Transcript Document

State of the Art Gas Absorption
Technologies
CANSOLV TECHNOLOGIES INC.
www.cansolv.com
CANSOLV SO2 SCRUBBING SYSTEM:
Review of Commercial Applications
for Smelter SO2 Emissions Control
Presented at:
The Southern African Institute of Mining & Metallurgy
ZAMBIA
By: Valérie Léveillé,
May 5, 2009
Eng.
1
State of the Art Gas Absorption
Technologies
Outline
1.
Overview of CTI;
2.
Description of the SO2 technology;
3.
Review of commercial applications;
4.
Integration to smelter emissions management.
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State of the Art Gas Absorption
Technologies
Corporate Profile

Cansolv Technologies Inc. (CTI) founded in 1997
– Headquarters in Montreal, Canada
– Technology acquired from Union Carbide

Cansolv Technologies Shenzhen (CTS) founded in 2004
– Chinese subsidiary for Sales/Marketing & Procurement in Asia

Acquisition by Shell Global Solutions in December 2008

Chemical Initiatives appointed agents for Africa 2009
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State of the Art Gas Absorption
Technologies
Corporate Profile

SO2 Technology
– 9 Cansolv SO2 Scrubbing units in operation;
– 5 Cansolv SO2 Scrubbing units to start-up in 2009;
– 5 Cansolv SO2 Scrubbing units to start-up in 2010;

CO2 Technology
– 3 Cansolv CO2 Capture demo plants in detailed engineering
– Successful demonstration in 6 piloting campaigns
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State of the Art Gas Absorption
Technologies
CANSOLV® SO2 Scrubbing System
 A regenerable SO2 absorption process
 Similar to H2S/CO2 amine treater units
 Aqueous diamine absorbent is highly selective for SO2
 Pure, water- saturated SO2 byproduct
 Robust, easy to operate process with low emissions
 Handles gas with varying SO2 concentrations
 High tolerance for dust and SO3/acid mist in gas
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State of the Art Gas Absorption
Technologies
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with
new acid converter for SO2 by-product
Treated Offgas to stack
< 200 ppmv SO2
SO2 product gas, 99.99%
basis, dry
(constant flowrate)
Condensate
APU Effluent
Caustic
Quenched
Offgas
APU
Smelter Offgas
SO2 Content: 0.1% to 15%
Main SO2
Absorber
Tower
SO2 Stripper
Tower
Makeup
Water
Lean Amine
Tank
Prescrubber Effluent
Rich Amine
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO2
Lean Amine
SINGLE ABSORPTION
ACID PLANT
AP SO2
Absorber
Tower
Acid Plant Tail Gas
SO2 Content: 0.5%
Constant
Flowrate and SO2
Content
Dilution air
Constant flowrate of
H2SO4 to storage
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State of the Art Gas Absorption
Technologies
Amine Characteristics

Amine developed for oxidised environments
– Oxidation degradation losses per year < 2% of annual
inventory

Very low amine volatility (ppb levels)
– Amine in salt form  undetectable losses with treated gas


High tolerance for dust ingress
High tolerance for strong acid ingress
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State of the Art Gas Absorption
Technologies
SO2 Product Management
 SO2 by-product is high purity
– 99.9% SO2 dry basis, balance composed of traces of CO2, N2, O2
– Food grade quality SO2 product demonstrated

SO2 product handling:
– Return to new/existing sulphuric acid plant;
– Return to existing sulphur recovery unit;
– Compress and liquefy;
– Convert to bisulfite
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State of the Art Gas Absorption
Technologies
How CTI Customers Handle By-Product
Byproduct
processed
in New
Facilities, 7
SO2 Safe, 1
Liqu. SO2, 1
Sulfur, 8
May 5, 2009
H2SO4, 11
Byproduct
processed
in existing
facilities,
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By-Product
Profile
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State of the Art Gas Absorption
Technologies
Commercial Units – Metallurgical and Acid Plant Applications
Application
Location
Flow
(Nm3/hr)
By-Product
Feed SO2
Conc.
SO2
Emissions
N/S
America
40,000
H2SO4
(existing)
5,000 ppm
15 ppm
Operating
(s/u 2002)
Lead Smelter
Asia-Pacific
34,000
H2SO4
(existing)
0.1 – 12.5%
90 ppm
Operating
(s/u 2005)
Copper Anode
Furnace
Asia-Pacific
43,000
H2SO4
(existing)
0.09 – 2%
50 ppm
Operating
(s/u 2007)
N/S
America
48,000
Liquid
SO2/Bisulfite
(new)
9100 ppm
100 ppm
Operating
(s/u 2008)
Sinter Machine
(secondary)
Asia-Pacific
350,000
H2SO4
(existing)
2400 ppm
140 ppm
Start-up
Sinter Machine
(primary)
Asia-Pacific
2 x 510,000
H2SO4
(new)
800 ppm
40 ppm
Start-Up
Lead Smelter +
AP
Asia-Pacific
83,000
H2SO4
(new)
0.1 – 8%
140 ppm
Construction
(s/u 2009)
SARP Acid Plant
Catalyst
recovery roaster
May 5, 2009
Status
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State of the Art Gas Absorption
Technologies
Active Projects – Non ferrous and Acid Plant Applications
Application
Location
Flow
(Nm3/hr)
ByProduct
Feed SO2
Conc.
AsiaPacific
95,000
sulphur
(new)
15-30%
250 ppm
Engineering
N/S
America
100,000
H2SO4
(existing)
0.1 – 3%
200 ppm
Engineering
(piloting
campaign 2007)
Lead Sinter
Machine
AsiaPacific
265,000
H2SO4
(new)
1 – 2%
200 ppm
Engineering
(piloting
campaign 2008)
Copper
Smelter
Converters
N/S
America
600,000
H2SO4
(existing)
4,000 ppm
200 ppm
Engineering
Fertilizer Acid
Plant
N/S
America
160,000
H2SO4
(existing)
5,000 ppm
20 ppm
Engineering
Copper
Smelter
Furnace
Nickel Smelter
Converter +
Furnace
May 5, 2009
SO2
Status
Emissions
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State of the Art Gas Absorption
Technologies
SARP Acid Plant Tail Gas



