www.alfalaval.com Marcelo Gabriel Nov/13 Technical Cooperation
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Objectives
• Outline specific waste heat recovery opportunities within sulphuric acid processing
• Show how you can profit from waste heat recovery with Alfa Laval solutions
• Show the improvements in Alfa Laval equipments for Sulphuric acid processing
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
We serve most industries
Biofuels
Biotech and pharmaceutical
Chemicals
Engine and transport
Fluid power
Food and beverages
HVAC
Industrial fermentation
Latex
Machinery
Marine and diesel
Metal working
Mining and mineral processing
Oil and gas
Oil refinery
Power
Pulp and paper
Refrigeration and air-conditioning
Steel and coke oven gas
Sulphuric acid
Sugar
Wastewater treatment
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Experience counts – over 40 years of industry experience
First unit for sulphuric acid delivered in 1969 to Australia
Thousands of heat exchangers sold since then
across the globe
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
Sulphuric acid plant
Converter IAT FAT Drying tower
Electrostatic precipitator Washing
Tower (scrubber)
Humidifying tower
Intermediate Absorption Tower
Final Absorption Tower
Weak Acid Cooler (WAC)
Drying tower cooler
IAT cooler FAT cooler
5-20% H2SO4
93-96% H2SO4
98.5% H2SO4
98.5% H2SO4
Hot SO2 gas
SO2
SO2 SO2
Tail gas
SO3
SO2+ SO3
SO2 gas cooler • Oleum Inter- changer (SHE) • Oleum cooler (SHE/PHE)
Sulphur
Air
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval / Clark-Koch solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
Energy demand is increasing International Energy Agency forecasting a 45% rise
until 2030
Source: International Energy Agency, World Energy Outlook 2008
1980 1990 2000 2010 2020 2030 0
1 000
2 000
3 000
4 000
5 000
6 000
Mto
e
Oil Coal Gas Biomass Nuclear Hydro Other renewables
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© Alfa Laval
The sulphuric acid power plant
65 MW
1000 tons/day sulphur burning acid plant
1/3
Waste
Steam generation 2/3
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Heat recovery opportunities In sulphuric acid processing
REDUCE OPEX: Reduced steam / fuel consumption
INCREASE REVENUES: Energy sales / Increase production
REDUCE CAPEX: Installation costs / Utility system / Compact solution
PROFITABILITY
< 1 year
Rapid payback!!!
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Heat recovery opportunities Reduced steam / fuel consumption
Ore processing or
chemical plant
Coal fired boiler
Sulphuric acid plant
10 MW
10 MW
Steam Hot
Water
Example: Boiler Feed Water heating
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© Alfa Laval
Heat recovery opportunities Reduced steam / fuel consumption
H2SO4 98% 110 °C
80 °C
P2O5 30% 45 °C
Trim cooler
80 °C
90 °C
50 °C
Water loop
• Hot water from the acid plant used to pre-heat the P2O5 instead of Low pressure steam.
• More steam is then available for electricity generation in the turbine
• Less fuel is consumed in the boilers
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Copper electrolyte heating Heating electrolyte from 50°C à 70°C
Stripping
Washing
Extraction Leaching
PLS PLS Copper
ore
Grinding
Raffinate
Rich electrolyte
Spent electrolyte Spent electrolyte
Rich electrolyte
Raffinate
Copper cathodes
Electro- winning Steam or
hot water
- +
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Zinc sulphate solution heating Heating from 50°C à 85°C
Zinc ore
Spent electrolyte
Zinc cathodes
Electro- winning
- +
Leaching
Grinding
Rotation
SO2 to sulphuric acid
production
Roasting
Purification
Zinc dust
Cu, CD, Ni removal
Hot acid leaching
Purification
Ag, Fe, As, Pb removal
Steam or hot water
Steam or hot water
Steam or hot water
Spent electrolyte
Ammonia Or NaOH
Spent acid
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Heat recovery opportunities Reduced electricity cost
• Low pressure steam in the process (Copper / Nickel / Zinc / P2O5 / etc) is replaced with hot water from the acid plant
• More steam is then available for electricity generation in the turbine
Steam
Turbine
50 bar
steam
0.1 bar steam
5 bar steam
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Heat recovery opportunities Energy sales – district heating
Kemira Sulphuric acid plant
22 MW
Industry Park of Sweden Power company
22 MW
City of Helsingborg Gas fired
boiler 22 MW
• Replace district heating boilers with acid plant heat
• Sulphuric acid plants are perfect heat sources
• Profitable for both city and acid plant
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
Heat integration network
Sulphuric acid plant
Heat recovery applications Heat integration network
Sulphuric acid cooler
Back-up steam heater
Heater
Trim cooler
Boiler feed water
heating
Copper electrolyte
heating
Zinc sulphate solution heating
EXAMPLES
District heating
Absorption tower
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Why use an intermediate circuit?
