MESA REDONDA 2010Latest Developments in

Sulphuric Acid Technology by

MESA REDONDA 20102

Extract of Developments in last years

Outotec Acid Technology in brief OTOVentTMTM – Venturi Quench System Energy Recovery HEROSHEROSTM TM ProcessProcess Drying & Absorption Towers

- FiDiTM TM System – Film Distributer- Vertical Wire MeshTMTM

- Candle Filter Plate Support SystemTMTM

in Presentation Noracid Sulphur Combustion – New LURO2TMTM Sacrificial Heat Exchanger

MESA REDONDA 2010

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Outotec in briefOutotec in brief

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Operational model

© Outotec

Technology Management

Market Operations (incl. Market Areas)

Supply

Business Infrastructure

Strategy

Finance & Control

Legal Affairs

Human Capital

ServicesServices

Sh

ared

Su

pp

ort

Fu

nct

ion

s

Business Areas

CustomersCustomers

Energy, Light

Metals & Environ-mental

Solutions

Energy, Light

Metals & Environ-mental

Solutions

Ferrous Solutions

Ferrous Solutions

Non-ferrous

Solutions

Non-ferrous

Solutions

2010

4

Services

5 2010 © Outotec

Lifecycle service solutions and a global network of service centers for Outotec’s customersServices from spare parts support and delivery, site and equipment maintenance and plant audits to optimization and upgrades, project management and training.

Recent acquisitions 2010 Millteam maintenance services for mining

companies and special expertise in grinding mill service

Ausmelt complements our smelting technology portfolio

Larox filtration technologies and services enable us to offer solutions for the whole value chain from mine to metal

Edmeston

Specializing in engineering and supply of process equipment for sulfuric acid plants.

Unique know-how of special stainless steel grades suitable for use in highly corrosive environment.

© Outotec6 2010

MESA REDONDA 2010

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OTOVent

Quench Venturi System

Traditional Areas of Concern withQuench Towers or Quench Venturis

Nozzle Area of Quench VenturiGas Inlet of Quench Tower

Areas where Hot & Dry and subsequent Cold & Wet Conditions are manifest

MESA REDONDA 2010

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Requirements for Improvementrealized by OTOVent

hot/dry conditionand

wet/cold condition

1. Defined Areas for only Hot / Dry and only Cold / Wet Conditions AND

2. Avoidance of Dust / Partical Deposits at Wall and In / On Acid Overflow

MESA REDONDA 2010

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Developement of Design Features

1. Separation of Hot & Dry and Cold & Wet Areas

Creation of an Overall Localized Even Acid Film at Wall / Bricklining above Acid Spray Nozzle Level

2. Avoid Dust & Partical Deposits on Wall

Wall / Bricklining above Acid Spray Nozzle Level is in the Shadow of the Gas Inlet ( larger inside diameter )

3. Avoid Dust & Partical Deposits In & On Acid Overflow

Acid Overflow Channel is Conical

- to Avoid Partical Deposits in Channel by Higher Acid Velocity at the Bottom - to Create an equal Film at the Overflow by Lower Velocity at Top

MESA REDONDA 2010

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Thickness of Film (m)

MESA REDONDA 2010

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Temperature of Film (K)

Flow Analysis by Fluent Wall by Loadcase 380 / 70

Temperature ( K ) Analysis by Fluent for Loadcase 380 / 70

MESA REDONDA 2010

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of Droplets of Gas

MESA REDONDA 2010

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Types of Application

Retrofit to OptimizeExisting Quench Tower

Green Field Application

MESA REDONDA 2010

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MESA REDONDA 2010

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Energy Recovery Energy Recovery

HEROSHEROSTM TM ProcessProcess

MESA REDONDA 2010

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product aciddrying tower

main blower

air

sulphur

waste heatboiler

combustionfurnace

converter

superheater

evaporator

intermediate absorption tower

intermediateheatexchanger

economizerfinal absorption tower

stack

atmosphere

HP STEAM GENERATION

LOW TEMPERATURE HEAT RECOVERY

Excess Energy RemovalExcess Energy Removal

04/12/2317

LP-Steam

Boiler Feed Water

Feed WaterPreheating

Dilution Water

gas in outAcid Cross-flow

c/w

Outotec HEROS System Outotec HEROS System Recent advances - Enhanced HEROSRecent advances - Enhanced HEROSTMTM

IIN COMPARISON TO N COMPARISON TO HHEROSEROSTMTM WITH WITH EARLIER EARLIER DDESIGNESIGN

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Outotec HEROS SystemOutotec HEROS System – Design Philosophy – Design Philosophy

Aspect Description Related HEROS feature Advantages

Operational Flexibiity • Ability to vary the amount of LP steam production without altering the production of the Acid plant

• Controlled bypass of the venturi absorber system• IAT designed for 100% capacity

• LP Steam can be easily adjusted in HEROS and absorption of SO3 in IAT is ensured

Safety • Minimize corrosion in case of normal operation and off-set conditions

• Material selection (alloy 3033)• New boiler concept• Enhanced safety concept (leak detection)

• Plant operation in a range of 97.5 – 99.5 % • Fast isolation of boiler• Early detection of leaks in water/steam circuit

Overall Plant Availability • Failure of hot circuit must not lead to plant shutdown

• Seperation of hot acid circuit from system by gravity• IAT design for 100 % capacity

• Acid and HP steam production at nominal capacity possible.

