Abstract SYMPHOS 2011

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48 Marie VOGNSEN HALDOR TOPSOE A/S, Lyngby/DENMARK CATALYST SOLUTIONS FOR LOWER SO2 EMISSIONS AND REDUCED PRESSURE DROP BUILD-UP SW-O-01 In 1996 Topsoe introduced a new caesium-promoted vanadium catalyst, VK69, designed for operation in the pass(es) after the intermediate absorption tower in double absorption plants. The high activity of VK69 opens opportunities for a more than 50% reduction in SO 2 emissions from existing double-absorption plants or alternatively the acid production rate can be boosted by 15-20% without increasing SO 2 emissions. Today, 15 years later, Topsoe has close to 100 installations with VK69. However, still more stringent regulations are being placed on the sulphuric acid industry to lower SO 2 emissions. TopsÆe has responded to these challenges by developing a new sulphuric acid catalyst designated VK-701 LEAP5 TM . This catalyst was introduced to the market in 2010. VK-701 LEAP5 TM is based on a novel technology which circumvents the internal transport deficiencies of existing commercial sulphuric acid catalysts and thereby offers exceptionally high activity at low temperatures in strong gases. SO 2 emissions from existing four-bed single-absorption sulphuric acid plants can typically be reduced by 30-40% by loading VK-701 in the final pass compared to a standard potassium-promoted catalyst. SO 2 emissions from the most efficient double-absorption plants already operating with VK69 can typically be further reduced by up to 40% when loading VK-701 in the third pass of a 3:1 plant. It is now possible to achieve in the order of 50 ppm SO 2 emissions in the stack depending on plant layout. For existing plants the reduced SO 2 emissions achievable with VK-701 provides an attractive alternative to investing in a caustic or hydrogen peroxide scrubber. Even for plants equipped with tail-gas scrubbing, the VK-701 can be a cost-efficient way of reducing consumption of chemicals for the scrubbing. The first part of this paper describes case stories disclosing some of the operating experience we have gained on VK69 and VK-701 LEAP5 TM . For many sulphuric acid plants the bottleneck for prolonged operating time between plants shutdowns is the screening requirement of Bed 1 due to increased pressure drop build-up caused by plugging by dust present in the feed gas. An improved protection against pressure drop build-up can be obtained by the use of a dust protection catalyst in the top of Bed 1. In 2007 TopsÆe introduced a new dust protection catalyst in the shape of a 25-mm Daisy. Installation of a 15cm top layer of this unique VK38 dust protection catalyst results in a doubling of the operating time between screenings compared to the 12 mm Daisy. Consequently, the number of time-consuming and expensive shutdowns for catalyst screening is reduced and at the same time significant savings in blower energy result from the lower pressure drop. Today, 4 years later, close to 80 installations with 25 mm Daisy dust protection catalyst are in operating around the world. The second part of this paper discloses actual operating experience obtained from one of our 25-mm daisy dust protection installations.
ENHANCED HEAT RECOVERY WITH HEROS® AND HIPROS® IN SULFURIC ACID PLANTS SW-O-02 Michael Kemmerich, Outotec, Ludwig Erhard Strasse 21, 61440 Oberursel, GERMANY Outotec’s technology portfolio includes the design, construction and initial operation of sulfuric acid plants worldwide with a focus on the most economic and efficient solutions for customers during the entire life cycle of a plant. Sulfuric acid plants based on burning sulfur produce large amounts of thermal energy in the various process steps involved. In modern production facilities, the reaction heat from the combustion of sulfur and oxidation from sulfur dioxide to sulfur trioxide is used to produce high-pressure steam. Often, the sulfuric acid plant is the primary single source of steam, serving various industries including those involved with pressure leaching, evaporators or turbo generators. The focus on maximum heat recovery is an essential prerequisite towards achieving low operational costs. For each joule recovered, the benefit is doubled by increasing the amount of useable energy and decreasing the overall cooling load. For these various applications, Outotec has developed solutions for waste heat recovery for both process gases, including those which produce high-pressure superheated steam, as well for sulfuric acid recirculation, such as lowpressure steam, hot water or other forms used to optimize overall plant performance and economy. Obviously, to develop the most suitable comprehensive solution for a customer, it is always necessary to take into consideration the local conditions and the existing infrastructure. This presentation will provide a summary of the various design options and solutions for increasing the efficiency of a sulfuric acid plant based on a customer’s specific needs. Both equipment enhancements and complete process technologies such as Outotec’s proprietary HIPROS* solution as well as our enhanced heat recovery system, HEROS*, will be outlined and