The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 201
CRITICAL ASPECTS IN THE DEFINITION CRITICAL ASPECTS IN THE DEFINITION
OF THE OPTIMUM CONFIGURATION OF A OF THE OPTIMUM CONFIGURATION OF A
SULPHUR BURNING PLANTSULPHUR BURNING PLANT
SUN CITY SUN CITY –– SOUTH AFRICASOUTH AFRICA
May 4May 4thth -- 66thth,, 20092009
BASE DECISIONS FOR THE DEFINITION BASE DECISIONS FOR THE DEFINITION
OF THE CONFIGURATION OF A SULPHUR OF THE CONFIGURATION OF A SULPHUR
BURNING PLANTBURNING PLANT
TYPE OF RAW MATERIALTYPE OF RAW MATERIAL
PRODUCTSPRODUCTS CO CO -- PRODUCTSPRODUCTS
EMISSSIONSEMISSSIONS
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
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TYPE OF RAW MATERIALTYPE OF RAW MATERIAL
PRODUCTSPRODUCTS
SULPHUR LIQUID
SOLID
WHICH ?
HOW MUCH ?
QUALITY ?
S.A. 92-99,5% wt
OLEUM 20-25% free SO3
SO2
GASEOUS (CONC.?)
LIQUID
SO3 GASEOUS (CONC.?)
LIQUID
OTHER
SPECIFICATIONS
COCO--PRODUCTS PRODUCTS
STEAM & ELECTRIC POWER REQUIREMENTSSTEAM & ELECTRIC POWER REQUIREMENTS
SUPERHEATED
STEAM
P > 40 barg
T >370 °C
SATURATED OR
SLIGHTLY
SUPERHEATED
Condensing
Turbine
Condensate
L.P. Steam bleeding for site users
(up to 25% of the steam fed flow)
M.P./L.P. Steam for site usersBack
Pressure
Turbine
Second
turbine Condensate
M.P./L.P. Steam for site users
E.P.
E.P.
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 203
COCO--PRODUCTS PRODUCTS
STEAM & CONDENSATE CIRCUIT DEFINITIONSTEAM & CONDENSATE CIRCUIT DEFINITION
H2SO4 PLANT STEAM USER
The user does not
consumes all the
steam produced
and/or does not
g i v e b a c k
c o n d e n s a t e
SteamExtra
Steam
Condensate
S T E A M
C O N D E N S E R
I N S T A L L A T IO N
or
RELEASE OF THE
EXCESS STEAM TO
THE ATMOPSHERE
AND SIGNIFICANT
OV E RDE S IGN OF
THE DEMI WATER
UNIT (UP TO 5 TIME
L A R G E R )
T h e u s e r
consumes all the
steam fed and
g i v e s b a c k
c o n d e n s a t e
H2SO4 PLANT
Condensate return
STEAM USER
Steam
PURGE / LOSSES
EMISSIONSEMISSIONS
DCDA
WITHOUT SCRUBBER
DCDA or SCSA
WITH SCRUBBER
STANDARD
CONFIGURATION
EMISSION
MINIMIZATION
SO2: 350-417 PPM
Acid mist + SO3: 80 mg/Nm3
SO2: down to 100 PPM
Acid mist + SO3: up to 30 mg/Nm3
H2O
2
NaOH
Others (Limestone)
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 204
BASE CONFIGURATIONBASE CONFIGURATION
Sulphur
burningAir drying
W H R B +
ECONOMIZERS
4° pass
3° pass
2° pass
1° pass
CIP/HIP SO3 absorption &
acid circulation
Deareator
AIR SULPHUR DEMI-WATER MAKE-UP PLUS
CONDENSATE RECOVERY (IF ANY)
M.P. STEAM H2SO
498,5%
BASE CONFIGURATIONBASE CONFIGURATION
DEAREATORAIR
DRYING
ACID
CIRCULATION
CONVERSION
CIP/HIP
WHRB + ECO
SULPHUR
BURNING
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-
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PLANT
Impianto
TITLE
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SHEET
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SHEET REVISION
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SCALE
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SECTION
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1 / 1
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PRELIMINARY ISSUE0 Frontino 17/02/09
REVISION
Revisione
REVISION HISTORY
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DRAWN
Autore
DATE
Data
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-
-
H2SO4 + OLEUM
-----------
-
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 205
BASE CONFIGURATION BASE CONFIGURATION
Reference & Performance dataReference & Performance data
PRODUCTS H2SO
4500 TPD 98,5% conc.
STEAM DATA medium pressure steam
(slightly superheated)
30.800 Kg/h 25 bar (g)
245°C
SO2-SO
3CONVERSION 99,7-99.75%
EMISSIONS DATA SO2: 417-350 PPM vol.
SO3
+ acid mist: 80 mg/Nm3 (as H2SO
4)
INVESTMENT FACTOR * 100
* For process plant engineering and procurement cost
CASE STUDY 1: CASE STUDY 1:
HH22SOSO44 concentration/dilution & OLEUM productionconcentration/dilution & OLEUM production
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Commessa
MILANO - Italy
DRAWING Nr. / Disegno Nr.
