

www outotec comwww.outotec.com

40 | 26 October 2010 | TAK-S Meeting Worms40 | 26 October 2010 | BHP – Olympic Dam