Sulphuric acid cooler
Back-up steam heater
Heater
Trim cooler
• Acts as a safety barrier – prevents mixing
• If long distances needs to be covered
• Flexibility and reduced interdependence
• Multiple heat sources can connect to circuit
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Energy Integration H2SO4 98,5% -Boiler Feed Water Heating
Hast D205
AISI 316
Absoption Tower
S&T Anodic protection
BFW Out / 100 °C
BFW In / 50 °C
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© Alfa Laval
Energy Integration H2SO4 98,5% -Boiler Feed Water Heating
BW In // 50 °C
BW Out // 100 °C
110 °C
Absorption Tower Hast D205 AISI 316
Expansion tank
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Proven plate technology Plate Heat Exchangers enables superior heat recovery – at profitability
Thermal efficiency Crossing temperatures
Advanced alloys used
5x 47 40
90 87
Lower investment cost
Higher grade energy
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Proven plate technology Five times more thermally efficient than competing technology
Thermal efficiency
5x High turbulence
High heat transfer coefficient
Minimized fouling
Compact solution!
Less material required!
Less space!
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Proven plate technology Crossing temperatures possible thanks to the true counter current flow
47 40
90 87
Plate heat exchanger
47 40
90
47
Shell & tube
True counter current flow Cross flow
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Discover hidden assets How Alfa Laval can help in waste heat recovery • Alfa Laval Energy Review – helps you identify
your heat recovery potential
• Standard WHR Skid – Package for heat integration system (Clark – Koch)
• Supply of semi-welded D-205 plate heat exchangers
• Service of heat exchangers
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© Alfa Laval
Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
Plate materials for sulphuric acid duties
Diabon
254 SMO
Alloy G-30
AISI 316 AISI 316
150
100
50
0
°C
150
100
50
0
°C
0 10 20 30 40 50 60 70 90 80 100%
D205
C276
Iso corrosion diagram (0.1 mm/year)
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High acid temperatures possible with Hastelloy D-205 material
130°C Enabling maximum
usage of low grade heat!
0.4
0.3
0.2
0.1
0 90 105 110 130 150 95
Cor
rosi
on r
ate
(mm
/yea
r)
Acid temperature (°C)
Alloy C-276
Hastelloy D-205
Corrosion curve 98.5% H2SO4
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Resistance against chlorides
0
50
100
Tem
pera
ture
(°C
)
No corrosion 316
C-276
254 SMO
Crevice corrosion
D-205
pH = min 7.0
10 102 103 104 105 ppm chlorides
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D-205 for strong acid cooling The semi-welded heat exchanger
Gasketed channel for cooling medium
Welded channel for aggressive fluid
Weld Gasket
Flow pattern in a welded plate heat exchanger
Gasket exposure to aggressive fluid virtually eliminated
Peripheral weld
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Why D205 can take high acid temperatures
C-276 D-205
Passivating layer
D205’s passivating film SiOx is:
• Thicker
• Stronger
• Not as sensitive to velocity
• Rebuilds faster
SiOx CrOx
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Material composition (%) Key difference between D-205 and C-276
D-205
C-276
Material Ni
64.5
58
Cr
20
15.5
Mo
2.5
16
Cu
2
0
Fe
6
5
W
0
4
Stabilizes material
Chloride resistance
Acid resistance
H2SO4 resistance
Si
5
0
!
