The BAYQIK® Technology - COBRAS 2015
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Transcript of The BAYQIK® Technology - COBRAS 2015
Introduction and typical applicationsThe BAYQIK® Technology
Torsten Weber
Page 1
Forward-Looking StatementsThis presentation may contain forward-looking statements based on current assumptions and forecasts made by Bayer Group or subgroup management.
Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Bayer’s public reports which are available on the Bayer website at www.bayer.com.
The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.
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Page 3
BAYQIK®
Sulfuric Acid Technology
Introduction of Bayer Technology Services GmbH (BTS)
Introduction of the BAYQIK® Technology
Examples of applications
SulfO2Bay
Summary
• 118,900 employees
• Full year sales: EUR 42.2 billion
• 302 subsidiaries
• R&D expenditures: EUR 3.6 billion
As of December 31, 2014
Bayer Group
Page 4
Bayer Technology Services – A Leading Technology CompanyTechnology solutions, services, know-how – our core competencies for your success.
Competent service partner for value-generating, holistic solutions along the entire life cycle of chemical/pharmaceutical products, processes and plants – we initiate, implement and support technological innovations over the long term from development through engineering and construction to process optimization. Complete technology packages go beyond our spectrum of services.
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Technology Development
Project Management & Engineering
Operation Support & Safety
Bayer Technology Services –Full Year 2014
Page 6
Employees 2,300*
Full Year Sales EUR 480 millionGlobal network 21 offices in 10 countries
* as permanent or fixed-term contracts, in FTE
Global Network & Local Offices
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Leverkusen (global headquarters)Bergkamen, Berlin, Dormagen,
Krefeld, Wuppertal, WendelsheimMexico-City
Berkeley
Baytown
Pittsburgh
New Martinsville
Belford Roxo
Antwerp
Mumbai
Singapore
ShanghaiBeijing
Moscow
Saskatoon
Vapi
Sulfuric Acid Technology competence of BAYER
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Why choosing BAYER as Sulfuric Acid Technology Provider?
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Why choosing BAYER as Sulfuric Acid Technology Provider?
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• Deep knowledge in Sulfuric Acid Technology with more than 100 years of experience• Bayer has a long track record as innovator in Sulfuric Acid Technology• Inventor of the Double Absorption Process, Fluidized Bed Technology and BAYQIK®
• Strong Materials Technology competence in Sulfuric Acid Applications• Unique combination of experience in design and operation of Sulfuric Acid Plants• Strong experience in in chemical and petrochemical processes• Familiar with safety procedures and standards being mandatory in the chemical and
petrochemical industry• Provision of customized added value solutions• High reputation
BAYQIK®
Technology
Page 11
Superior process to treat
gases from any source ofSO2 at any concentration
Challenges in SO2-Gas ProcessingInitiator for Invetion – Primary off gas treatment from Nonferrous Metal Production
RoastingSmelting
Converting
Heat RemovalSteam generation Dust removal
QuenchingScrubbingSulfidic ore
Air
SteamMetal Slag
Wet-ESPHg-Removal
ExistingSulfuric acid
plant
Stack
Sulphuric Acid
High strength SO2-process gasOxygen enriched air
Cd-, As-RemovalGas drying
Bottleneck
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Equilibrium CurveSO2-c
onve
rsio
n [%
]
bed exit temperature [°C]400 450 500 550 600 650 700 750
10
20
30
40
50
60
70
80
90
100
0
Operation temperature of catalyst
Catalytic Processes using V2O5Adiabatic SO2-conversion
Bed 2
Bed 1
Bed 3
Adiabatic Process of SO2-conversion
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Equilibrium CurveSO2-c
onve
rsio
n [%
]
bed exit temperature [°C]400 450 500 550 600 650 700 750
10
20
30
40
50
60
70
80
90
100
0
Operation temperature of catalyst
Limits of the adiabatic process
Catalytic Processes using V2O5Adiabatic SO2-conversion (Limits)
14% SO2
16% SO2
18% SO2
12% SO2
Page 14Page 14
SO2-concentrations above 13 Vol.% lead to temperatures that exceed the thermal stability limits of the catalyst
SO2-c
onve
rsio
n [%
]
bed exit temperature [°C]400 450 500 550 600 650 700 750
10
20
30
40
50
60
70
80
90
100
0
Operation temperature of catalyst
Catalytic Processes using V2O5Isothermal SO2-conversion
No limitation in
SO2 concentration
Continuous removal of the heat of reaction to keep the temperature within the operation limits of the catalyst at any time
Isothermal Processing
Equilibrium Curve
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What is BAYQIK®?
