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Sulphuric acid plants as a source of carbon free energy export

Summary

The sulphuric acid process is virtually carbon free and, as such, it is important to consider the energy requirements of the associated industrial complex before deciding upon what form the energy should be exported from the acid plant. In this article, Stefan Braeuner, Stefan Mohsler and Anne Mohsler of Metso Outotec use case studies to exemplify the need to fully analyse the local conditions at site before a decision is taken on a specific flowsheet.

Abstract

First, some home truths regarding sulphuric acid plants as a source of carbon free energy. In general, sulphur burning sulphuric acid plants can be considered virtually carbon free in their entirety. Keywords: sulphuric acid plant, energy export, steam export, heat utilisation, heat recovery, sustainable operation, acid plant retrofit, copper smelter, Boliden Harjavalta, Eti Bakir, Mazidagi, Green Zinc Odda, Metso Outotec

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SulGas Mumbai 2023

Summary

SulGas, South Asia's sulphur recovery and gas treating conference, returned to a live event in 2023, providing participants with a platform to interact with experts in the field, share best practices and troubleshooting tips with fellow refiners and discuss advanced technologies and operating procedures with technology providers, vendors and licensors.

Abstract

Three Ten Initiative Technologies LLP organised the 5th edition of SulGas from 1-3 February 2023 at the Hotel Holiday Inn Mumbai International Airport, Mumbai, bringing together public sector oil companies, private refiners, petrochemical, chemical and fertilizer plants, licensors, engineering companies, solvent and column equipment manufacturers, and control and instrumentation companies. Keywords: SulGas 2023, conference, sulphur recovery, gas treating, SRU instrumentation, control, SRU feeds, sour water system, sulphur degassing, CO2 capture, thermal reactor, sulphur reaction furnace, troubleshooting, lessons learned, 310i, Three Ten Initiative Technologies

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A better understanding of SRU ammonia salt formation

Summary

Gerald Bohme and Joe Brindle of Sulphur Experts Inc. combine new learnings, historical data, and recent onsite experience from operating companies to show what factors really impact ammonia plugging risk and what can be done to control them in order to allow for a wider operating range for SWS processing in the refinery SRU.

Abstract

Processing sour water stripper (SWS) gas in the refinery sulphur recovery unit (SRU) has always come with warnings about plugging downstream of the reaction furnace due to ammonia salt formation. These warnings usually result in self-imposed operating limits for SWS gas that may not be required and may limit production for the refinery. Keywords: SWS gas processing, ammonia salt formation, ammonia plugging, sulphur recovery unit, refinery SRU, SO3 formation, ammonia destruction, ammonia breakthrough, Sulphur Experts

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Improving the performance of the SRU thermal incinerator

Summary

Following the success of VectorWalls™ in the reaction furnace of sulphur recovery units over many years, VectorWalls™ are now delivering similar benefits in SRU thermal incinerators. Uday N. Parekh of Blasch Precision Ceramics reports on the deployment of VectorWalls™ to improve the performance of the SRU thermal incinerator and provide benefits such as lower fuel gas consumption and lower CO2 emissions.

Abstract

Thermal incinerators treat the tail gas effluent from SRUs prior to emitting the waste gas to the atmosphere. Their key function is to facilitate the combustion / oxidation of H2S, COS, CS2, sulphur vapour, H2 and CO to the mandated stack gas outlet specs for CO, TRS, etc. Keywords: sulphur recovery unit, SRU thermal incinerator, reaction furnace, VectorWall, fuel gas consumption, CO2 emissions, three Ts, catalyst, residence time, fuel gas firing, high efficiency burner, oxygen enrichment, Blasch Precision Ceramics

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Sneaky SO2 breakthroughs

Summary

SO2 breakthroughs remain an ever present threat to the successful operation of reductive, quench-amine-based tail gas clean-up units (TGUs). Effects can range from mild and annoying to quite severe, including failure to comply with environmental permit regulations and refinery shutdown. G. Simon A. Weiland, Nathan A. Hatcher, Prashanth Chandran, Daryl Jensen, Ralph H. Weiland, Jeff Weinfeld of Optimized Gas Treating, Inc. and Michael Huffmaster, Consultant.

Abstract

It has been shown that SO2 breakthroughs are one of the most damaging and devastating process upset events that can occur within a sulphur processing unit. The damage, if not caught and mitigated in time, can include both the quench water loop and TGU amine section. Keywords: Claus tail gas treating, environmental regulations, SO2 breakthrough, reductive, quench amine-based tail gas clean-up units, reaction kinetics, mass transfer rate model, intervention techniques, mitigation methods, hydrogenation reactor model, SulphurPro, Optimized Gas Treating

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Life cycle of a sulphur melting plant

Summary

Mathijs Sijpkes, Nuria Pascual Vasco and Jan Hermans of Sulphurnet discuss the importance of a whole life cycle cost analysis at the conceptual design phase when making investment decisions about new sulphur processing facilities.

Abstract

Sulphuric acid is one of the most widely used chemicals in the world, its main applications are the extraction of minerals in the mining industry as well as the production of fertilizers. Keywords: sulphur processing, whole life cycle cost analysis, sulphur melting plant, sulphur filtration plant, Sulphurnet

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Advances in sulphur battery technology

Summary

Lithium sulphur batteries have many advantages over conventional lithium ion batteries in terms of energy density, and they also avoid the use of costly cobalt, but they deteriorate rapidly and cannot be recharged as frequently. However, recent advances in Li-S batteries could overcome this problem and lead to widespread adoption.

Abstract

The electrification of our society, now beginning to extend into personal transportation as well as all of the other myriad ways we consume electricity these days, puts a premium on electricity storage, especially for mobile applications such as smartphones, laptops, tablets etc. Keywords: SODIUM, NICKEL, HYDRIDE, LEAD, ANODE, CATHODE, MINING, ENERGY, ELECTRIC, VEHICLES

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Controlling SO2 emissions

Summary

Most processes involving sulphur, from smelting to refining, produce sulphur dioxide as a by-product. Regulations continue to tighten on industrial SO2 emissions worldwide, leading to greater recovery of sulphur and sulphuric acid at these sites.

Abstract

Sulphur dioxide’s deleterious effects on human health and the environment are well known. In the presence of water and oxygen, either in atmospheric water or moist mucous membranes in the human body, SO2 can react to form sulphuric acid, leading to irritation of eyes and lungs in humans or in large scale deposition as ‘acid rain’. Keywords: POWER, TRANSPORT, SMELTER, INDUSTRY, SMELTING, DIESEL, GASOLINE, PPM, IMO, ACID, DESULPHURISATION, GYPSUM

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Metals markets after China's slowdown

Summary

China has been the major market for base metals, including copper, nickel, lead and zinc over the past two decades as the country rapidly industrialised. But with China's growth slowing due to demographics and market saturation, where are metals markets and production of/demand for sulphuric acid likely to go next?

Abstract

China’s growth, since Deng Xiaoping began his ‘Four Modernisations’ in 1979, has been spectacular. GDP growth averaged around 10% year on year from 1980-2010, in effect multiplying the size of the economy 15-fold over that period. Keywords: LEAD, ZINC, NICKEL, COPPER, SMELTER, SMELTING, PERU, CHILE, DRC, INDONESIA, PYRITE, GDP

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