state of the art gas absorption technologies may 5, 20091 cansolv technologies inc. cansolv so 2...
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State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 1
CANSOLV TECHNOLOGIES INC.CANSOLV TECHNOLOGIES INC.www.cansolv.comwww.cansolv.com
CANSOLV SOCANSOLV SO22 SCRUBBING SYSTEM: SCRUBBING SYSTEM:Review of Commercial ApplicationsReview of Commercial Applications
for Smelter SOfor Smelter SO22 Emissions Control Emissions Control
Presented at:Presented at:The Southern African Institute of Mining & MetallurgyThe Southern African Institute of Mining & Metallurgy
ZAMBIAZAMBIA
By: Valérie Léveillé, By: Valérie Léveillé, Eng.Eng.
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 2
OutlineOutline1.1. Overview of CTI;Overview of CTI;
2.2. Description of the SODescription of the SO22 technology; technology;
3.3. Review of commercial applications;Review of commercial applications;
4.4. Integration to smelter emissions Integration to smelter emissions
management.management.
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 3
Corporate ProfileCorporate Profile Cansolv Technologies Inc. (CTI) founded in 1997Cansolv Technologies Inc. (CTI) founded in 1997
– Headquarters in Montreal, CanadaHeadquarters in Montreal, Canada
– Technology acquired from Union CarbideTechnology acquired from Union Carbide
Cansolv Technologies Shenzhen (CTS) founded in 2004Cansolv Technologies Shenzhen (CTS) founded in 2004
– Chinese subsidiary for Sales/Marketing & Procurement in AsiaChinese subsidiary for Sales/Marketing & Procurement in Asia
Acquisition by Shell Global Solutions in December Acquisition by Shell Global Solutions in December
20082008
Chemical Initiatives appointed agents for Africa 2009Chemical Initiatives appointed agents for Africa 2009
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 4
Corporate ProfileCorporate Profile
SOSO22 Technology Technology
– 9 Cansolv SO9 Cansolv SO22 Scrubbing units in operation; Scrubbing units in operation;
– 5 Cansolv SO5 Cansolv SO22 Scrubbing units to start-up in 2009; Scrubbing units to start-up in 2009;
– 5 Cansolv SO5 Cansolv SO22 Scrubbing units to start-up in 2010; Scrubbing units to start-up in 2010;
COCO22 Technology Technology
– 3 Cansolv CO3 Cansolv CO22 Capture demo plants in detailed Capture demo plants in detailed
engineeringengineering
– Successful demonstration in 6 piloting campaignsSuccessful demonstration in 6 piloting campaigns
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 5
CANSOLVCANSOLV®® SO SO2 2 Scrubbing Scrubbing SystemSystem
A regenerable SOA regenerable SO22 absorption process absorption process
Similar to HSimilar to H22S/COS/CO22 amine treater units amine treater units
Aqueous diamine absorbent is highly selective for SOAqueous diamine absorbent is highly selective for SO22
Pure, water- saturated SOPure, water- saturated SO22 byproduct byproduct
Robust, easy to operate process with low emissionsRobust, easy to operate process with low emissions
Handles gas with varying SOHandles gas with varying SO22 concentrations concentrations
High tolerance for dust and SOHigh tolerance for dust and SO33/acid mist in gas/acid mist in gas
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 6
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with new acid converter for SO2 by-product
Lean Amine Tank
Condensate
Caustic
Treated Offgas to stack< 200 ppmv SO2
APU
MakeupWater
Smelter OffgasSO2 Content: 0.1% to 15%
Quenched Offgas
Prescrubber Effluent
Rich AmineLean Amine
SO2 product gas, 99.99% basis, dry(constant flowrate)
SO2 Stripper Tower
APU Effluent
Rich Amine TankTreated Offgas to stack
< 50 ppmv SO2
Acid Plant Tail GasSO2 Content: 0.5%
Constant flowrate of H2SO4 to storage
Dilution air
Main SO2
Absorber Tower
AP SO2
Absorber Tower
SINGLE ABSORPTION ACID PLANT
Constant Flowrate and SO2
Content
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with new acid converter for SO2 by-product
Lean Amine Tank
Condensate
Caustic
Treated Offgas to stack< 200 ppmv SO2
APU
MakeupWater
Smelter OffgasSO2 Content: 0.1% to 15%
Quenched Offgas
Prescrubber Effluent
Rich AmineLean Amine
SO2 product gas, 99.99% basis, dry(constant flowrate)
SO2 Stripper Tower
