However, to comply with the still more stringent regulations being placed on the sulfuric acid industry to lower SO2 emissions, Topsøe has developed a new sulfuric acid catalyst designated VK-701 LEAP5™. This catalyst was introduced to the market in 2010. VK-701 LEAP5™ is based on a novel technology which circumvents the internal transport deficiencies of existing commercial sulfuric acid catalysts and thereby offers exceptionally high activity in strong gases. Since the introduction of this catalyst, sulfuric acid plants have used this catalyst to meet emission requirements lower than previously possible with any catalyst solution.
During Cobras, Topsoe will present examples on reducing SO2 emissions during both Start-up and steady operation, by implementing a tailor-made catalyst solution using VK59, VK69 and VK-701 LEAP5™.
Topsoe wsa technology for small compact sulfuric acid production units - Haldor Topsoe - COBRAS 2015
1. Topsoe WSA technology
for small compact
sulfuric acid production
units
COBRAS 2015, Fortaleza, Brazil
1
2. 2
Presentation – main contents
• Introduction to Rio Seco
• Introduction to the WSA technology
• Typical WSA plant design
• WSA plant equipment
• References
• Summary
3. 3
Rio Seco
• Part of the large Buenaventura group in Peru
• Procesadora Industrial Rio Seco S. A. plant, Hural 100 km from Lima
• Processing of silver ore by use of among other things sulfuric acid
• Magnesium sulphates are produced and an H2S stream is generated which needs cleaning
• The H2S stream and sulfur is burned in WSA plant for making 60 MTPD of 98 % acid for local
consumption at the site
• Gas cleaning and acid production in same unit
• High pressure steam from the WSA process is used for electricity production
• Remote location so local electricity production has value
• Avoid authority inspections/problems related to buying acid
4. 4
What is WSA?
Wet gas Sulfuric Acid
A catalytic process for purification of sulfur- containing streams while producing
concentrated sulfuric acid
S
H2S
RSH
COS
CS2
SO2
SO3
(NH4)2SO4
H2SO4
Sulfuric acid
Cleaned gas
HP Steam
5. 5
Why WSA?
• Up to 99.95 % of the sulfur content is recovered
• Treats the mixture of H2S and S
• Sulfur is recovered as concentrated sulfuric acid of commercial grade
• No waste products
• NH3 and hydrocarbons are accepted in the feed gas
• Excellent heat management
• Simple lay-out, few components
• Attractive operating cost and lower investment than competing technologies
21. 21
Rio Seco plant data
• Acid capacity is 60 MTPD of 98 % acid. 50 % from H2S gas and 50 % from burning of S
• Electricity production approx 1 MW(e)
• Foot print is 30 m x 18 m
• Cooling water consumption (circulating) is very low
• H2S waste gas incinerated with the sulphur
• H2S = 28 % vol
• N2 = 25 % vol
• CO2 = 45 % vol
• H2O = 2 % vol
22. 22
Typical scope of supply
• License package
• Basic engineering
• Proprietary equipment
• Catalyst
• Supervision during erection and commissioning
Optional:
• Detailed engineering
• Supply of other equipment
• WSA condenser internals
• Acid vessel, pumps and cooler
• Acid piping and instruments
• Interbed heat exchangers
• Process gas cooler
• Mist control units
23. 23
WSA plants – applications
• Oil refining (39)
• Coking (33)
• Gasification (31)
• Metallurgical industry (14)
• Viscose fibre industry (8)
• Other applications (10)
• Total (135) – From the 135 plants 11 plants are burning sulphur as feed
25. 25
WSA technology summary
• Clean, proven and reliable technology
• No consumption of chemicals or other additives, and no production of waste products
• High conversion of sulfur containing feeds into commercial-grade sulfuric acid, with
possibility for NOx reduction if required
• Effective heat recovery
• Simple layout with relatively small plot area
• Attractive operating economy