Single absorption
Replace alkali scrubbing
process
Modular Plant
– Absorber retrofit (FRP)
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State of the Art Gas Absorption
Technologies
Lead Smelter Offgas


Batch anode furnace
Load levelling design
– 0.1 – 12% SO2
– Constant SO2 production

SO2 recycle to existing acid
plant
– Main acid plant feed is roaster
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State of the Art Gas Absorption
Technologies
Co-gen boiler flue gas

965,000 Nm3/hr
– 5 absorbers, 1 regenerator

New sulphuric acid plant
– Single absorption with
Cansolv APTG
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State of the Art Gas Absorption
Technologies
Key Advantages in Smelter Applications
1.
Suitability to treat variable and dilute (<5%)
SO2 loads
2.
Flexibility in gas cleaning design
3.
Manage SO2 from multiple sources at a single
site
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State of the Art Gas Absorption
Technologies
1. Treats Variable & Dilute SO2 Load

Load levelling design
– Vary lean amine flow to SO2 absorber
– Constant rich amine flow to regenerator
– Larger amine inventory


Maintain SO2 emissions
Decouple variable nature of smelter gas from sulphuric acid
production
– SO2 product & Sulphuric acid production are continuous at
constant flowrate
– Eliminates need to burn sulphur to strengthen AP feed
– Design capacity based on average smelter SO2 load
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State of the Art Gas Absorption
Technologies
Load Levelling
9000
8000
SO2 Flowrate (kg/hr)
7000
6000
5000
4000
3000
2000
1000
0
0
50
100
150
200
250
Time (hours)
Offgas SO2 Load (Cansolv inlet)
May 5, 2009
SO2 Product (Cansolv outlet)
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State of the Art Gas Absorption
Technologies
2. Flexibility in gas cleaning design

Amine has high tolerance for
dust and SO3 ingress

Optimise between gas cleaning
and amine purification
– Reduced gas cleaning increases
amine purification required
– Capital/operating cost
advantages often favour amine
purification
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State of the Art Gas Absorption
Technologies
2. Flexibility in gas cleaning design
Plant
Coal-fired co-gen
boilers
Oil Refinery FCCU
Dry gas
[SO3]
43 ppmv
22 ppmv
Wet acid mist removal
SO3 / mist wet
SO3 Removal
pre-treatment
Efficiency
None
0%
Inlet [SO3]
to Cansolv
40 ppmv
APU Salt
Removal
Ion Exchange
Incinerated SRU
Tail Gas
SARP Tail Gas
1500 ppmv
200 ppmv
High DP dynamic
scrubber
Brownian candle
mist eliminators
None
Lead Smelter + AP
110 ppmv
None
0%
110 ppmv
Ion Exchange
Copper Anode
furnace
170 ppmv
None
0%
170 ppmv
Ion Exchange
May 5, 2009
88%
3 ppmv
Electrodialysis
99%
20 ppmv
Electrodialysis
0%
200 ppmv
Ion Exchange
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State of the Art Gas Absorption
Technologies
3.
Manage SO2 from multiple sources at a
single site

Multiple absorbers may be used with a single regenerator

Several secondary sources: furnaces, converters

Acid plant tail gas has low SO2 load vs. smelter

Leverage existing Cansolv plant to minimise capex
May 5, 2009
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State of the Art Gas Absorption
Technologies
Cansolv® SO2 SCRUBBING SYSTEM – Integrated Configuration for Smelting Applications with
new acid converter for SO2 by-product
Treated Offgas to stack
< 200 ppmv SO2
SO2 product gas, 99.99%
basis, dry
(constant flowrate)
Condensate
APU Effluent
Caustic
Quenched
Offgas
APU
Smelter Offgas
SO2 Content: 0.1% to 15%
Main SO2
Absorber
Tower
SO2 Stripper
Tower
Makeup
Water
Lean Amine
Tank
Prescrubber Effluent
Rich Amine
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO2
Lean Amine
SINGLE ABSORPTION
ACID PLANT
AP SO2
Absorber
Tower
Acid Plant Tail Gas
SO2 Content: 0.5%
Constant
Flowrate and SO2
Content
Dilution air
Constant flowrate of
H2SO4 to storage
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State of the Art Gas Absorption
Technologies
Thank you!
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