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940-1 MECS INC.. 940-2 Meeting EPA Consent Decree Compliance with DynaWave Scrubbing Presented by Larry Paschke. Presented by Larry Paschke.

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Presentation on theme: "940-1 MECS INC.. 940-2 Meeting EPA Consent Decree Compliance with DynaWave Scrubbing Presented by Larry Paschke. Presented by Larry Paschke."— Presentation transcript:

1 940-1 MECS INC.

2 940-2 Meeting EPA Consent Decree Compliance with DynaWave Scrubbing Presented by Larry Paschke. Presented by Larry Paschke.

3 940-3 Background/History l Headquarters - St. Louis, Missouri l Global Business l 250 Employees l 75 Years - Monsanto/MECS designed and constructed over 800 chemical and cogeneration projects l 1969:MECS formed l 2005, Management Buyout from Monsanto and MECS Inc. formed. l Headquarters - St. Louis, Missouri l Global Business l 250 Employees l 75 Years - Monsanto/MECS designed and constructed over 800 chemical and cogeneration projects l 1969:MECS formed l 2005, Management Buyout from Monsanto and MECS Inc. formed.

4 940-4 MECS Inc. Capabilities l Design and supply air pollution control products –DynaWave Scrubbers –Brink Mist Eliminators l Design and build sulfuric acid plants l Supply proprietary products to the sulfuric acid industry –Specialty alloys –Catalyst –Tower internals l Design and supply air pollution control products –DynaWave Scrubbers –Brink Mist Eliminators l Design and build sulfuric acid plants l Supply proprietary products to the sulfuric acid industry –Specialty alloys –Catalyst –Tower internals

5 940-5 Important Issues To Be Addressed l Performance –SO 2 Removal –SO 3 Removal –PM Removal –Other Consideration/Effluent Treatment l Applications –FCCs –SRUs l Performance –SO 2 Removal –SO 3 Removal –PM Removal –Other Consideration/Effluent Treatment l Applications –FCCs –SRUs

6 940-6 SO 2 Removal

7 940-7 l Mass Transfer –Gas/Liquid Contact Mechanism – Total L/G (gpm / 1000 acfm) –Reagent Kinetics n Caustic n Soda Ash n Lime n Limestone l Mass Transfer –Gas/Liquid Contact Mechanism – Total L/G (gpm / 1000 acfm) –Reagent Kinetics n Caustic n Soda Ash n Lime n Limestone

8 940-8 DynaWave Scrubber

9 940-9 SO 2 Mass Transfer / Reagent

10 Reagent Overview ReagentReactivityOperating Cost CausticMost reactive Highest cost Soda AshVery Reactive Moderate Cost Magnesium Hydroxide Moderately Reactive Moderate Cost LimeLess Reactive Lower Cost LimestoneLeast Reactive Lowest Cost

11 Reagent Costs Required Reagent Lb/Lb of SO 2 Relative Reagent Cost NaOH = 1 Treatment Cost/lb of SO 2 Caustic (NaOH) Soda Ash (Na 2 CO 3 ) Mag Oxide (Mg(OH) 2 ) Lime (Ca(OH) 2 ) Limestone (CaCO 3 )

12 Reagent Reaction Products l CausticSoluble Salt l Soda Ash Soluble Salt l Trona Soluble Salt l Lime Insoluble Solid l Limestone Insoluble Solid l CausticSoluble Salt l Soda Ash Soluble Salt l Trona Soluble Salt l Lime Insoluble Solid l Limestone Insoluble Solid

13 Navajo Test Data Pilot Plant Full Scale Installation CEM measures < 1 ppm vd 0% O 2 corrected Run 1Run 2Run 3Ave SO 2 Inlet (lb/h) SO 2 Outlet (lb/h) Outlet ppmvd 0% O SO 2 % Removal

14 Particulate Removal

15 Particulate Matter l Size Distribution of catalyst fines (PSD) l Gas side pressure drop used by scrubber l Size Distribution of catalyst fines (PSD) l Gas side pressure drop used by scrubber  Smaller particles require more pressure drop

16 Particulate Removal < 0.1 microns 0.1 Wt% < 0.3 microns 4% < 1.0 microns 35% < 1.5 microns 54% < 3.0 microns 75% > 20 microns 6% Typical FCC PSD