APU Effluent
Rich Amine TankTreated Offgas to stack
< 50 ppmv SO2
Acid Plant Tail GasSO2 Content: 0.5%
Constant flowrate of H2SO4 to storage
Dilution air
Main SO2
Absorber Tower
AP SO2
Absorber Tower
SINGLE ABSORPTION ACID PLANT
Constant Flowrate and SO2
Content
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with new acid converter for SO2 by-product
Lean Amine Tank
Condensate
Caustic
Treated Offgas to stack< 200 ppmv SO2
APU
MakeupWater
Smelter OffgasSO2 Content: 0.1% to 15%
Quenched Offgas
Prescrubber Effluent
Rich AmineLean Amine
SO2 product gas, 99.99% basis, dry(constant flowrate)
SO2 Stripper Tower
APU Effluent
Rich Amine TankTreated Offgas to stack
< 50 ppmv SO2
Acid Plant Tail GasSO2 Content: 0.5%
Constant flowrate of H2SO4 to storage
Dilution air
Main SO2
Absorber Tower
AP SO2
Absorber Tower
SINGLE ABSORPTION ACID PLANT
Constant Flowrate and SO2
Content
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 7
Amine CharacteristicsAmine Characteristics
Amine developed for oxidised environmentsAmine developed for oxidised environments– Oxidation degradation losses per year < 2% of Oxidation degradation losses per year < 2% of
annual inventoryannual inventory Very low amine volatility (ppb levels)Very low amine volatility (ppb levels)
– Amine in salt form Amine in salt form undetectable losses with undetectable losses with treated gastreated gas
High tolerance for dust ingressHigh tolerance for dust ingress High tolerance for strong acid ingressHigh tolerance for strong acid ingress
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 8
SOSO2 2 Product ManagementProduct Management
SOSO22 by-product is high purity by-product is high purity
– 99.9% SO99.9% SO2 2 dry basis, balance composed of traces of COdry basis, balance composed of traces of CO22, N, N22, O, O22
– Food grade quality SOFood grade quality SO22 product demonstrated product demonstrated
SOSO22 product handling: product handling:
– Return to new/existing sulphuric acid plant;Return to new/existing sulphuric acid plant;
– Return to existing sulphur recovery unit;Return to existing sulphur recovery unit;
– Compress and liquefy;Compress and liquefy;
– Convert to bisulfiteConvert to bisulfite
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 9
How CTI Customers Handle By-ProductHow CTI Customers Handle By-Product
Liqu. SO2, 1
SO2 Safe, 1
H2SO4, 11Sulfur, 8
Byproduct processed
in New Facilities, 7
Byproduct processed in existing facilities,
14
By-Product Profile
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 10
Commercial Units – Metallurgical and Acid Plant Commercial Units – Metallurgical and Acid Plant ApplicationsApplications
Application Location Flow (Nm3/hr)
By-Product Feed SO2 Conc.
SO2 Emission
s
Status
SARP Acid SARP Acid PlantPlant
N/S N/S AmericaAmerica
40,00040,000 H2SO4H2SO4
(existing)(existing)5,000 ppm5,000 ppm 15 ppm15 ppm Operating Operating
(s/u 2002)(s/u 2002)
Lead SmelterLead Smelter Asia-Asia-PacificPacific
34,00034,000 H2SO4H2SO4
(existing)(existing)0.1 – 0.1 –
12.5%12.5%90 ppm90 ppm Operating Operating
(s/u 2005)(s/u 2005)
Copper Anode Copper Anode FurnaceFurnace
Asia-Asia-PacificPacific
43,00043,000 H2SO4H2SO4
(existing)(existing)0.09 – 2%0.09 – 2% 50 ppm50 ppm Operating Operating
(s/u 2007)(s/u 2007)
Catalyst Catalyst recovery recovery roasterroaster
N/S N/S AmericaAmerica
48,00048,000 Liquid Liquid SO2/Bisulfite SO2/Bisulfite
(new)(new)
9100 ppm9100 ppm 100 ppm100 ppm Operating Operating
(s/u 2008)(s/u 2008)
Sinter Machine Sinter Machine (secondary)(secondary)
Asia-Asia-PacificPacific
350,000350,000 H2SO4 H2SO4
(existing)(existing)2400 ppm2400 ppm 140 ppm140 ppm Start-upStart-up
Sinter Machine Sinter Machine (primary)(primary)
Asia-Asia-PacificPacific
2 x 2 x 510,000510,000
H2SO4 H2SO4
(new)(new)800 ppm800 ppm 40 ppm40 ppm Start-UpStart-Up
Lead Smelter Lead Smelter + AP+ AP
Asia-Asia-PacificPacific
83,00083,000 H2SO4H2SO4
(new)(new)0.1 – 8%0.1 – 8% 140 ppm140 ppm Construction Construction
(s/u 2009)(s/u 2009)
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 11
Active Projects – Non ferrous and Acid Plant Active Projects – Non ferrous and Acid Plant ApplicationsApplications
Application
Location
Flow (Nm3/hr)
By-Product
Feed SO2 Conc.
