WorleyParsons Gas Cleaning - WorleyParsons.com

WorleyParsons Gas Cleaning

“There is no task so important or sourgent in our business, or our customers’businesses, that it overrides the need towork safely…”John Grill, WorleyParsons CEOZero Harm is our corporate vision for health, safety & theenvironment (HSE).We are committed to our vision; it applies to all of our operations,at all times, in all locations, and at all levels of responsibility.We will actively work to align our expectations and behaviorswith those required to achieve our vision through a dedicationto continuous improvement.The launch of our HSE framework, OneWay, enables us tofurther align and consolidate our global systems and proceduresand continue to work with our personnel to reinforce a culture thatunderpins our drive to achieve our corporate differentiatorof industry leadership in HSE performance.Corporate OverviewWorleyParsons is a leading global provider ofprofessional services to the resources & energysectors and the complex process industries.We cover the full asset spectrum, both in size and lifecycle, from thecreation of new assets, to services that sustain and improve operatingassets.Our business has been built by working closely with our customersthrough long term relationships, anticipating their needs and deliveringinventive solutions through streamlined, proprietary project deliverysystems. Strong growth continues to characterize our performance boththrough organic development and through strategic acquisition as westrive to provide tailored services wherever our customers need us.EcoNomics is our range of services and technologies that profitablyembed environmental, social and financial sustainability into projectdelivery, across the asset lifecycle. It is a seamless extension of ourestablished project delivery capability in the key areas of Assessment,Efficiency and Treatment & Mitigation. We are committed to workingwith our customers to turn their sustainability objectives into goodbusiness practice.• Mineral & Metals• Hydrocarbons• Power• Infrastructure &Environment37countries120offices28,800personnel

WorleyParsons Gas CleaningWorleyParsons Gas Cleaning has built a reputation as aresponsive, solutions-driven organization with strongtechnical qualifications and a proven record ofaccomplishment by delivering high quality, nicheprocess engineering services at cost competitive prices.80WorleyParsons Gas Cleaning provides specializedprocess engineering and multi-disciplinary capabilitiesto the minerals and metals, hydrocarbons (downstream), and power industries.Process PlantsAreas of specialization include:● Process engineering● Process gas handling and cleaning system design● Process troubleshooting and optimization●Process plant tfugitive emissions i control● Process modeling● Heat recovery and energy optimization● Field testing and monitoring● Evaluation of new processes● Process operations training46Scope of services includes feasibility / conceptual studies, basic and detaileddengineering, and plant commissioning support.WorleyParsons Gas Cleaning’s goal is to exceed customer expectations byalways focusing on a strong commitment to employee health and safety, aswell as improving the environment and addressing compliance requirementsthrough sustainability projects. Engineering solutions are developed with thesefactors in mind coupled with a solid understanding of process operations.WorleyParsons Gas Cleaning successfully executes strong scheduleperformance and effective cost control, and delivers innovative, high qualityproducts and services. The end results of our engineering efforts are improvedplant operating performance, employee safety, and a cleaner environment.Major Clients

Process Gas Handling and Cleaning System DesignWorleyParsons Gas Cleaning has extensive experience in gashandling system design for both ferrous and non-ferrous metallurgicalfurnaces, including drying, calcining / roasting, smelting / melting,heating, and refining. Specific capabilities surrounding process gashandling system design include:●●●●●●Process gas characterizationProcess gas heat recovery, including waste heat boilers and heatexchangersProcess gas conditioning, including combustion chambers, watercooledducts, and evaporative coolersFlue gas desulfurization (FGD)Process NOx controlGas cleaning system equipment selection, including baghouses,scrubbers, electrostatic precipitators (ESPs), and fansEnergy Optimization & Greenhouse Gas (GHG) EmissionsWorleyParsons Gas Cleaning has extensive expertise in heatrecovery and energy optimization, including process plant energyintensity assessments, and process unit energy optimization,which directly impact GHG emissions. WorleyParsons GasCleaning regularly performs energy assessments for processequipment and off-gas systems. Potentially up to 50% of energyinput into a pyrometallurgical process could be lost through theoff-gas. WorleyParsons Gas Cleaning identifies practicalapproaches to recover heat from the off-gas in the form of steam,preheated air, or direct recycle that can be used in otherprocesses to reduce fuel consumption. WorleyParsons GasCleaning assesses energy usage in all areas of a process plant.These energy intensity evaluations provide an understanding oftotal energy consumption by each process unit and identifyopportunities for efficiency gains, energy savings, and reductionin GHG emissions. Specific capabilities include:●●●●Audit and assessment of existing process operations with respectto productivity, efficiency, and environmental considerationsBenchmarking of energy consumption in process operationsDetermination of GHG emissions associated with processoperations, and development of process strategies aimed atreduction of GHG’sEvaluation of material inputs, equipment capabilities and operatingpractices aimed at improved operating efficiency and reduction ofGHG generation