discussed. SULFURIC ACID CATALYSTS – CHANCES AND LIMITS SW-O-03 Dr. Michael Krämer, Dr. Frank Rosowski, Thomas Lautensack, Dr. Jürgen Zühlke BASF SE, GERMANY After a long period using mostly platinum based catalyst, BASF disclosed groundbreaking patents 1 claiming catalysts for the production of SO 3 containing vanadium pentoxide and alkali metal oxides on porous, silicacontaining supports in 1913 which are still today the standard catalysts for industrial production of sulphuric acid. For thermodynamic reasons, the oxidation of SO 2 to SO 3 needs be run at temperatures as low as possible to ensure high conversions of SO 2 . Global challenges drive sulphuric acid production. In parallel SO 2 emission are to be reduced – driven either by emission regulations or company policy. The combination of increasing production at reduced emissions challenges producers, engineering companies as well as catalyst suppliers. 49
Page 2 and 3: Dear participants, On behalf of the
Page 4 and 5: EXTRACTION Mansour ASRI, Chercheur
Page 7: PLENARY LECTURES KEYNOTES MINING PH
Page 10 and 11: 10 L’INNOVATION TECHNOLOGIQUE DAN
Page 12 and 13: NANOSTRUCTURE PROCESSING OF ADVANCE
Page 15 and 16: II - KEYNOTES 15
Page 17 and 18: LES MÉTHODES GÉOPHYSIQUES DE SUBS
Page 19 and 20: LES PHOSPHATES, LE LITHIUM ET LE ST
Page 21 and 22: material engineering concepts can b
Page 23 and 24: PHOSPHATE FERTILIZER PRODUCTION FRO
Page 25 and 26: ENVIRONMENTAL ISSUES The plants tha
Page 27: FOOD SECURITY AND THE ROLE OF FERTI
Page 30 and 31: 30 CONCEPTION ET RÉALISATION DES T
Page 32 and 33: LE SURFACE MINING: UN STANDARD INTE
Page 34 and 35: 34 LA STRATIGRAPHIE SEQUENTIELLE OU
Page 36 and 37: - Calcul de Ressources et Étude É
Page 38 and 39: 38 I
Page 40 and 41: 40 BENEFICIATION OF INDIAN LOW GRAD
Page 42 and 43: 42 Johan SIIRAK, AkzoNobel Surface
Page 44 and 45: Pour améliorer davantage la qualit
Page 46 and 47: Results REE elements recovery is ex
Page 50 and 51: This contribution gives an overview
Page 52 and 53: 52 Marten WALTERS KEMWorks Technolo
Page 54 and 55: PH-O-04 B. Messnaoui : Laboratoire
Page 56 and 57: at a considerable cost and the wate
Page 58 and 59: phosphate recovery will be determin
Page 60 and 61: The residence time of product in a
Page 62 and 63: 62 IMPROVING PHOSPHORUS USE EFFICIE
Page 64 and 65: PH-O-16 Todd Hutchinson Director of
Page 66 and 67: Wet process phosphoric acid is fed
Page 68 and 69: 68 Louis Paul Irwin, ArrMaz Custom
Page 70 and 71: 70 FLUOROSILICIC ACID RECOVERY FROM
Page 73 and 74: VII - ENVIRONMENT & SUSTAINABLE DEV
Page 75 and 76: infiuence, 2 - average, 1 - less es
Page 77 and 78: downstream weir at the end of the p
Page 79 and 80: Pascale Compain Bertin Technologies
Page 81 and 82: WATER MANAGEMENT IN PHOSPHORIC ACID
Page 83 and 84: Suppression of plumes at the exhaus
Page 85 and 86: key pollutants including heavy meta
Page 87 and 88: VIII - INDUSTRIAL MANAGEMENT 87
Page 89 and 90: BELGHITI ALAOUI Mohamed OCP, MOROCC
Page 91 and 92: IX - MATERIALS & NEW PRODUCTS 91
Page 93 and 94: • La supervision des réparations
Page 95 and 96: FLUORINE RECOVERY TECHNOLOGY (INTRO
Page 97 and 98: HCl regeneration CaCl 2 + H 2 SO 4
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proposées comme la télomérisatio
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PRODUCTION OF GRANULAR AMMONIUM SUL
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X - POSTERS 103
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La série phosphatée étudiée s
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A SIMULATION PACKAGE FOR THE PHOSPH
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FABRICATION DES SUPERPHOSPHATES SSP
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LA SILICIFICATION DES PHOSPHATES MA
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ANALYSIS OF THE LIKELY SUPPLY SIDE
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Many REE are well known as luminesc
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OPERATION OF SURFACE MINER: RETROSP
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Harris Jack, President, VIP Interna
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D.Oussi OCP - MAROC PROJET DE RENOU
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XI - WORKSHOPS 123
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De par ses activités dans le secte
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Re-cyrstalllized structure of a cry
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Pour les professionnels : - les eng
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Pour des engrais de forme aplatie o
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Coatings The underlying principle o
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HOW IS BINDING ACHIEVED? Trace Elem
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MODÉLISATION THERMOCINÉTIQUE DES
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Garret Palmquist (MECS-DuPont), Sen
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The ideas emerged from looking at h
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PH-O-25 ...........................
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