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Outotec HEROS System Outotec HEROS System Recent advances - Enhanced HEROSRecent advances - Enhanced HEROSTMTM

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Sulphuric Acid

BFW

LP-Steam Process Gaswith

SO2 & SO3

SO2 gas

Process

water

1

2

3

4

5

6

Shell and tube type heat exchanger (3)

Horizontal arrangement above pump tank

Mixer with water injection at inlet at (8)

Tube side boiling

Separate steam drum (1)

Forced circulation (2)

Bricklined Venturi 1. maximum reliability2. 100% acid production even in case of boiler failure!

04/12/2320

CS / Bricks 40, 2 x 65

Insert: Glass / PTFECover: 3033

Sleeve

Flange: 316L

Piping: 3033

HHEROSEROSTMTM: Application of Material: Application of Material

MESA REDONDA 2010

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Nicrofer 3033 - Excellent weldability, high ductility

0

50

100

150

200

250

300

96.5 97.0 97.5 98.0 98.5 99.0 99.5 100.0

Acid Concentration % H2SO4

Tem

pera

ture

°C

Sandvik SX

Nicrofer 3033

Super Ferrite

310 SS

HEROS™ – Material SelectionHEROS™ – Material Selection

HEROSTypical range of operation

04/12/2322

LEAKAGE / FAILURE Fast detection vital Supervision of

Acid Concentration Boiler Water Contamination Process- and BFW-Management Energy Balance

Loss prevention Separate drains for acid and water:

fast and safely

Summary

Can operate 97.5 – 99.5 % H2SO4 (98.5 ± 1.0 %)

Employs proven equipment and materials of construction

For piping and evaporator, special material 3033

Is easy to install as a plant upgrade, revamps

Risk MitigationRisk Mitigation

0

5

10

15

20

25

30

40 60 80 100

Plant load in %

Flo

w in

m³/

h BFW

Process water

-5.00

10.0015.0020.0025.0030.0035.0040.0045.0050.00

0 1 2 3 4 5 6 7 8 9 10 11 12

Leak size in mm

Flo

w in

m³/

h

BFW

Process water

MESA REDONDA 2010

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HEROS™ – LayoutHEROS™ – Layout

MESA REDONDA 2010

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HEROS™ – SectionHEROS™ – Section

MESA REDONDA 2010

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Drying &Drying &

Absorption TowersAbsorption Towers

MESA REDONDA 2010

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Tower - OptionsTower - Options

Self-supporting dome Acid exit at side Process water addition

Conventionaltower design

Combinedventuri +

packed bed

Integratedtop heat

exchanger

Integratedventuri for

large plants

MESA REDONDA 2010

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CONVENTIONAL TOWER DESIGN

with special attention to:

-multi-layer bricklining

- self-supporting domes

-distribution system of SX

- adequate acid mist and

droplet removal

MESA REDONDA 2010

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Outotec Edmeston TOWER DESIGN

with special attention to:

-SX Stainless Steel

-one-layer bricklining up to dome

- self-supporting domes

-distribution system of SX

- adequate acid mist and

droplet removal with shell of 316L

MESA REDONDA 201029

SS Towers of SX and Top of 316L

MESA REDONDA 201030

SX Material by Outotec Edmeston

For

• Towers

• Pump Tanks

• Irrigation System

• Acid Coolers

• Piping

MESA REDONDA 2010

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p a c k i n g

nozzle

deflector plateliquidtrajectory

Conventional Acid DistributionConventional Acid Distribution

MESA REDONDA 2010

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Modern Acid DistributionModern Acid Distribution

Stainless Steel Tower SX3,000 t/d S-burning Plant

FiDiTMTM system Elemants

MESA REDONDA 201033

Optimization of Acid Distributionby Fluid Dynamic Analysis

Standard configuration without orifices

Orifice of 80% at arm 4, orifice of 60% of radius at arm 5

MESA REDONDA 201034

Comparison of Irrigation Systems

Free Gas Flow Areathrough Irrigation System

45 to 55 %

Trough System LURGI System Outotec FiDiTMTM System

Free Gas Flow Areathrough Irrigation System

55 to 60 %

Free Gas Flow Areathrough Irrigation System

65 to 75 % %

MESA REDONDA 201035

LAB Test - FIDITMTM

Sulphur Burning Plants

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Fluid Dynamic Analysis Vertical Wire MeshTMTM

Sulphur Burning Plants

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Pictures of Vertical Wire MeshTMTM

MESA REDONDA 201038

Outotec Support TM TM of Candle Filter Plate

Dia 5.4 m - Dead weight & 250 kg / candle

Old Design New

Deflection ( mm 170 Center 3 170 Maximum 16

Main Benefit: Due to Less in Deflection nearly no Bending at Flange / Gasket

MESA REDONDA 201039

Not mentioned Developments today

Propriety Equipment New Design of SS Converter Outotec Edmeston SX Tower without Bricks 2 New Designs of High Efficiency Scrubber Enhanced Design of Wet ESP

Process Applications LuRec Concentration Expand Etc.

MESA REDONDA 2010

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40 | 12 April 2023 | TAK-S Meeting Worms40 | 12 April 2023 | BHP – Olympic Dam

www.outotec.com

Thank you forThank you foryour attention !your attention !