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
www.alfalaval.com 39
© Alfa Laval
Heat recovery cases Extract from reference list
China
Country Company
Sweden Kemira, Helsingborg Sweden Boliden, Skellefteå Finland Yara, Silinjärvi Finland Boliden, Harjavalta
UK Courtalds Germany Capro Leuna Germany Sachtleben
India Varinder Agro
Wuxin Copper
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MARKET CASE
Kemira Helsingborg, Sweden Start-up:1999
• 22 MW recovered using Alfa Laval plate heat exchangers in D-205 / FKMS gaskets
• 3 semi-welded PHEs replaced 5 anodically protected S&T
• Sale to municipal district heating system
• Recovered heat corresponding to 22,000 m3 of oil saved every year Payback <12 months
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MARKET CASE
Kemira Helsingborg, Sweden • Initial direct cooling system before 1999
• Absorption towers: 2 x 2 anodically protected S&T
• Drying tower: Anodically protected S&T
• Replaced with three PHE-SW in D205 / FKMS
• Three tanks acid tanks replaced with one common tank
• Plant capacity: 1000 tons/day
• Recovered: 530 MWh/day (22 MW), 240 GWh corresponding to 22,000 m3 of oil
• Payback less than a year
• Eliminated need for cooling water
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Boliden Harjavalta, Finland Start-up:1995
• 40 MW of heat recovered with Alfa Laval plate heat exchangers in D-205
• Sale to municipal district heating system (20MW)
• Use in Nickel production plant (12MW)
• Use in Copper production plant (8MW)
MARKET CASE
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Wuxin Copper, China Start-up:2013
MARKET CASE
• Original • Total 5 Waste Heat Boiler generate 74.7 t/h steam
• Consumption summer: 38.2 t/h
• Consumption winter: 78.5 t/h
• Heat recovery • Distance between plants: ca 500m
• Temperature program
– Acid side (98% H2SO4): 112°C à 85°C
– Water loop: ~100°C
• Alfa Laval equipment: 2 x MA30-W in D205/FKMS with portfilters
Payback <12 months
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Wuxin Copper WHR set-up
Sulphuric acid plant
Heat recovery applications Heat integration network
Sulphuric acid coolers
Heater
Trim cooler (S&T)
Boiler feed water
heating
Copper electrolyte
heating
EXAMPLES
District Heating for the plant
Intermediate Absorption
Tower
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17.4 MW
Heat recovered in various applications
IAT heat load
79%
Summer time heat applications
Cu electrolyte heating
9.2 MW
BFW heating 4.5 MW
100% Recovery rate:
Winter time heat applications
Cu electrolyte heating
12.2 MW
Plant heating 5.2 MW
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Substantial savings achieved
Increased heat recovery 14-17 MW
Reduced cooling need / freed cooling capacity 14-17 MW
Reduced steam consumption 150 ktons/year
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Sulphuric acid plant IAT: 2 x MA30W / D205 / FKMS (parallel installation)
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Sulphuric acid plant Filter before acid inlet and HE port filters on water and acid inlets
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Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
• Hot acid external leakage Environmental, capital and human danger.
• Micro leakage may give secondary corrosion. Results in rapid general corrosion!
Hot acid leaking by droplets to the leak chamber
Humidity
Diluted acid!
The sealing is important
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Gasket selection
0
10
20
30
40
50
60
70
1 2 3
% S
wel
ling
Viton G FKMS
The gaskets were placed in 98% acid at 110°C (1 for 14 days, 2-3 for additional 7 days respectively) and then subjected to water for one day. This was repeated 3 times. After each test the swelling was measured.
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© Alfa Laval
Viton Gaskets Resistance in Sulphuric Acid
• Viton A 65 Dissolved • Viton B 67 48 • Viton G 69 10 • FKMS >70 ?
Swelling due to high acid temperature 98% acid at 110°C during 60 days
Rubber Type % Fluor % swelling
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Alfa Laval Port Filter Design
Guiding ring
Port filter inserted through
pressure plate
Frame plate
Pressure plate
Inlet port
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Alfa Laval Port Filter Design
• A simple solution without a separate filter
• Cylindrical perforated tube
• Protects at the inlet port
• Mounted and dismantled from pressure plate
• Requires – Hole in the pressure plate
– Lining
– Inspection cover
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For predictable operations & total peace of mind
• Extends normal Performance Agreements
• Guaranteed results
• Commitment to an agreed outcome, such as uptime
• We analyze, plan and perform all required services
• Total tailored solution
– Example of content: Uptime Commitment, Total Care Agreement, 24/7 Support Service, Lead Time Guarantee – Services and Spare Parts, Extended Warranty
Performance Agreements with Extended Commitments
Description Alfa Laval Performance Agreements
Performance Agreements
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An Italian Ferry Co. Performance Agreement based on preventive maintenance on 7 ferries and 49 high speed separators
Benefits • Fixed maintenance cost
• Optimized maintenance
• 24/7 support
Cargill Cargill in Netherlands signed a Performance Agreement with extended commitments to get maximum benefits from their new equipment
Benefits • Maximized uptime • Lowered total cost of ownership • Optimized maintenance
Stockholm vatten Stockholm’s municipal water company signed a Performance Agreement covering 15 decanters at three different sites
Benefits • Fixed annual service cost
• Lowered total cost of ownership
• More reliable operation
Boliden This smelter signed a Performance Agreement with condition monitoring, Cleaning-in-place, recond-itioning and optimization
Benefits • Reduced energy cost
• Improved environmental performance
• Maximized uptime
PROCESS INDUSTRY ENVIRONMENT FOOD TECHNOLOGY MARINE
Customer stories
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© Alfa Laval
Content
• Short about Alfa Laval
• Alfa Laval products for sulphuric acid processing
• Waste heat recovery (WHR) opportunities
• Alfa Laval solutions in WHR
• Plate material for WHR
• Heat recovery cases
• Alfa Laval improvements
• Summary
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© Alfa Laval
Summary
• Importance of efficient energy usage will increase
• Many opportunities exist in waste heat recovery
• Heat recovery means increased profits – here and now! Payback below 1 year.
• Proven technology and solutions are available from Alfa Laval / Clark-Koch.