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J ACID PLANT CAPACITY INCREASE PRESENTER:SIYABONGA MALEVU COMPANY:CHEMICAL INITIATIVES DEPARTMENT:TECHNICAL.

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Presentation on theme: "J ACID PLANT CAPACITY INCREASE PRESENTER:SIYABONGA MALEVU COMPANY:CHEMICAL INITIATIVES DEPARTMENT:TECHNICAL."— Presentation transcript:

1 J ACID PLANT CAPACITY INCREASE PRESENTER:SIYABONGA MALEVU COMPANY:CHEMICAL INITIATIVES DEPARTMENT:TECHNICAL

2 J PLANT BACKGROUND

3 FULL RATES PRIOR TO CAPACITY INCREASE  Production rate:500 tons/day of H 2 SO 4  Air flow rate:45 000m 3 /hr  Sulphur rate:7 tons/hr  Burner SO 2 conc.: 10.5% (burner temp of 1000 o C)  Catalyst loading:LP12O for 1 st and 2 nd pass & LP110 for 3 rd & 4 th pass  Converter overall conv.:99.5%  SO 2 emission:350 – 500ppm

4 PRE-PROJECT SIMULATION DATA  Production rate:547tons/day of H 2 SO 4  Air Flow rate:47 500m 3 /hr  Sulphur rate:7.4 tons/hr  Burner SO 2 conc.:11% (Burner temp: 1025 o C)  Catalyst loading:LP120:1 st &2 nd Pass, LP110:3 rd pass&VK69: 4 th Pass  Overall converter conv.:99.79%  SO 2 emission:100 – 350ppm

5 CONVERTER MODIFICATION  3 rd pass catalyst loading increased by 18.6% (from to litres).  The extra litres obtained from 4 th pass.  4 th pass LP110 catalyst replaced with VK69 catalyst.  4 th pass catalyst loading increased by 26.7 % (from litres to litres).  3 rd and 4 th pass thermocouples re-allocated to accommodate the increased catalyst bed depths.

6 VK 69 BENEFITS  High surface area high activity  High void fraction low pressure drop  Reduced SO 2 emissions  Increased production with low SO 2 emission levels  Long lifetime

7 EVALUATION OF CAPACITY OF MAJOR EQUIPMENT Critical investigated areas were: AIR BLOWER CAPACITY AIR BLOWER CAPACITY Prior – running at m 3 /h at discharge pressure 42 kPa Design max capacity – m 3/ h at 47 kPa discharge pressure Blower curves – m 3 /h at 46.5 kPa discharge pressure Possible by increasing blower vanes angle to maximum Increase power consumption by 4 kW. SULPHUR BURNER CAPACITY SULPHUR BURNER CAPACITY Sulphur consumption – increase from 6.8 ton/h to 7.4 ton/h Consultation with original designers – burner large enough to increase acid plant by 20%. CONVERTER CAPACITY CONVERTER CAPACITY 3 RD Pass maximum catalyst volume: litres 4 th Pass maximum catalyst volume: litres Increase 4 th pass pressure drop from 0.5 kPa to 0.79 kPa. COOLING CAPACITY COOLING CAPACITY Burner temperature increased to C. 1 st Pass Converter temperature decrease from 433 to C WHB #1 – enough capacity for additional 1.8 ton/h steam generation

8 EVALUATION OF CAPACITY OF MAJOR EQUIPMENT  Drying, Interpass, Final Absorption Towers  Sulphur pump, BFW pump, Acid pumps  Hot and cold heat exchangers  Main Benefits: –Additional 47 ton/day acid production –Additional 43.2 ton/ day steam generation  Payback period: 6 months

9 ECONOMIC EVALUATION  Main Benefits: –Additional 47 ton/day acid production –Additional 43.2 ton/ day steam generation  Payback period: 6 months

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11  Prior to implementation: 477 tpd  Target : 547 tpd  After implementation : 533 tpd Failure of maintaining the 4th pass inlet temperature below C without compromising the desired export steam temperature at the boiler station

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13 ACID PLANT 20% UPRATE PHASE II 550 to 600 MTPD EXPORT STEAM TEMPERATURE AIR BLOWER CAPACITY MAIN COOLING TOWER CAPACITY PLANT PRESSURE DROP OPERATE THE BOILER AT MAX PRESSURE REDUCING HEAT EXPORT LINE GENERATE ELECTRICITY FROM STEAM REDUCE CONVERTER PRESSURE DROP REDUCE IAT & FAT PRESSURE DROP


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