• BAYQIK is a Technology for the treatment of SO2 containing process gases from any sources with the intention to produce sulfuric acid, Oleum or SO3 (gaseous or liquid).
• Basic idea is an isothermal tubular converter for the conversion of SO2 to SO3.
• Due to the unique design of converter and process the limits of existing dry and wet sulfuric acid production technologies are eliminated.
• Standard commercially available Vanadium Pentoxide or cesium promoted Vanadium Pentoxide Catalyst is used in the process.
Modular SO2-converter
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Bringing the Converter…
…into the Heat Exchanger!
BAYQIK® – Converter
• Tubes are filled with conventional V2O5-catalyst
• Reaction SO2 + ½ O2 SO3 takes place inside the tubes
• Heat of reaction is removed continuously by cooling medium
Cooling media In
Process gas
Cooling medium
Cooling medium
Process gasProcess gas
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Temperature Profile
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Tube length x
Tem
pera
ture
t
Hot Spot with maximum temperature difference
Temperature curve of process gas
Temperature curve of cooling medium
Temperature Process gas outlet
Temperatur Process gas inlet
Xm
tmax
Temperature Cooling medium outlet
Temperature Cooling medium inlet
Catalyst filling procedure
Funnel with orifice
Support for catalyst
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• Choosing right catalyst type (clients preferred catalyst possible)
• Installation of catalyst support
• Filling via orifice with specified diameter
• Pressure drop measurements
• Adjusting and documentation of pressure drop
• Discharge of catalyst from the bottom by removing support or
• from top with pressurized air lance and vacuum device
BAYQIK®
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GAS / GAS –HX
Start-upHeater
COOLING AIRBLOWER
HEAT REMOVALBAYQIK® CONVERTER
RICH SO2
PROCESS GAS
LEAN SO2
PROCESS GAS
BAYQIK® Add-on configuration
Example – Primary off gas treatment from Nonferrous Metal ProductionInstallation of BAYQIK® eliminates bottlenecks in existing sulphuric acid plants and improves SO2-capture
RoastingSmelting
Converting
Heat RemovalSteam generation Dust removal
QuenchingScrubbingSulfidic ore
Air
SteamMetal Slag
Wet-ESPHg-Removal
ExistingSulfuric acid
plant
Stack
Sulphuric Acid
High strength SO2-process gasOxygen enriched air
Cd-, As-RemovalGas drying
Bottleneck
Page 21
BAYQIK®
HighSO2-concentration
LowSO2-concentration
SO2-concentrationat Design value
of Sulfuric Acid plant
BAYQIK® Add-onTypical Plant Configuration
Page 22
Start-upheater
COOLING AIRBLOWERHEAT REMOVALBAYQIK® CONVERTER
GAS-GASHEAT EXCHANGER
SO2-BLOWER
BAYQIK®
ADD-ON PLANT
DRYINGTOWER
MAINBLOWER
HX III HX I HX II INTERMEDIATEABSORPTION
FINALABSORPTION STACK
AMBIENTAIR
HX IV
WHB
Bed 1
Bed 2
Bed 3
Bed 4
INTERMEDIATEABSORPTION
H2SO4
EXISTING DOUBLEABSORPTION PLANT
BAYQIK® Add-onControl Mode
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HX Converter Pass 1
BAYQIK
HX Absorber
QIC
M
SO2
SO2 > 8 Vol%
n
t
Blower Speed
Volume FlowV
t
c
t
SO2 Concentration
Set Point = 8 Vol% SO2
BAYQIK® Add-onControl Mode
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HX Converter Pass 1
BAYQIK
HX Absorber
QIC
M
SO2
Set Point = 8 Vol% SO2
c
t
SO2 Concentration
n
t
Blower Speed
V
t
Volume Flow
c
t
8 Vol%c
t
