sebastian brechtel product & strategy manager - h2so4 … · heat recovery – efficiency at...

Heat recovery – efficiency at any price? Sebastian Brechtel

Product & Strategy Manager

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Agenda

• Efficiency – General terms • Automotive fuel consumption – „Clean diesel“ • Thermal efficiency in acid plants • Financial efficiency - ROI • Facing real life • Take care of your cash cows • HEROS heat recovery system design • Getting digital support

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Efficiency – General terms

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Removal or conversion efficiency

Operational efficiency

Energy efficiency


Efficiency – Automotive fuel consumption

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Standard operation


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Standard operation



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loss

Best operation

Standard operation



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loss

Standard operation

Best operation



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loss

Standard operation

Best operation

Too small particle filter



Thermal efficiency – Waste heat recovery in sulfuric acid plants (sulfur burner)

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Sulphur Melting 1% 34%

10% Intermediate Heat Exchanger

Evaporator Economizer

Final Absorber

Acid Coolers

Tail Gas 3%

11% 3%

Sulphur 98%

Electric Energy 2%

Blower

Drying Tower

Air

Acid Coolers

6%

23% 9% 1%

Steam 57.5%

Acid Cooling 39%

Intermediate Absorber

Waste Heat Boiler

Converter Tray No.1

Converter Tray No.2

Converter Tray No.3

Converter Tray No.4

Sulphur Combustion Furnace

Production Acid 0.5%

Steam Superheater


Thermal efficiency – Waste heat recovery in sulfuric acid plants (sulfur burner)

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Sulphur Melting 1% 34%

10% Intermediate Heat Exchanger

Evaporator Economizer

Final Absorber

Acid Coolers

Tail Gas 3%

11% 3%

Sulphur 98%

Electric Energy 2%

Blower

Drying Tower

Air

Acid Coolers

6%

23% 9% 1%

Steam 57.5%

Acid Cooling 39%

Intermediate Absorber

Waste Heat Boiler

Converter Tray No.1

Converter Tray No.2

Converter Tray No.3

Converter Tray No.4

Sulphur Combustion Furnace

Production Acid 0.5%

Steam Superheater


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Financial efficiency – Return on Investment (ROI)


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?




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Design basis for a financial efficiency calculation

Plant capacity 4500 mtpd H2SO4 (as 100wt%) Plant location Europe Plant type Sulphur burning, 3+1

Utility concept “Over the fence” – purchase of electricity, cooling water, demin water and LP steam. Sale of HP and LP steam.

Financial concept Plant cost fully financed by a commercial loan: interest rate 6%, depreciation based on a 20 year period.


ROI – HEROS heat recovery system

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0

0,2

0,4

0,6

0,8

1

1,2

1,4

0 1 2 3 4

Cum

uala

tive

RO

I

Operational years

HEROS

$$


ROI - SAP and HEROS™

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0 0,2 0,4 0,6 0,8

1 1,2 1,4

0 2 4 6 8 10 12 14

Cum

uala

tive

RO

I

Operational years

SAP HEROS

$$

$$


Facing real live – Failure scenarios

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Heat recovery (HR) failure scenarios

Short term failure Long term failure

Failure mode Acid pump failure Boiler leakage with weak acid scenario

HR shutdown duration 3 days 3 months Additional cost [% of initial investment]

3% 20%

$$

$$


Interdependency of Acid plant & Heat recovery system

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loss loss

One way option

Two way option


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loss loss

Plant down time & production

loss

Fall back to standard operation

One way option

Two way option

Interdependency of Acid plant & Heat recovery system

Shut down of heat recovery system


ROI - Heat recovery system (failure)

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0 0,2 0,4 0,6 0,8

1 1,2 1,4

0 1 2 3 4

Cum

uala

tive

RO

I

Operational years

HR short term failure

HR long term failure

$$


ROI - Heat recovery system (failure)

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0 0,2 0,4 0,6 0,8

1 1,2 1,4

0 1 2 3 4

Cum

uala

tive

RO

I

Operational years



$$ ??


ROI - Sulphuric acid plant (failure)

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0 0,2 0,4 0,6 0,8

1 1,2 1,4

0 2 4 6 8 10 12 14

Cum

uala

tive

RO

I

Operational years



$$


ROI - Sulphuric acid plant (failure)

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0 0,2 0,4 0,6 0,8

1 1,2 1,4

0 2 4 6 8 10 12 14

Cum

uala

tive

RO

I

Operational years



?


HEROS design aspect: Plant Availability

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Advantage Acid and HP steam production guaranteed even if

HEROS ís not in operation.

Features Separation of hot acid

circuit from system possible

IAT design for 100 % capacity

Target Failure of hot circuit must not lead to plant

shutdown


HEROS design aspect: Safety precaution 1

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Advantage Wide operational window & minimized

corrosion under off-set conditions

Feature Material selection: stainless steel & acid

resistant bricklining (indicated in red)

Target

Limit hazard potential


HEROS design aspect: Safety precaution 2

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Advantage Minimized corrosion in case of

heat exchanger failure and emergency stop

Features Heat exchanger

outside of acid tank Fast isolation of acid

and water circuit

Target

Limit hazard potential


Getting digital support

•  The PORS (Plant Operability Reliability and Safety) system is a virtual process expert - it is our online know-how at plant site

•  Analysis of plant operation for potentially hazardous situations

•  Guidance and support for plant operators

Plant Operability Reliability and Safety System

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PORS

Operational Data

Process know-how

Awareness of key

operational trend / upset


PORS system – virtual process expert

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Benefits

Value proposition

Improved process safety and plant availability

Features

Operator support and guidance

Process know-how delivered to site in black box “traffic light” system

Permanent systemic process monitoring and analysis of plant status

Risk mitigation - early detection of developing hazards and reduction of response time to upset conditions

Improved awareness of operators for plant mal-operation

Improved plant availability


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Risk mitigations for heat recovery systems

HEROS™ feature

Availability Flow Sheet Fundamental principle is that HR plant failure will not lead to SAP plant shutdown. The hot acid circuit is completely separated from rest of the acid plant. Intermediate absorption tower is designed for complete SO3 absorption at 100% plant load.

✔

Availability

Material of Construction

All vessels are acid-brick lined to minimize corrosion. Use of Alloy 3033, which allows for wide operational window where no brick lining is possible

✔

Safety Flow Sheet Material of Construction Automation

In fail-safe mode, automatic draining of hot acid by gravity into brick lined equipment, reducing corrosion to minimum levels. ✔

Operability Support tools PORS system for additional high level trending/critical process information requiring operator action to safeguard operating plant integrity. Operator training simulator as optional training measure.

✔


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sebastian brechtel product & strategy manager - h2so4 … · heat recovery – efficiency at...

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