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-
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PLANT
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DATE
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-
-
H2SO4 + OLEUM
-----------
-
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Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
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CASE STUDY 1: CASE STUDY 1:
H2SO4 concentration/dilution & OLEUM production H2SO4 concentration/dilution & OLEUM production
Reference & performance dataReference & performance data
PRODUCTS H2SO
4400 TPD
(as 100% H2SO
4)
98,5 %
OLEUM 100 TPD
(as 100% H2SO
4)
105,5% (25% free SO3)
STEAM DATA medium pressure steam
(slightly superheated)
30.400 Kg/h 25 bar (g)
245°C
SO2-SO
3CONVERSION 99,7-99.75%
EMISSIONS DATA SO2: 417-350 PPM vol.
SO3
+ acid mist: 80 mg/Nm3 (as H2SO
4)
INVESTMENT FACTOR 104
CASE STUDY 2: CASE STUDY 2:
H2SO4 and SO2 gas productionH2SO4 and SO2 gas production
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Desmet Ballestra s.p.a.
JOB
Commessa
MILANO - Italy
DRAWING Nr. / Disegno Nr.
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PLANT
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DATE
Data
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-
-
H2SO4 + SO2 GAS
-----------
-
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
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CASE STUDY 2: CASE STUDY 2:
H2SO4 and SO2 gas productionH2SO4 and SO2 gas production
Giacalone
H2SO4 + SO2 GAS
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C U STOM ER N r. / Nr. Cliente
PLANT
Impianto
TITLE
Tito lo
S HE ET
Foglio
S HE ET R EV ISION
R ev isione Foglio
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S cala
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A utore
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Data
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-
-
-----------
-
CASE STUDY 2: CASE STUDY 2:
HH22SOSO44 and SOand SO
22 gas production gas production
Reference & performance dataReference & performance data
PRODUCTS H2SO4 350 TPD
(as 100% H2SO4)
98,5% conc.
SO2 GAS 100 TPD
(as 100% SO2)
10% conc.
2 bar (g) ; 100°C
STEAM DATA medium pressure steam
(slightly superheated)
29.000 kg/h 25 bar (g)
245°C
SO2-SO
3 CONVERSION 99,7%
EMISSIONS DATA SO2: 417-350 PPM vol.
SO3
+ acid mist: 80 mg/Nm3
INVESTMENT FACTOR 125
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 208
CASE STUDY 3: CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation POWER generation
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DRAWING Nr. / Disegno Nr.
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PLANT
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HIGH PRE4SSURE STEAM
-----------
-(ELECTRIC POWER PRODUCTION)
CASE STUDY 3: CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation POWER generation
CONDENSER
TURBINE
SUPERHEATED STEAM FROM H2SO4 BOILER 42 Barg / 400°C
H2O (LIQUID) 90°C
0.0 Kg/h
ELECTRIC POWER
FOR H2SO4
PLANT OPERATION
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MILANO - Italy
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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.
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PLANT
Impianto
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HIGH PRE4SSURE STEAM
-----------
-(ELECTRIC POWER PRODUCTION)
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 209
CASE STUDY 3: CASE STUDY 3:
HIGH PRESSURE STEAM configuration for ELECTRIC HIGH PRESSURE STEAM configuration for ELECTRIC
POWER generation POWER generation
Reference & performance dataReference & performance data
PRODUCTS H2SO
4500 TPD 98,5% conc.
STEAM DATA High pressure steam
(superheated)
27.000 Kg/h 42 bar (g)
400°C
ELECTRIC POWER
PRODUCTION
5,5 MWh/h
SO2-SO
3CONVERSION 99,7-99.75%
EMISSIONS DATA SO2: 417-350 PPM vol.
SO3
+ acid mist: 80 mg/Nm3
INVESTMENT FACTOR 132
CASE STUDY 4: CASE STUDY 4:
EMISSIONS MINIMIZATIONEMISSIONS MINIMIZATION
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EMISSION MINIMIZATION
-----------
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The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 210
CASE STUDY 4: CASE STUDY 4:
EMISSIONS MINIMIZATION EMISSIONS MINIMIZATION
Reference & performance dataReference & performance data
PRODUCTS H2SO
4500 TPD 98,5% conc.
STEAM DATA medium pressure steam
(slightly superheated)
30.600 kg/h 25 bar (g)
245°C
SO2-SO
3CONVERSION 99,90%
EMISSIONS DATA SO2: 100 PPM vol.
SO3
+ acid mist: 35 mg/Nm3
INVESTMENT FACTOR 110
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 211
The Author
Maurizio VERRI, Desmet Ballestra SpA (Italy), Deputy Process Manager
1983 : MS degree in Chemical Engineering
1984 : Started working as Process Engineer for Offshore Installation for TECNOMARE S.p.A.
1988 : Joined Ballestra S.p.A – Process Engineer for Sulfonation, Spray Drying and Detergent
Plants
1992 : Deputy Process Manager
2002 : Technical Coordinator of Chemical Plants Division (DIC) of DBI. Technologies covered:
- Dodecyl Benzene Production (UOP Licence)
- Sulfuric Acid Plants (MECS Licence and In-house technology for small plants).
- Fertilizers (SSP / NPK production)
- Zeolite 4A (detergent grade)
- Sodium Silicate
Working experience includes Process Design, Commissioning and Start-up for all the
technologies outlined.
The Southern African Institute of Mining and Metallurgy
Sulphur and Sulphuric Acid Conference 2009
M Verri
________________________________________________________________________
Page 212
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