BAYQIK® Add-onProject Example
Page 25
Natural gas
Ambient air
Combustion airblower
Start-upheater
Cooling airblowerHeat removalBAYQIK® Converter
Gas-GasHeat Exchanger
SO2-Blower
DryingMain
Blower HX HX HXSteamsuperheater
IntermediateAbsorber
FinalAbsorber Stack
BAYQIK®
Add-on Unit
Ambientair
SO2-Gas
HX
IntermediateAbsorber
Steam 45 bar
Water injection
QSO2
BAYQIK® Add-onProject Example
Customer: Berzelius Stolberg, GermanySO2-Gas source: Metallurgical Plant
SO2-concentration: 18 Vol% (peaking up to 23 Vol%)
Total Capacity: 450 metric tons H2SO4 per day
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BAYQIK® Add-onDealing with fluctuating process conditions
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DATA FROM PROCESS CONTROL SYSTEM
Extended Catalyst Lifetime SO2 inlet concentration
18,2 Vol% SO2 outlet concentration 3,0 Vol%
Temperature curve over tube length
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CAPEX Comparison
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BAYQIK Technology shows lowest CAPEX Cost compared to alternative conventional options
Cooling airblower
BAYQIK®
ConverterHX
Blower
Pass 5
Pass 4
Pass 3
Pass 1
Pass 2
BAYQIK Add-on
WHB
Gas fromS-Burner
Superheater
SO2-conc. ≤ 10 Vol%
EconomizerInterpass-HX
Gas toIAT
Gas fomIAT
Economizer
Gas toFAT
BAYQIK® Add-on configurationElemental Sulfur Burning Plant (1)
30
WHB,Superheater. or Eco
Existing Plant
Cooling airblower
BAYQIK®
Converter
Pass 5
Pass 4
Pass 3
Pass 1
Pass 2
WHB,Superheater. or Eco
Existing Plant
WHB
Gas fromS-Burner
Superheater
Flowrate reduced by ~ 25%
EconomizerInterpass-HX
Gas toIAT
Gas fomIAT
Economizer
Gas toFAT
BAYQIK® Add-on configurationElemental Sulfur Burning Plant (2)
WHB,Superheater. or Eco
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BAYQIK Add-on
Cooling airblower
BAYQIK®
ConverterHX
Blower
Pass 5
Pass 4
Pass 3
Pass 1
Pass 2
AbsorptionTower
Existing Plant
WHB
Gas fromS-Burner
Superheater
SO2-conc. ≤ 10 Vol%
EconomizerInterpass-HX
Gas toIAT
Gas fomIAT
Economizer
Gas toFAT
BAYQIK® Add-on configurationElemental Sulfur Burning Plant (3)
Sulfuric Acid
Make-upwater
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Flow reduced by 7%
WHB,Superheater. or Eco
BAYQIK Add-on
Regenerable SO2 Scrubbing + BAYQIK® Plant configuration
DryingTower
HX AbsorbtionTower
Stack
Ambient Air(or Oxygen)
RegenerableSO2 Scrubbing
SO2 - Gas
Clean GasWet SO2-Gas (95 – 98 Vol% of SO2)
Start-upheater
Cooling airblower
EnergyRecoveryBAYQIK® Converter
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H2SO4
98,5%
DeminWater
SULFO2BAY®
Technology
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SulfO2Bay®
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HP Steam 47 t/h
TGSV=200Nm3/h
Sulphur 10t/hOxygen
BAYQIK®
Absorber
Burner
Boiler
HTSCoolingsystem
LP steam 9 t/h
Sulfuric Acid 31 t/h
Overall Conversion99,99%
SummaryBAYQIK® – Process
No limitation in SO2-concentration
Has an operating range from 0 – 100% load Deals with fluctuating process conditions of input streams Low CAPEX and OPEX Improves on-stream time of upstream processes Easy implementation / Short time for Tie in Operates fully automated Has lowest catalyst demand & increased catalyst lifetime Is proven technology, safe and reliable
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Thank you!
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