17 Example: 25” wc required for 90% particulate removal

18 Navajo Test Data Run 1Run 2Run 3Ave PM Inlet (lb/h) PM Outlet (lb/h)0.01 PM % Removal Pilot Plant Full Scale Installation Reduction of PM by 93%

19 SO 3 /Acid Mist Removal

20 SO 3 Removal Mechanism (NOT the same as SO 2 ) l Opacity –Diffraction of light waves by particles l Hydrolyzed to H 2 SO 4 liquid droplets –0.4 micron size l Not absorbed, mechanical removal l Opacity –Diffraction of light waves by particles l Hydrolyzed to H 2 SO 4 liquid droplets –0.4 micron size l Not absorbed, mechanical removal  Gas side pressure drop required

21 Example: 40” wc gas pressure drop required to remove 90% of SO 3

22 Other Considerations Effluent Treatment

23 COD Chemical Oxygen Demand l Measured as mg O 2 / liter solution or ppm l Convert sodium sulfite/bisulfite salts to sulfate salts l Forced oxidation to sodium sulfate –O 2 to S ratio –Residence time –Air dispersion l Measured as mg O 2 / liter solution or ppm l Convert sodium sulfite/bisulfite salts to sulfate salts l Forced oxidation to sodium sulfate –O 2 to S ratio –Residence time –Air dispersion

24 COD Chemical Oxygen Demand l Typical COD target range 50 to 200 ppm l Consider “pre-existing” COD in makeup water l Two oxidation methods –In-Situ –Ex-Situ l Typical COD target range 50 to 200 ppm l Consider “pre-existing” COD in makeup water l Two oxidation methods –In-Situ –Ex-Situ

25 DynaWave Scrubber In-Situ Oxidation

26 Effluent Rate Requirements l Set by dissolved solids concentration l Salt concentrations up to 20 wt% l Low effluent rate to waste water treatment desirable l Set by dissolved solids concentration l Salt concentrations up to 20 wt% l Low effluent rate to waste water treatment desirable

27 Effluent Rates 5% 10% 15% 20% gpm % salts Assumes 1000 lb/h SO 2 removed

28 Other Considerations Materials of Construction

29 Materials of Construction l Considerations –Inlet temperature –Wet / dry interface –Chlorides l Considerations –Inlet temperature –Wet / dry interface –Chlorides AlloyApprox. Relative CostChloride Limit ppm w * 316L Duplex RA ,000 AL6XN3.3+30,000 Hastelloy C ,000 * By Rolled Alloys.

30 DynaWave Scrubber Reaction zone: AL6XN Hastelloy Duplex 2205 Vessel: Duplex L stainless

31 Sources of Chlorides l Caustic l Make-up Water l FCC Off Gas l Caustic l Make-up Water l FCC Off Gas

32 Monsanto DynaWave Scrubber

33 On-Line Reliability l Minimal mechanical equipment l Withstands upset conditions- –Large catalyst carryover to scrubber –Abrasion/pluggage design considerations l Large Reverse Jet nozzles l Minimal mechanical equipment l Withstands upset conditions- –Large catalyst carryover to scrubber –Abrasion/pluggage design considerations l Large Reverse Jet nozzles

34 Monsanto Refinery Experience

35 Navajo Installation 30,000 BPD FCC

36 DynaWave in SRU l Very cost competitive versus conventional technology l Designed to meet –100 ppmvd SO2, corrected to 0% O2 –100 mg/L COD –Less than 10% opacity l Handles high sulfur loadings during off ratio and SRU bypass cases l Very cost competitive versus conventional technology l Designed to meet –100 ppmvd SO2, corrected to 0% O2 –100 mg/L COD –Less than 10% opacity l Handles high sulfur loadings during off ratio and SRU bypass cases

37 Conclusion l DynaWave Applications –FCC, SRU, Calciner, S-Zorb l Compliance Help with –Consent Decrees –MACT II l Lower capital and operating costs l Proven Experience l DynaWave Applications –FCC, SRU, Calciner, S-Zorb l Compliance Help with –Consent Decrees –MACT II l Lower capital and operating costs l Proven Experience

38 Thank you.


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