SO2 Emission
s
Status
Copper Copper Smelter Smelter FurnaceFurnace
Asia-Asia-PacificPacific
95,00095,000 sulphur sulphur
(new)(new)15-30%15-30% 250 ppm250 ppm EngineeringEngineering
Nickel Nickel Smelter Smelter Converter + Converter + FurnaceFurnace
N/S N/S AmericaAmerica
100,000100,000 H2SO4 H2SO4 (existing)(existing)
0.1 – 3%0.1 – 3% 200 ppm200 ppm Engineering Engineering (piloting (piloting campaign campaign 2007)2007)
Lead Sinter Lead Sinter MachineMachine
Asia-Asia-PacificPacific
265,000265,000 H2SO4 H2SO4
(new)(new)1 – 2%1 – 2% 200 ppm200 ppm Engineering Engineering
(piloting (piloting campaign campaign 2008)2008)
Copper Copper Smelter Smelter ConvertersConverters
N/S N/S AmericaAmerica
600,000600,000 H2SO4 H2SO4 (existing)(existing)
4,000 4,000 ppmppm
200 ppm200 ppm EngineeringEngineering
Fertilizer Fertilizer Acid PlantAcid Plant
N/S N/S AmericaAmerica
160,000160,000 H2SO4 H2SO4 (existing)(existing)
5,000 5,000 ppmppm
20 ppm20 ppm EngineeringEngineering
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 12
SARP Acid Plant Tail SARP Acid Plant Tail GasGas
Single absorptionSingle absorption Replace alkali scrubbing Replace alkali scrubbing
processprocess Modular PlantModular Plant
– Absorber retrofit (FRP)Absorber retrofit (FRP)
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 13
Lead Smelter OffgasLead Smelter Offgas
Batch anode furnaceBatch anode furnace Load levelling designLoad levelling design
– 0.1 – 12% SO0.1 – 12% SO22
– Constant SOConstant SO22 production production
SOSO22 recycle to existing recycle to existing acid plantacid plant– Main acid plant feed is Main acid plant feed is
roasterroaster
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 14
Co-gen boiler flue gasCo-gen boiler flue gas
965,000 Nm965,000 Nm33/hr /hr – 5 absorbers, 1 5 absorbers, 1
regeneratorregenerator New sulphuric acid plantNew sulphuric acid plant
– Single absorption with Single absorption with Cansolv APTGCansolv APTG
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 15
Key Advantages in Smelter Key Advantages in Smelter ApplicationsApplications
1.1. Suitability to treat variable and dilute Suitability to treat variable and dilute
(<5%) SO(<5%) SO22 loads loads
2.2. Flexibility in gas cleaning designFlexibility in gas cleaning design
3.3. Manage SOManage SO22 from multiple sources at a from multiple sources at a
single sitesingle site
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 16
1.1. Treats Variable & Dilute SOTreats Variable & Dilute SO22 LoadLoad
Load levelling designLoad levelling design
– Vary lean amine flow to SOVary lean amine flow to SO22 absorber absorber
– Constant rich amine flow to regeneratorConstant rich amine flow to regenerator
– Larger amine inventoryLarger amine inventory
Maintain SOMaintain SO22 emissions emissions
Decouple variable nature of smelter gas from Decouple variable nature of smelter gas from sulphuric acid productionsulphuric acid production
– SOSO22 product & Sulphuric acid production are continuous product & Sulphuric acid production are continuous
at constant flowrateat constant flowrate
– Eliminates need to burn sulphur to strengthen AP feedEliminates need to burn sulphur to strengthen AP feed
– Design capacity based on average smelter SODesign capacity based on average smelter SO22 load load
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 17
Load Levelling