Smart-Gas ® TechnologySmart-Gas ® is a proven low maintenance, user-friendly, and modular toolusing proprietary software which enables meltshops to optimize theirEAF’s total energy usage in real-time, while providing guaranteedminimum overall net savings of at least US$1.00/ton plus safety andenvironmental benefits without the need to measure off-gas chemistry.Validated over thousands of heats in multiple installations around theworld, Smart-Gas ® also provides a continuously updated denergy balancefor every heat, historical tracking of furnace energy performance,assessment of injection carbon recovery, and comprehensive hands-onoperator training for enhanced learning, in both open and closed-loopcontrol conditions. In addition, Smart-Gas ® can be readily customized toprovide similar benefits to other energy intensive industries including nonferrous,power generation, cement, and petrochemicals.Process Plant Fugitive Emissions ControlWorleyParsons Gas Cleaning staff has extensive experience in reducingfugitive emissions from plants in order to achieve environmentalcompliance requirements. WorleyParsons Gas Cleaning also hasexpertise in the engineering and design of industrial ventilation systems.Specific WorleyParsons Gas Cleaning capabilities in the areas of fugitiveemissions prevention and industrial ventilation include:●●●●●●●Protecting employees and equipment from heat stress and dustexposureField measurements and emissions quantificationSecondary emissions controlMolten metal transfer emissions controlProcess vessels secondary hoodingMeet environmental compliance for visible emissions through buildingroof lineMaterials handling dust controlProcess Evaluation and OptimizationWorleyParsons Gas Cleaning performs a wide range of process evaluationstudies for existing plant operations for both ferrous and non-ferrousmetallurgical applications. Typical studies involve process audits, energyaudits and determination of requirements for adjustment of operatingpractices and evaluation of upgrades required for process equipment.Specific tasks may include:●●●●●●●●●Evaluation of process flowsheets for existing processesDevelopment of process flowsheets for new processesTechno-economic evaluation of new process technologiesPilot scale testing for new process technologiesProcess vessel design/re-designDevelopment of process sensors to provide enhanced process controlDevelopment of modified operating practicesBenchmarking of raw material consumption in process operationsDebottlenecking and process optimization for ferrous, non-ferrousindustries

Process Operations Training and Start-up AssistanceWorleyParsons Gas Cleaning staff has experience in the start-up ofprocess equipment, such as electric arc furnaces and ladle furnaces.Services span the fields of equipment selection, classroom training, as wellas hands-on training and development of operating practices. Specificcapabilities include:●●●●●●●●Development of customized process training programsDevelopment of operating practicesAssistance with selection of raw materialsHands-on training in the plantTraining the Trainers – programs are developed to assist supervisors indeveloping plant training programs for their specific areas ofresponsibilityCoordination of benchmarking activities at similar process operationsAssistance with obtaining ggovernment grants for trainingList of specific process training modules are available upon requestEngineering Design of Kilns and FurnacesWorleyParsons Gas Cleaning staff has experience in the engineeringdesign of kilns and furnaces. Our kiln and furnace design applicationsoffer:●●●●●●●●Process design and metallurgical expertiseUnique design application and expertise in copper cooling technologiesand refractoriesDesign of high power, high productivity unitsDesign of various furnace types (electric furnace, blast furnace, cupola,fluid bed, and solid/gas reaction)Long campaign life, operating time, and less maintenanceSpecialized applications to obtain high processing ratesNumerous proven retrofit improvements and greenfield installationsCommissioning, ramp-up, and debottlenecking/optimization expertiseProcess ModelingWorleyParsons Gas Cleaning utilizes proprietary and in-house mathematicalmodels for process simulation to optimize system design of gas handlingsystems and secondary fume control systems in process plants. We useComputational Fluid Dynamic (CFD) models as an effective design tool topredict the performance of gas handling systems for process plants. CFDprovides the means to compare the relative performance of several designscenarios. Specific benefits of our CFD modeling techniques include:●●●●●●Predicting heat and contaminant exposure levelsEvaluating performance of ventilation systems in process plantsPredicting airflow patterns and contaminant migration pathsOptimizing primary and secondary capture hood performancePredicting and optimizing process gas mixing and combustion systemsEvaluating burner configuration and selection

For further information about our global capability email:gascleaning@worleyparsons.comwww.worleyparsons.com