WSA technology for treatment of H2S and SO2 gases producing sulphuric acid including acid production based

on molten sulphur
Torben Christensen

Presentation - Main contents

Introduction to the subject WSA technology Treatment of the feed streams SO2, H2S and S The basic concept of the WSA process The detailed WSA process Reference situation Conclusion

WSA technology - The concept

Converts SO2 in off-gases into commercial-grade sulphuric acid Treats the off-gas in wet condition, i.e. no drying of the off-gas is required No consumption or additives No production of waste products Simple, efficient, reliable and competitive process

Principles of the WSA process, H2S and sulphur

Clean process gas to stack Hot combustion air Cooling water

H2S gas/ Molten sulphur

Incineration

SO2 conversion

Gas cooling

Acid condensation

Acid cooling

Product acid

Atmospheric air HP superheated steam

Cooling water return

Combustion Hydration Oxidation Condensation Large export of high pressure steam, 2-3 ton/ton acid produced Low cooling water consumption, 8-9 m acid produced H2S SO SO O H (gas) O= = H = SO H H SO SO O + 99 (gas) (liquid) SO kJ/mole +101 518 +3/ton 90 kJ/mole kJ/mole kJ/mole 2 +41.5 3 2O 2 2= 2 2 3 2 4+ 4 2+

Principles of the WSA process, SO2 gas

Clean process gas to stack Hot air for preheating Cooling water

SO2 rich off-gas

Preheating

SO2 conversion

Gas cooling

Acid condensation

Acid cooling

Product acid

Atmospheric air HP superheated steam

Cooling water return

Hydration Oxidation Condensation No fuel consumption with an SO2 content above 3 % (vol.)
3/ton acid produced SO Low cooling consumption, 8-9 m90 H SO +H O (gas) Owater = == H SO H SO SO + (gas) 99 (liquid) kJ/mole + 101 + kJ/mole kJ/mole

23 2 4 2 2

22 3 44

WSA plant lay-out, H2S gas and sulphur

Stack gas Combustion air H2S gas Incinerator Blower

SO2 converter
Interbed cooler Interbed cooler Gas cooler Steam system Acid pump Superheated steam Acid cooler

Blower Air

WSA condenser

Product acid

WSA plant lay-out, H2S gas and sulphur

Stack gas Combustion air H2S gas Incinerator Blower SO2 converter Interbed cooler Interbed cooler Gas cooler Steam system Acid pump Superheated steam Acid cooler Product acid Blower Air

WSA condenser

WSA plant lay-out, H2S gas and sulphur

WSA plant lay-out, SO2 gas

Stack gas Preheating SO2 gas Heat exchanger Blower

SO2 converter
Interbed cooler Interbed cooler Gas cooler Heat recovery system Superheated steam

Blower Air

WSA condenser

Acid pump Acid cooler Product acid

WSA plant lay-out, SO2 gas

Preheating SO2 gas Heat exchanger Blower SO2 converter Interbed cooler Interbed cooler Gas cooler Heat recovery system

Stack gas

Blower Air WSA condenser

Acid pump Acid cooler Product acid

Superheated steam

WSA plant lay-out, SO2 gas

WSA - Simple system, few components

Stack gas Blower Combustion air/preheating SO2 gas

SO2 converter
Interbed cooler Interbed cooler Gas cooler Heat recovery system Superheated steam

Blower Air

WSA condenser

Acid pump Acid cooler Product acid

SO2 converter details

SO2 converter
SO2 gas 400-420C 400-420C

Catalyst layer

400-420C

Heat recovery system Superheated steam

265-290C Off-gas with H2SO4(gas) Interbed cooler

SO2 converter

SO2 converter incl. interbed cooler

Heat transfer system

WSA condenser - Principle design

Clean Gas Outlet

Cooling Air Inlet

Acid Gas Inlet

Hot Air Outlet

Product Acid Outlet

WSA condenser details

Clean gas outlet

Cooling air inlet

Hot air outlet

70%

98% Acid strength (%) Acid gas inlet Sulphuric acid

WSA condenser erection

WSA condenser erection

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WSA condenser erection

WSA condenser erection

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WSA condenser erection

Installation of WSA condenser module

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WSA condenser internals

WSA condenser internals

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WSA acid cooling system

WSA acid cooling system

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WSA/SNOX references
3/hr Gas Gasflow: flow:2,000 2,000 1,200,000 1,200,000Nm Nm3 /hr Acid Acidproduction: production:8 8 1,140 1,140MTPD MTPD More Morethan than70 70units units
1 1 2 3 1 3 3 7 1 5 25 2 1 5 46 5 4 2 4 9 19 20 2 6 1722 14 18 5 15 6 16 23 8 24 7 21

8 12 8 9 23 20 21 15 1419 11 6 13 10 6 18 16 11 22 10

1112 17 3

7 4

7 8

2 7

12 10

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Power plants
3 9 8

Oil refining and petrochemical industry Metallurgical and minerals industry Coking and coal-based chemical industry March 2008 Sundry applications

SO2 gas - Metallurgical plants

Contracted plants: 6 in molybdenum roasting 4 in PbS sintering/ZnS roasting 1 in lead smelting 1 in copper smelting

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H2S gas plants

Contracted plants: 15 in refineries and petrochemical 13 in coking 9 in gasification

S-burning plants
Contracted plants, only burning S 1 in acid production for super phosphate

Contracted plants, burning H2S and S 7 in combined H2S and S combustion

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Typical scope of supply

License package (min scope) Basic engineering of WSA plant (min scope) Supply of proprietary equipment (min scope) Catalyst (min scope) Detailed engineering of WSA plant Supply of IBL equipment of WSA plant Supervision during erection and commissioning

SO2 gas - Pb/Zn plant at Kazzinc, Kazakh.

Steam 7 ts/hr 15 barg

WSA

6.5% SO2 5% H2O 14% O2 125,000 Nm3/hr

854 MTPD H2SO4 (98% purity)

Clean off-gas 0.1% SO2 (98.1% reduction)

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H2S gas - gasification plant, Guanghui, China

Steam 26 ts/hr 4 barg

WSA

51.5% CO2 4,7% H2S 9,340 Nm3/hr

168 MTPD H2SO4 (98% purity)

Clean off-gas 175 ppm SO2 (99.2% reduction)

Sulphur burn. - acid plant, Meranol, Argentina

Steam xx ts/hr 40 barg

WSA

4,025 kg/h S

300 MTPD H2SO4 (98% purity)

Clean off-gas 350 ppm SO2 99.5 % reduction

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Salient features of WSA

More than 99% of the sulphur content is recovered Sulphur is recovered as concentrated sulphuric acid of commercial quality (~98%) Very low consumption of cooling water No waste products or waste water No consumption of chemicals or other additives

Salient features (cont.)

Efficient heat recovery
(superheated high pressure steam export)

Wide turn-down range (1:10) Simple lay-out, small plot area Low investment and attractive operating economy One point responsibility

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Thank you for your attention!

Any questions ?

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