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 50 100 150 200 250
Time (hours)
SO
2 F
low
rate
(kg
/hr)
Offgas SO2 Load (Cansolv inlet) SO2 Product (Cansolv outlet)
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 18
2.2. Flexibility in gas cleaning Flexibility in gas cleaning designdesign
Amine has high tolerance for Amine has high tolerance for
dust and SOdust and SO33 ingress ingress
Optimise between gas cleaning Optimise between gas cleaning
and amine purificationand amine purification
– Reduced gas cleaning Reduced gas cleaning
increases amine purification increases amine purification
requiredrequired
– Capital/operating cost Capital/operating cost
advantages often favour amine advantages often favour amine
purificationpurification
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 19
2.2. Flexibility in gas cleaning Flexibility in gas cleaning designdesign
Wet acid mist removal Plant Dry gas
[SO3] SO3 / mist wet pre-treatment
SO3 Removal Efficiency
Inlet [SO3] to Cansolv
APU Salt Removal
Coal-fired co-gen boilers
43 ppmv None 0% 40 ppmv
Ion Exchange
Oil Refinery FCCU 22 ppmv High DP dynamic scrubber
88% 3 ppmv
Electrodialysis
Incinerated SRU Tail Gas
1500 ppmv Brownian candle mist eliminators
99% 20 ppmv
Electrodialysis
SARP Tail Gas 200 ppmv None 0% 200 ppmv
Ion Exchange
Lead Smelter + AP 110 ppmv None 0% 110 ppmv
Ion Exchange
Copper Anode furnace
170 ppmv None 0% 170 ppmv
Ion Exchange
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 20
3.3. Manage SOManage SO22 from multiple sources from multiple sources at a single siteat a single site
Multiple absorbers may be used with a single Multiple absorbers may be used with a single
regeneratorregenerator
Several secondary sources: furnaces, convertersSeveral secondary sources: furnaces, converters
Acid plant tail gas has low SOAcid plant tail gas has low SO22 load vs. smelter load vs. smelter
Leverage existing Cansolv plant to minimise Leverage existing Cansolv plant to minimise
capexcapex
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 21
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with new acid converter for SO2 by-product
Lean Amine Tank
Condensate
Caustic
Treated Offgas to stack< 200 ppmv SO2
APU
MakeupWater
Smelter OffgasSO2 Content: 0.1% to 15%
Quenched Offgas
Prescrubber Effluent
Rich AmineLean Amine
SO2 product gas, 99.99% basis, dry(constant flowrate)
SO2 Stripper Tower
APU Effluent
Rich Amine TankTreated Offgas to stack
< 50 ppmv SO2
Acid Plant Tail GasSO2 Content: 0.5%
Constant flowrate of H2SO4 to storage
Dilution air
Main SO2
Absorber Tower
AP SO2
Absorber Tower
SINGLE ABSORPTION ACID PLANT
Constant Flowrate and SO2
Content
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with new acid converter for SO2 by-product
Lean Amine Tank
Condensate
Caustic
Treated Offgas to stack< 200 ppmv SO2
APU
MakeupWater
Smelter OffgasSO2 Content: 0.1% to 15%
Quenched Offgas
Prescrubber Effluent
Rich AmineLean Amine
SO2 product gas, 99.99% basis, dry(constant flowrate)
SO2 Stripper Tower
APU Effluent
Rich Amine TankTreated Offgas to stack
< 50 ppmv SO2
Acid Plant Tail GasSO2 Content: 0.5%
Constant flowrate of H2SO4 to storage
Dilution air
Main SO2
Absorber Tower
AP SO2
Absorber Tower
SINGLE ABSORPTION ACID PLANT
Constant Flowrate and SO2
Content
State of the Art Gas Absorption State of the Art Gas Absorption TechnologiesTechnologies
May 5, 2009 22
Thank you!Thank you!